Part 2

U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY - Continued

37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

(a) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT: Select an appropriate flange from the table below so that it will meet the specified value.

Standard flange thickness:

(b) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
(c) Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

(a) Install the underdrive clutch to the 1-way clutch.
(b) Check that the underdrive 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration.
If the result is not as specified, replace the underdrive 1-way clutch.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the 1-way clutch.
NOTE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.

(b) Install the 1-way clutch to the transaxle case.
NOTE: Make sure that the mark on the 1-way clutch outer race is visible.

(c) Using a screwdriver, install the snap ring to the transaxle case.
NOTE: The snap ring should be fully engaged in the groove of the transaxle case.

40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petrolatum, and install them onto the underdrive clutch.
Standard bearing and bearing race diameter:

(b) Install the underdrive clutch to the transaxle case.
NOTE: Do not damage the oil seal when installing the underdrive clutch drum.

41. INSTALL PARKING LOCK PAWL

(a) Install the pawl pin and spring to the parking lock pawl.

(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the underdrive planetary gear to the transaxle case.
- Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear and install them securely.
- Check the position and number of the grooves on each end face of the differential drive pinion gear.

(b) Install the parking lock pawl shaft.

(d) Using a straightedge and vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).
NOTE: Record dimension E for the following process.

(e) As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.
NOTE: Record dimension F for the following process.
HINT: Dimension F = Dimension (1) - Dimension (2)

43. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Install the thrust bearing race to the transaxle case while checking its direction.
Standard bearing race diameter:

(b) Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.
Standard thrust bearing and race diameter:

(d) Install the needle roller bearing to the multiple clutch hub.
Standard bearing diameter:

(e) Install the multiple clutch hub to the transaxle case.
44. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward clutch.
Standard thrust bearing diameter:

NOTE: Install the thrust bearing properly so that the non-collared race or blue ink jet race will be visible.

(c) Install the forward clutch to the transaxle case.
- Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
- Be careful not to damage the bushing inside of the forward clutch hub during installation.

45. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear to the transaxle case.
NOTE: Check the position and number of the grooves on each end face of the differential ring gear.

47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the thrust bearing underdrive race to the underdrive planetary gear.
48. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula and values of Dimension E and F that were measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race which satisfies the specified end play value, and install the selected bearing race.
Standard end play:
0.498 to 0.993 mm (0.0196 to 0.0391 in.)
HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race thickness.

Standard race thickness:

Standard bearing and bearing race diameter:

49. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22 Nm (226 kgf-cm, 16 ft-lbf)

(b) Coat the O-ring of oil pump with ATF.
NOTE: Confirm that the input shaft rotates smoothly by manual operation after installing the oil pump.

50. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(c) Apply adhesive or equivalent to bolts A and D.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(d) Install the transaxle housing and 16 bolts to the transaxle case.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
Torque: 29 Nm (295 kgf-cm, 21 ft-lbf)
Torque: 29 Nm (295 kgf-cm, 21 ft-lbf)
Torque: 22 Nm (226 kgf-cm, 16 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
50 mm (1.97 in.) for bolt A
50 mm (1.97 in.) for bolt B
42 mm (1.65 in.) for bolt C
72 mm (2.84 in.) for bolt D
NOTE: Tighten the bolts within 10 minutes of adhesive application.

51. INSPECT INPUT SHAFT END PLAY

(a) Using a dial indicator, measure the input shaft end play.
Standard end play:
0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY

(a) Fix the transaxle.
53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST: 09950-60010
09951-00230
SST: 09950-70010
09951-07100
Standard depth:
0 +-0.5 mm (0 +-0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft to the transaxle case.
NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.

(b) Using a pin punch and hammer, drive in a new pin.

(c) Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small hole.
(e) Check that the spacer does not turn.
56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
NOTE: Hang the spring on the shaft firmly.

57. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
HINT: The bolt length is indicated below.

Bolt length:
25.0 mm (0.984 in.)
NOTE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.

58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring and cover with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
- Tighten bolt A first, and then bolt B.
- Each bolt length is indicated below.
Bolt length:
27 mm (1.06 in.) for bolt A
16 mm (0.63 in.) for bolt B
NOTE: Make sure to install the manual detent spring and cover in this order.

59. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.

(b) Install the accumulator piston to the transaxle case.
(1) Coat the piston with ATF.
(2) Install the 2 springs to the piston, and install the piston (with springs) to the transaxle case.
NOTE: Before installing the springs, check the identification color of each spring. Standard accumulator spring

Standard accumulator spring:

60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the reverse accumulator piston.
NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.

(b) Install the piston to the transaxle case.
(1) Coat the accumulator piston with ATF.
(2) Install the spring to the piston, and install the piston (with spring) to the transaxle case.
NOTE: Before installing the spring, check the identification color of the spring.

Standard accumulator spring:

61. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.

(b) Install the piston to the transaxle case and coat the piston with ATF.

(c) Install the spring to the C-3 accumulator piston.
(d) Install the spring to the C-3 accumulator piston.
NOTE: Before installing the spring, check the identification color of the spring.

Standard accumulator spring:

62. INSTALL CHECK BALL BODY

(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTE: Be sure to place the spring in the hole in the check ball body. Be careful of the direction of the parts.

63. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, and install it to the transaxle case.
NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.

64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.

65. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new governor apply gasket with ATF, and install it to the transaxle case.
NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful of the direction of parts.

66. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF, and install it to the transmission wire.
NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.

(b) Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
67. CONNECT TRANSMISSION WIRE

(a) Coat the O-ring of the ATF temperature sensor with ATF.
(b) Apply ATF to the bolt.
(c) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)
(d) Connect the 7 solenoid valve connectors.
68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Apply ATF to the 17 bolts.

(b) While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
25.0 mm (0.984 in.) for bolt A
57.0 mm (2.244 in.) for bolt B
41.0 mm (1.614 in.) for bolt C
- Push the valve body against the accumulator piston spring and the check ball body to install the valve body.
- When installing the valve body to the transaxle case, do not hold the solenoids.
- Temporarily tighten the bolts marked with (1) in the illustration first because they are positioning bolts.

69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the oil strainer.
NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.

(b) Apply ATF to the 3 bolts.