Part 1

U140F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION

Standard bearing position:

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube and clamp to the transaxle housing with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
NOTE: Make sure to insert the pipe to the stopper.

3. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
(a) Install a new oil seal ring to the transaxle housing.

4. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, press in the underdrive cylindrical roller bearing.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07100
NOTE: Do not apply excessive pressure.

5. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Install 2 new oil seal rings to the transaxle.
6. INSTALL UNDERDRIVE BRAKE PISTON

(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.)
SST: 09950-60010
09951-00320
NOTE: Clean SST to remove deposited oil before winding a vinyl tape.

(b) Using SST and a press, press in the needle-roller bearing to the transaxle until the wound vinyl tape contacts the transaxle case.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100

(d) Install the underdrive brake piston to the transaxle.

(e) Using SST, a snap ring expander and press, press in the piston return spring and snap ring to the transaxle.
SST: 09387-00020
NOTE: Do not apply excessive pressure.

7. INSTALL NO. 2 BREATHER PLUG

8. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, press in the snap ring to the transaxle.
9. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, press in the 2 bearings outer races to the transaxle.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150

(b) Using SST and a press, press in the tapered roller bearing to the counter drive gear until the bearing race contacts with the snap ring.
NOTE: Do not apply excessive pressure.

SST: 09649-17010

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle.
SST: 09950-70010
09951-07150
SST: 09950-60020
09951-00750
NOTE: Do not apply excessive pressure.

10. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-ring to the 1st and reverse brake piston.

11. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Using SST, a press and snap ring expander, press the piston return spring and snap ring to the transaxle.
SST: 09387-00070
NOTICE:
- Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deform.
- Do not expand the snap ring excessively.

12. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
13. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear.
SST: 09950-60010
09951-00500
SST: 09950-70010
09951-07100
NOTE: Do not apply excessive pressure.

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 280 Nm (2,855 kgf-cm, 206 ft-lbf)

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST: 09387-00080
Turning torque at 60 rpm - Torque: 0.51 to 1.02 Nm (5.1 to 10.0 kgf-cm, 4.4 to 8.7 in-lbf)
Turning torque at 60 rpm - Torque: 0.3 to 0.5 Nm (3.1 to 5.1 kgf-cm, 27 to 4.4 in-lbf)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

(f) Using a chisel and hammer, stake the front planetary gear washer.

14. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, bearing race and front planetary sun gear to the front planetary gear.
Standard bearing and race diameter:

15. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Coat the bearing race with ATF, and install it to the rear planetary gear assembly.
Standard bearing race diameter:

(b) Install the No. 2 thrust washer.

(d) Using a screwdriver, install the snap ring.
16. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the pack clearance will meet the specified value.
0.745 to 1.21 mm (0.0293 to 0.0476 in.)
HINT: Piston stroke = Dimension A - Flange thickness

Standard flange thickness:

(d) Install the flange.

17. INSTALL 2ND BRAKE PISTON ASSEMBLY
(a) Install the 2nd brake piston to the transaxle.
(b) Install the snap ring and measure the inside diameter.
Standard inside diameter:
More than 167 mm (6.57 in.)
NOTICE:
- Because the taper snap ring has the positioning direction, check it when installing.
- When the diameter does not satisfy the specified value, replace the snap ring with a new one.

18. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch outer sleeve to the 2nd brake cylinder.
NOTE: Check the positioning direction of the outer sleeve.

19. INSTALL 1-WAY CLUTCH ASSEMBLY

(a) Install the inner race to the 1-way clutch.
NOTE: Check the direction of the inner race.

(b) Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in illustration.

NOTE: Install the thrust bearing properly so that no-colored race will be visible.

20. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 1 thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.

(b) Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.
Standard bearing diameter:

(a) Install the 3 discs and 3 plates to the transaxle.
Standard install in order:
P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Temporarily install the snap ring.

(c) Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the pack clearance will meet the specified value.
Standard pack clearance:
0.50 to 0.91 mm (0.0197 to 0.0358 in.)
HINT: Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Standard flange thickness:

(e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
NOTE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

22. INSTALL DIRECT CLUTCH

(a) Install the bearing race to the direct clutch.
Standard bearing race diameter:

(b) Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

(c) Clean the connector part of the transaxle case and rear cover.
(d) As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).

(e) Measure the 2 places of the rear cover as shown in the illustration. Calculate a dimension C using the following formula.
HINT: Dimension C = Dimension (1) - Dimension (2)

(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play:
0.198 to 0.936 mm (0.00780 to 0.03685 in.)
NOTE: Make sure that the colored race side is facing the direct clutch assembly.
HINT: End play = Dimension C - Dimension B

Standard bearing thickness and diameter:

23. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new governor apply gaskets.

24. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

25. INSTALL BRAKE APPLY TUBE

(a) Install the clamp to the brake apply tube.
NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

(b) Install the 2 apply tubes and to the transaxle with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: Each pipe should be securely inserted until it reaches the stopper.

26. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
27. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Using SST and a press, press in the bearing.
SST: 09950-60010
09951-00230
09952-06010
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
NOTICE:
- Face the inscribed mark side of the bearing race up.
- Repeat the press-fit until the specified value is obtained.

(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Using a T30 ''TORX'' socket wrench, install the transaxle rear cover plate with the 2 screws.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

(e) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.
(f) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(g) Coat the needle roller bearing with ATF.

(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(i) Install the 11 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf) for bolt A.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf) for other bolt
SST: 09950-60010
09951-00230
09952-06010