Part 2

U140F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY - Continued

28. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

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

(b) Using a screwdriver, install the snap ring.

(c) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392kPa, 4.0 kgf/cm2, 57 psi).
Standard pack clearance:
1.59 to 2.20 mm (0.0626 to 0.0866 in.)
HINT: Select an appropriate flange from the table below so that it will meet the specified value.

Standard flange thickness:

(d) Temporarily remove the snap ring and attach the flange. Restore the snap ring.
29. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Transaxle Unit

30. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the 1-way clutch.

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

31. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
Standard race diameter:

(b) Install the underdrive clutch to the transaxle.
32. INSTALL UNDERDRIVE PLANETARY GEAR

(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.

(c) Install the underdrive planetary gear to the transaxle.
NOTE: Engage all the discs of underdrive clutch and the hub splines of the underdrive planetary gear firmly and assemble them securely.

(d) Install the parking lock pawl shaft.

(e) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)

(f) Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
NOTE: Make a note of dimension D as it is necessary for the following process.

(g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
NOTE: Make a note of dimension E as it is necessary for the following process.
HINT: Dimension E = Dimension (1) - Dimension (2)

33. INSTALL MULTIPLE DISC CLUTCH HUB

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

(b) Coat the thrust bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.
Standard thrust bearing and race diameter:

(d) Install the forward clutch hub to the transaxle.
34. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Install the thrust bearing to the forward clutch.
Standard bearing diameter:

NOTE: Install the thrust bearing properly so that the race "B" will be visible.

(b) Install the forward clutch to the multiple clutch hub.
NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

35. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.

36. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle.

37. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
(a) Install the thrust bearing race to the underdrive planetary gear.

38. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and instal it.
End play:
0.498 to 0.993 mm (0.0196 to 0.0390 in.)
HINT: End play = Dimension E - Dimension D - thrust bearing thickness 3.28mm (0.1291 in.) - underdrive thrust bearing race thickness.

Standard race thickness:

Standard bearing and bearing race diameter:

39. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle with the 7 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)

(b) Coat the O-ring of the oil pump with ATF.
40. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to get oil on the contacting surface of the transaxle housing.
(b) Apply FIPG to the transaxle.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Install the transaxle housing to the transaxle with the 16 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
HINT: Each bolt length is indicated below.

Bolt length:
50 mm (1.969 in.) for bolt A
50 mm (1.969 in.) for bolt B
42 mm (1.654 in.) for bolt C
NOTE: Because the bolt labeled A are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.

Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent

41. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle housing.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
42. INSPECT INPUT SHAFT END PLAY Transaxle Unit

43. FIX AUTOMATIC TRANSAXLE ASSEMBLY

44. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with ATF.
(b) Install the oil seal to the transaxle.

45. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft to the transaxle.

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

(c) Turn the spacer and lever shaft to align the small hole for locating 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.

47. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
(a) Using needle-nose pliers, install the retainer spring.

48. 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)
Bolt length:
25 mm (0.984 in.)

49. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
(a) Install the manual detent spring with the 2 bolts.
NOTE: Make sure to install the manual detent spring and cover in this order.

Torque: 20 Nm (204 kgf-cm, 16 ft-lbf) for bolt A
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf) for bolt B
HINT: Each bolt length is indicated below.
- 27 mm (1.063 in.) for bolt A
- 16 mm (0.630 in.) for bolt B

50. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

(b) Coat the piston with ATF, install it to the transaxle.
Standard accumulator spring:

51. INSTALL C-1 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.

(b) Coat the piston with ATF, and install it to the transaxle.
Standard accumulator spring:

52. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

(b) Coat the piston with ATF, install it to the transaxle case.
Standard accumulator spring:

53. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.

54. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install it to the transaxle.

55. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle.

56. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle.
57. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF, and install it to the transaxle solenoid wire.

(b) Install the solenoid wire retaining bolt
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve with the pin of lever.
(b) Install the 17 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
NOTICE:
- Push the valve body against the accumulator piston spring and the check ball body to install it.
- Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
HINT: Each bolt length is indicated below.

Bolt length:
25 mm (0.984 in.) for bolt A
41 mm (1.614 in.) for bolt B
45 mm (1.771 in.) for bolt C

(c) Connect the 5 solenoid connectors.
(d) Coat the O-ring of the temperature sensor with ATF.
(e) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)
59. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.