Part 2

U151F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY - Continued

36. INSTALL UNDERDRIVE CLUTCH DISC NO.2

(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle case.
NOTE: Be careful about the order of discs, plate and flange assembly.

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

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/cm 2, 57 psi).
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.

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

(a) Install the underdrive clutch assembly to the 1-way clutch.
(b) Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
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 fixed fully engaged in the groove of the transaxle case.

40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.

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

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 assembly to the transaxle case.
NOTE: Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.

(b) Install the parking lock pawl shaft.

(d) 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 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 No.1 to the transaxle case while checking its direction.

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

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

(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.

Thrust bearing diameter: mm (in.)

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

(c) Install the forward clutch to the forward clutch assembly.
- 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 assembly to the transaxle case.
47. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2

(a) Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly.
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 are measured when installing the 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 install the selected bearing race.
End play:
0.498 to 0.993 mm (0.01961 to 0.03909 in.)
HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race No.2 thickness.

Race thickness: mm (in.)

Bearing and bearing race diameter: mm (in.)

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 with the 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 FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent.

(c) Install the transaxle housing and 16 bolts to the transaxle case.
Bolt A - Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)
Bolt B - Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
Bolt C - Torque: 29 Nm (295 kgf-cm, 21 ft-lbf)
Bolt D - Torque: 22 Nm (226 kgf-cm, 16 ft-lbf)
HINT: Apply seal packing or equivalent to bolts A and D.

Seal packing:
THREE BOND 2403 or equivalent
Bolt length
Bolt A
50 mm (1.969 in.)
Bolt B
50 mm (1.969 in.)
Bolt C
42 mm (1.654 in.)
Bolt D
72 mm (2.835 in.)
NOTE: Tighten the bolts within 10 minutes of sealant application.

51. INSPECT INPUT SHAFT END PLAY

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

(a) Fix the transaxle assembly.
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
Oil seal installation 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)
Bolt length:
25 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.
NOTE: Make sure to install the manual detent spring and cover in this order.
HINT: Tighten bolt A first, and then bolt B.

Bolt A - Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
Bolt B - Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
Bolt length:
Bolt A
27 mm (1.063 in.)
Bolt B
16 mm (0.630 in.)
59. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, 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) Coat the piston with ATF, install it to the transaxle case.
NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, 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) Coat the piston with ATF, install it to the transaxle case.
NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

61. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, 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) Coat the piston with ATF, install it to the transaxle case.
NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

(c) Install the spring to the C-3 accumulator piston.
NOTE: Install the springs to each accumulator piston, checking the identification color or each 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 about the direction of the parts.

63. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, 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 about 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 about the direction of parts.

65. INSTALL GOVERNOR APPLY GASKET NO.1

(a) Coat a new governor apply gasket No.1 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 about 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 an O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
- Connect the connectors A, B, C, D, E, F, G, in the order from shortest to longest.
- Apply ATF to the bolt.

68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
Bolt length:
Bolt A
41 mm (1.614 in.)
Bolt B
57 mm (2.244 in.)
Bolt C
25 mm (0.984 in.)
- 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) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
NOTE: Apply ATF to the bolts.

70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 magnets to the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent

(c) Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
- Tighten the bolts within 10 minutes of sealant application.
- Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.