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Transaxle Reassembly: Notes

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. Soak clutch discs in ATF for at least 15 minutes prior to installation. For bearing race and thrust bearing installation direction and locations, See Figure. For bearing race and thrust bearing outer diameter specifications, see BEARING RACE & THRUST BEARING SPECIFICATIONS  table.
  1. Install governor pressure adapter into case. Align adapter and transaxle case hole and install torsion spring. Ensure adapter does not slide and spring does not fall out when pulled. Install manual valve lever shaft oil seal to transaxle case. Install NEW collar to manual valve lever. See Figure.
  2. Install manual valve lever shaft to transaxle case through manual valve lever. Using a pin punch, drive in roll pin until flush with manual valve lever surface. Align collar hole with notch in lever and stake in position using a hammer and punch. Install retaining spring. Ensure lever moves smoothly.
  3. Install parking lock pawl in transaxle case. Hook spring end on pawl and transaxle case. Install pin into hole of transaxle case, through spring and pawl. Install parking lock rod.
  4. Install parking lock pawl bracket. Tighten to 65 INCH lbs. (7.4 N.m). Check operation of parking lock pawl to ensure counter-driven gear is locked when manual valve lever is in "P" position. Install 1st and reverse brake piston (if necessary). See 1ST & REVERSE BRAKE PISTON  under COMPONENT DISASSEMBLY & REASSEMBLY. Install intermediate shaft. Install transaxle rear cover and gasket. Tighten bolts to 18 ft. lbs. (25 N.m).
  5. Ensure intermediate shaft turns smoothly. Using a dial indicator, check intermediate shaft end play. End play should be .019-.059" (.49-1.51 mm). If end play is not as specified, check installation of intermediate shaft. Install 1st and reverse inner flange with flat end facing upward. Install discs and plates starting with disc, alternating with plate and ending with disc.
  6. Install outer flange with flat side toward piston. Install snap ring. Ensure end gap of snap ring is not aligned with cutout of transaxle case. Apply compressed air to oil passage to ensure piston moves. See Figure. Coat bearings and races "E" with petroleum jelly and install on ring gear. See Figure. Install ring gear in transaxle case.
  7. Align flukes of discs in 1st and reverse brake. Coat thrust washer with petroleum jelly. Align tab of thrust washer with hollow of planetary carrier. Align planetary carrier splines with flukes of discs. Install rear planetary gear. Install No. 2 one-way clutch in transaxle case with shiny side upward. Install one-way clutch on inner race while turning planetary gear clockwise.
  8. Coat thrust washer with petroleum jelly and install on planetary gear. Check No. 2 one-way clutch operation by turning planetary gear. Gear should rotate freely in clockwise direction and lock in counterclockwise direction. See Figure. Install snap ring. Ensure snap ring end is not aligned with cutout of transaxle case.
  9. Install 2nd coast brake band guide with tip contacting transaxle case. Install 2nd brake flange with flat side facing upward. Install discs and plates in the following order: for A-131L transaxle install disc, plate, disc, plate, disc, plate. For A-132L transaxle install disc, plate, plate, disc, plate, plate.
  10. Install piston return spring assembly with springs over protrusions in transaxle case. Align groove of 2nd brake drum with guide. Install drum in transaxle case. Install snap ring. Using 2 hammers, compress piston return springs with handles. Install snap ring into groove. Ensure end gap of ring is not aligned with cutout in transaxle case.
  11. Install 2nd brake drum gasket until gasket makes contact with 2nd brake drum. Apply compressed air to center oil passage (next to manual valve lever shaft) and ensure piston movement. Align flukes of 2nd brake discs. Install hub on 2nd brake discs. Check distance between surfaces of 2nd brake hub and rear planetary gear. Distance should be approximately .20" (5.0 mm).
  12. Install sun gear and input drum on No. 1 one-way clutch while turning sun gear clockwise. Ensure thrust washer is on sun gear input drum. Coat bearings and races "D" and "C" with petroleum jelly and install on ring gear and front planetary gear. See Figure. Install planetary gear on ring gear. Install front planetary gear assembly on sun gear.
  13. If planetary gear is correctly installed, ring gear flange bushing will be flush with intermediate shaft shoulder. Coat race with petroleum jelly and install on ring gear flange. Install intermediate shaft oil seal ring.
  14. Install 2nd coast brake band in transaxle case. Install pin through oil pump mounting bolt hole. Coat bearings and races "A" and "B" with petroleum jelly and install on both sides of forward clutch drum. See Figure. Coat clutch drum thrust washer with petroleum jelly and install with oil groove facing upward on direct clutch drum. Align flukes of direct clutch discs.
  15. Mesh hub with direct clutch flukes while turning clutch drum or forward clutch. If disc flukes are meshed with hub correctly, end of direct clutch drum bushing will be flush with surface of forward clutch. Place direct clutch and forward clutch into transaxle case. Rotate forward clutch to mesh front planetary ring gear and discs. Assembly is fully seated when distance is approximately .118" (3.00 mm).
  16. Coat race "A" with petroleum jelly and install on stator shaft. See Fig 1. Install "O" ring on oil pump. Install oil pump into transaxle case. Hold input shaft and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum. Install and tighten bolts to 16 ft. lbs. (22 N.m).
    NOTE: DO NOT apply excessive pressure on oil pump. If excessive pressure is used, seal rings will stick to direct clutch drum.
  17. Measure input shaft end play. End play should be .012-.035" (.30-.90 mm). If end play is not as specified, replace oil pump race. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40 mm). Ensure input shaft rotates smoothly. Install "O" rings on brake piston cover. Install outer spring, 2nd coast brake piston and cover into bore. Install snap ring. Ensure front end of piston rod contacts center of 2nd brake band depression.
  18. Measure 2nd coast brake piston stroke by applying compressed air to oil passage in transaxle case. See Fig 1. Piston stroke should be .059-.118" (1.50-3.00 mm). If piston stroke is not within specification, replace piston rod. Piston rods are available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm). Recheck piston travel after changing piston rod. It travel still exceeds specification, replace 2nd coast brake band.
  19. Apply compressed air to oil passage and check piston rod movement. See Figure. Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons. Check accumulator spring free length. See appropriate table under ACCUMULATOR SPRING SPECIFICATIONS . Replace as necessary. Install pistons and springs in appropriate locations. See Figure. Install accumulator cover and gasket. Tighten bolts to 89 INCH lbs. (10 N.m).
  20. Install 2nd brake apply gasket and governor oil strainer. Install throttle cable into transaxle case. Use care not to damage "O" ring. Ensure cable is fully seated in transaxle case. Install control valve assembly. Ensure proper length bolt is used in proper location. See CONTROL VALVE ASSEMBLY  under ON-VEHICLE SERVICE. Tighten bolts to 89 INCH lbs. (10 N.m).
  21. Align manual valve with pin on manual shift lever. Install manual valve body. Tighten bolts to 89 INCH lbs. (10 N.m). Install detent spring on manual valve body. Tighten bolts to 89 INCH lbs. (10 N.m). Ensure manual valve lever is touching center of detent spring tip roller.
  22. Install oil tubes. DO NOT bend or damage tubes. Install oil tube bracket. Tighten bolts to 89 INCH lbs. (10 N.m). Install oil strainer. Tighten bolts to 89 INCH lbs. (10 N.m). Install magnets into oil pan. Ensure magnets do not interfere with oil tubes. Install oil pan with NEW gasket. Tighten bolts to 43 INCH lbs. (4.9 N.m).
  23. Install governor body adapter, governor body with plate washer and thrust washer onto governor body. Install cover and "O" ring. Install cover bracket with 2 bolts. Tighten bolts to 115 INCH lbs. (13 N.m). Install throttle cable retaining plate. Install filler tube and dipstick. Install seal and neutral safety switch. Tighten and secure with lock plate. Tighten nut to 61 INCH lbs. (6.9 N.m).
  24. Adjust neutral safety switch and tighten adjusting bolts to 48 INCH lbs. (5.4 N.m). Install manual shift lever. Tighten bolt to 115 INCH lbs. (13 N.m). Install oil cooler pipes and unions. Tighten unions to 20 ft. lbs. (27 N.m).
  25. Install torque converter on transaxle. Using a straightedge and calipers, measure torque converter installed depth. Distance should be .906" (23.00 mm) for Corolla, .787" (20.00 mm) for Prizm and .528" (13.40 mm) for Tercel. See Figure.
Fig 1: Checking 2nd Coast Brake Band
G93C24523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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