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Transaxle Reassembly

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cutouts of drum. Check thrust bearings and races for wear or damage. Use petroleum jelly to secure parts in place. Clutch discs should be soaked in ATF for at least 15 minutes before installation.
NOTE: Refer to illustration for thrust bearing and race locations. See Fig 19. For component dimensions, see THRUST BEARING & RACE SPECIFICATIONS  table.
  1. Install oil deflector (if equipped) with 3 bolts to transaxle housing. Install apply pipe and clamp. See Figure. Install bolt and tighten to 87 INCH lbs. (9.8 N.m). Ensure pipe is installed to stopper. Install oil seal ring to transaxle housing. See Figure. Using appropriate adapter and press, install underdrive cylindrical roller bearing into transaxle housing. DO NOT apply excessive pressure to bearing.
  2. Using vernier calipers, measure underdrive brake piston return spring free length with spring mounted to spring seat. Free length should be .553" (14.04 mm). Replace springs as necessary. Install 2 oil seal rings to transaxle case. See Figure.
  3. For needle roller bearing installation, wrap vinyl tape around bearing installer at a position .157" (4.00 mm) above bottom end of installer, until thickness of tape is about .197" (5.00 mm). Using bearing installer and press, install needle roller bearing to transaxle case until wound vinyl tape contacts transaxle case.
  4. Coat 2 NEW "O" rings with ATF and install on underdrive brake piston. See Figure. Using hand pressure, install piston into transaxle case. Using appropriate adapter and press, compress underdrive brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
  5. Install snap ring into transaxle case. Using appropriate bearing race adapter and press, install 2 bearing outer races into transaxle case. Press each outer race into transaxle case until race contacts snap ring. See Figure. Using appropriate adapter and press, install tapered roller bearing to counter drive gear until bearing contacts gear. DO NOT apply excessive force.
  6. Using appropriate adapter and press, install counter drive gear and bearing into transaxle case. DO NOT apply excessive pressure. Using vernier calipers, measure 1st/reverse brake piston return spring free length with spring mounted to spring seat. Free length should be .611" (15.51 mm). Replace springs as necessary.
    7. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  7. Coat 2 NEW "O" rings with ATF and install on 1st/reverse brake piston. Using hand pressure, install piston into transaxle case. See Figure. Using appropriate adapter and press, compress 1st/reverse brake piston return springs into transaxle case and install snap ring. DO NOT apply excessive force.
  8. Install front planetary ring gear and snap ring to brake hub. Install front planetary gear to brake hub. Using appropriate adapter and press, install brake hub with front planetary gear into transaxle case. See Fig 1. Install washer on counter drive gear in correct direction. See Fig 2.
  9. Using holding tool, socket and torque wrench, install nut and tighten to 207 ft. lbs. (280 N.m). Using socket, adapter and INCH-lb. torque wrench, measure counter drive gear tapered roller bearing starting torque. Starting torque should be 4.4-8.8 INCH lbs. (.5-1.0 N.m). See Fig 3. If starting torque is not within specification, gradually tighten nut until starting torque is within specification.
  10. Install 2 thrust bearings, bearing race and front planetary sun gear to front planetary gear. Coat bearing race with ATF and install race to rear planetary gear. Install thrust washer No. 2. Install rear planetary gear into transaxle case. Install snap ring.
    Fig 1: Installing Front Planetary Gear With Brake Hub Into Transaxle Case
    G00011294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Installing Counter Drive Gear Washer
    G00011295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Measuring Counter Drive Gear Bearing Starting Torque
    G00011296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Install 1st/reverse brake. Install 5 plates and 5 discs, starting with a plate and alternating with a disc. DO NOT install flange. Measure 1st/reverse brake piston stroke. Using vernier calipers, measure distance between disc surface and contact surface of 2nd brake assembly at transaxle case. See Fig 4.
  12. Piston stroke should be .040-.048" (1.02-1.21 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are marked in numeric order and are available in thicknesses from .071" (1.80 mm), marked with the number "1", to .098" (2.50 mm), marked with the number "8", in increments of .004" (.10 mm). Recheck piston stroke after flange is installed.
    Fig 4: Measuring 1st/Reverse Brake Piston Stroke
    G00011297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. Install 2nd brake assembly into transaxle case. Install snap ring and measure inside diameter. Snap ring inside diameter should be more than 6.57" (167.0 mm). Snap ring has a specific tapered installation direction. If inside diameter is not within specification, ensure snap ring is installed in correct direction. If snap ring is installed correctly, replace snap ring.
  14. Install one-way clutch outer sleeve to 2nd brake assembly. Ensure sleeve is positioned correctly. Install one-way clutch inner race to No. 1 one-way clutch. Ensure inner race is installed correctly. Check No. 1 one-way clutch operating direction. One-way clutch should rotate in counterclockwise direction and lock in clockwise direction. See Fig 5.
    Fig 5: Checking No. 1 One-Way Clutch Rotation
    G04486586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install No. 1 one-way clutch and thrust bearing into outer sleeve. See Fig 6. Ensure Black race on thrust bearing is visible upon installation. Coat thrust washer No. 1 with petroleum jelly and install on rear planetary sun gear. Coat thrust bearing with petroleum jelly and install on rear planetary sun gear. Install rear planetary sun gear onto rear planetary gear.
  16. Install 2nd brake. Install 3 discs and 3 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using vernier calipers, measure 2nd brake piston stroke between disc surface and snap ring surface. See Fig 7. Piston stroke should be .024-.036" (.62-.91 mm).
    Fig 6: Installing No. 1 One-Way Clutch & Bearing
    G00182300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Measuring 2nd Brake Piston Stroke
    G00011298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Select appropriate flange to ensure piston stroke is within specification. Use the following formula to determine flange thickness: measured distance, minus flange thickness, minus snap ring thickness of .063" (1.60 mm). Flanges are available in thicknesses from .118" (3.00 mm) to .142" (3.60 mm) in increments of .004" (.10 mm), and are marked in numeric order from "1" to "7". Remove snap ring, install appropriate flange and reinstall snap ring. Ensure snap ring end gap is visible through groove in transaxle case.
  18. Install bearing race over shaft and onto direct clutch. Install direct clutch assembly and thrust bearing onto rear planetary sun gear assembly. See Figure. Ensure discs in direct clutch completely mate with rear planetary sun gear to ensure rear cover can be installed correctly.
  19. Ensure transaxle case and rear cover mating surfaces are clean. Place a straightedge onto direct clutch drum. Using vernier calipers, measure distance between bottom of straightedge and transaxle case (dimension "B"). See Fig 8.
    Fig 8: Measuring Direct Clutch End Play (Dimension "B")
    G00011299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Measure dimension No. 1 and dimension No. 2 of rear cover in 2 places. See Fig 9. Subtract dimension No. 2 from dimension No. 1. This total equals dimension "C". Calculate direct clutch end play by subtracting dimension "B" from dimension "C". End play should be .008-.037" (.20-.94 mm).
  21. Select a thrust bearing to ensure end play is within specification. Thrust bearings are available in 2 thicknesses of .140" (3.55 mm) with an outside diameter of 2.74" (69.6 mm), and .152" (3.85 mm) with an outside diameter of 2.76" (70.18 mm). Inside diameter of both thrust bearings is 2.11" (53.6 mm). During installation, ensure Black race side of thrust bearing is facing transaxle rear cover.
    Fig 9: Measuring Distance Between Rear Cover Surfaces (Dimensions No. 1 & 2)
    G00011300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. Install 2 NEW apply gaskets to transaxle case. Install clamp to apply pipes prior to installing pipes to transaxle case. This will prevent apply pipes from being deformed or damaged. Install 2 apply pipes, clamp and bolt. See Figure. Ensure pipes are securely inserted into transaxle case until they reach the pipe stopper on pipe. Tighten bolt to 48 INCH lbs. (5.4 N.m).
  23. Install needle roller bearing onto transaxle rear cover with inscribed mark on bearing facing up. Using appropriate adapter and press, install needle roller bearing to transaxle rear cover. Press bearing in to a depth of .474-.502" (12.05-12.75 mm). Install transaxle rear cover plate and 2 screws. Apply thread sealant to screw threads and tighten screws to 66 INCH lbs. (7.5 N.m). Coat 2 oil seal rings with ATF and install on transaxle rear cover. See Figure.
  24. Install underdrive brake. Install 3 discs and 3 plates, starting with a plate and alternating with a disc. DO NOT install flange at this time. Temporarily install snap ring. Using a dial indicator, measure underdrive brake piston stroke by applying and releasing 57 psi (4 kg/cm2 ) of compressed air to transaxle case. See Figure and Fig 10 .
  25. Piston stroke should be .071-.087" (1.81-2.20 mm). Select appropriate flange to ensure piston stroke is within specification. Flanges are available in 3 thicknesses of .118" (3.00 mm), .126" (3.20 mm) and .134" (3.40 mm), and are marked in numeric order from "1" to "3". Remove snap ring, install appropriate flange and reinstall snap ring.
    Fig 10: Measuring Underdrive Brake Piston Stroke
    G00011301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. Ensure transaxle case and rear cover surfaces are clean. DO NOT allow oil to contact surfaces. Coat needle roller bearing with ATF. Apply Three Bond (1281) or equivalent gasket sealant to rear cover around inside edges of bolt holes. Install rear cover onto transaxle case. Install 11 rear cover bolts. Install thread sealant to 3 bolts at bottom of rear cover and tighten bolts to 14 ft. lbs. (18 N.m). Tighten all other bolts to 18 ft. lbs. (24 N.m).
  27. Install outer race retainer to No. 2 one-way clutch, ensuring long finger of retainer is facing up. See Figure. Install underdrive clutch to No. 2 one-way clutch. Rotate underdrive clutch to ensure correct installation. Underdrive clutch should rotate in a counterclockwise direction, and lock in a clockwise direction. See Fig 11.
    Fig 11: Checking Underdrive Clutch Assembly Rotation
    G00011302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. Install No. 2 one-way clutch into transaxle case. Note position of index marks on No. 2 one-way clutch. Ensure marks are facing up. See Fig 12. Install snap ring into transaxle case. Coat thrust bearing and bearing race with petroleum jelly and install onto underdrive clutch. Install underdrive clutch into transaxle case.
    Fig 12: Installing No. 2 One-Way Clutch & Retainer
    G00011303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. Install pawl pin and spring to parking lock pawl. Temporarily install parking lock pawl, shaft and spring to transaxle case. See Figure. Install underdrive planetary gear assembly into transaxle case. Engage all clutch discs and hub spline of planetary gear assembly firmly and securely. Install parking lock pawl shaft. Install lock pawl clamp and bolt. Tighten bolt to 87 INCH lbs. (9.8 N.m).
  30. Using vernier calipers and a straightedge, measure gap between top of differential drive pinion in underdrive planetary gear, and contact surface of transaxle case. See Fig 13. Record measurement as dimension "D".
  31. Measure dimension No. 1 and dimension No. 2 of transaxle housing in 2 places. See Fig 14. Subtract dimension No. 2 from dimension No. 1. Record measurement as dimension "E". Install bearing race onto counter drive gear in correct direction. See Figure.
    Fig 13: Measuring Gap Between Top Of Differential Drive Pinion & Transaxle Case (Dimension "D")
    G00011304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 14: Measuring Distance Between Transaxle Housing Surfaces (Dimensions No. 1 & 2)
    G00011305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Coat needle roller bearing with petroleum jelly and install onto multiple clutch hub (shaft side). Install multiple clutch hub into transaxle case. Install thrust bearing onto multiple clutch hub (forward clutch side). Install forward clutch onto multiple clutch hub. See Figure. Align splines of all discs of forward clutch with multiple clutch hub. Install thrust bearing onto forward clutch. Ensure Black side of thrust bearing is visible.
  33. Install 2 NEW apply gaskets to front of transaxle case. See Figure. Install differential assembly. Calculate transaxle housing-to-underdrive planetary gear assembly end play using the following formula: subtract dimension "D" from dimension "E", performed in steps  30 and  31 , minus thrust bearing thickness of .129" (3.28 mm), equals bearing race thickness. End play should be .020-.039" (.50-.99 mm).
  34. Select a bearing race to ensure end play is within specification. If dimension "E" minus dimension "D" is less than .292" (7.42 mm), bearing race thickness should be .138" (3.50 mm). If dimension "E" minus dimension "D" is .292" (7.42 mm) or more, bearing race thickness should be .150" (3.80 mm).
  35. Install appropriate bearing race onto underdrive planetary gear assembly to ensure end play is within specification. Bearing race outside diameter is 3.268" (83.00 mm). Bearing race inside diameter is 2.220" (56.40 mm). Install appropriate thrust bearing onto bearing race. Thrust bearing outside diameter is 3.345" (84.96 mm). Thrust bearing inside diameter is 2.252" (57.20 mm).
  36. Coat oil pump "O" ring with ATF. Install oil pump and 7 bolts. Tighten bolts to 16 ft. lbs. (22 N.m). Ensure transaxle case and transaxle housing surfaces are clean. DO NOT allow oil to contact surfaces. Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transaxle case around inside edges of bolt holes. Install transaxle housing to transaxle case.
  37. Install 16 transaxle housing bolts. Apply thread sealant to 5 lower bolts inside transaxle housing, and tighten these bolts to 16 ft. lbs. (22 N.m) within 10 minutes of installation. Tighten all other bolts to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. Longest bolts go inside transaxle housing. See Figure.
  38. Inspect input shaft end play. Using a dial indicator, measure input shaft end play. See Figure. End play should be .010-.049" (.26-1.25 mm). Recheck differential preload. Using appropriate adapter and INCH-lb. torque wrench, measure differential preload. See Figure. Preload should be 1.8-6.1 INCH lbs. (.20-.69 N.m) for new bearings and .9-3.1 INCH lbs. (.10-.35 N.m) for used bearings.
  39. If preload is not within specification, remove differential assembly from transaxle case and replace shim or plate washer behind transaxle case bearing race. See Figure.
  40. Place transaxle on 2 blocks of wood, with oil pan surface facing outward. Coat NEW manual valve lever shaft oil seal with ATF. Install oil seal into transaxle case. Install parking lock pawl rod to manual valve lever. Install NEW spacer and manual valve lever shaft into transaxle case. See Figure.
  41. Using a pin punch and hammer, drive in NEW roll pin. Turn spacer and lever shaft to align small hole for locating staking position in spacer with position mark on lever shaft. See Fig 15. Using a pin punch and hammer, stake spacer through small hole. Ensure spacer does not turn.
    Fig 15: Staking Spacer To Manual Valve Lever Shaft
    G00045615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. Using needle nose pliers, install retainer spring. Install parking lock pawl bracket. Install bolts and tighten to 15 ft. lbs. (20 N.m). Install cover, manual detent spring and 2 bolts. Ensure cover and detent spring are installed correctly. See Figure.
  43. Tighten 1.063" (27.00 mm) bottom bolt to 15 ft. lbs. (20 N.m). Tighten .630" (16.00 mm) top bolt to 106 INCH lbs. (12 N.m). Coat NEW "O" rings with ATF and install them onto accumulator pistons. Coat 4 springs and 3 accumulator pistons with ATF, and install components into transaxle case holes. See Fig 16. See ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS  table for spring specifications and identification.
    Fig 16: Identifying Accumulator Piston & Spring Locations
    G00011306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    ACCUMULATOR SPRING FREE LENGTH SPECIFICATIONS

    Application (Color) Free Length - In. (mm) Outer Diameter - In. (mm)
    Forward Clutch (Pink) 3.210 (81.53) .728 (18.50)
    Underdrive Brake
    Inner (Green) 2.372 (60.24) .626 (15.90)
    Outer (Blue) 2.859 (72.61) .657 (16.70)
    Underdrive Clutch (White) 3.563 (90.49) .756 (19.20)
  44. Install check ball body and spring. See Figure. Coat NEW "O" ring with ATF and install on transaxle solenoid connector. Install connector into transaxle case, above park/neutral position switch, and tighten bolt to 48 INCH lbs. (5.4 N.m). Coat NEW apply gaskets with ATF and install them into transaxle case, below valve body assembly. See Figure. Install brake drum gasket, located near 3 apply gaskets. See Figure.
  45. Align groove in manual valve with pin in manual valve lever. Push valve body assembly against accumulator piston springs and check ball body to assist in installation. Install valve body bolts. Hand tighten 2 bolts temporarily. See Fig 17. These bolts are positioning bolts.
  46. Ensure valve body is aligned. Ensure bolts are installed in correct locations. For bolt length, see VALVE BODY BOLT IDENTIFICATION  table. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW gasket on oil strainer. Install oil strainer and tighten bolts to specification. See TORQUE SPECIFICATIONS .
    VALVE BODY BOLT IDENTIFICATION

    Bolt Identification Length - In. (mm)
    A .98 (25)
    B 1.61 (41)
    C 1.77 (45)
    Fig 17: Identifying Valve Body Bolt Locations
    G00011239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. Connect 5 shift solenoid connectors. Install fluid temperature sensor, clamps and bolt. Tighten bolt to 58 INCH lbs. (6.6 N.m). See Figure. Install 3 magnets into oil pan in original locations. Apply Three Bond (2430) or equivalent to 18 oil pan bolt threads. Install NEW oil pan gasket, oil pan and bolts. Tighten bolts to 67 INCH lbs. (7.6 N.m) within 10 minutes of installation.
  48. Coat NEW "O" rings with ATF and install on speed sensors. Install input turbine and counter gear speed sensors into top of transaxle case. Tighten bolts to 97 INCH lbs. (11 N.m). Install NEW "O" rings on oil line union and elbow. Install oil line union and elbow into transaxle case. Tighten to 20 ft. lbs. (27 N.m). See Figure.
  49. Coat NEW "O" ring with ATF and install on transaxle test plug. Install transaxle test plug into transaxle case. See Figure. Install park/neutral position switch onto manual valve lever shaft and temporarily install 2 adjusting bolts. See Figure.
  50. Install NEW lock tab and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Temporarily install control shift lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove control shift lever. Align groove in park/neutral position switch to neutral basic line. Tighten 2 adjusting bolts to 48 INCH lbs. (5.4 N.m). Stake lock tab onto nut. Install control shift lever, washer and nut. Tighten nut to 10 ft. lbs. (13 N.m).
  51. Remove any debris between transfer case and transaxle case contact surfaces. DO NOT allow oil to contact surfaces. Coat NEW round gasket with petroleum jelly and install onto transfer case.
  52. Install intermediate shaft into transfer case assembly. Apply Three Bond (1281) or equivalent gasket sealant about .047" (1.20 mm) wide, to transfer case contact surface. Install transfer case by pushing straight up and into transaxle. Use care not to damage oil seal lip when installing transfer case. Install 2 bolts and 6 nuts and tighten to 51 ft. lbs. (69 N.m).
  53. Install torque converter into transaxle housing while rotating. Ensure converter is properly installed by measuring distance from edge of transaxle housing. See Fig 18. Distance should be .510" (12.95 mm) for all models.
    Fig 18: Measuring Torque Converter Depth
    G95J19280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 19: Identifying Thrust Bearing & Race Locations
    G00011307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING & RACE SPECIFICATIONS (1)

    Application Inner Diameter - In. (mm) Outer Diameter - In. (mm)
    A
    Bearing 2.252 (57.20) 3.345 (84.96)
    Rear Race 2.220 (56.40) 3.268 (83.00)
    B
    Bearing 1.485 (37.73) 2.283 (58.00)
    Rear Race 1.177 (29.90) 2.185 (55.50)
    C
    Bearing 1.333 (33.85) 2.055 (52.20)
    D
    Bearing .925 (23.50) 1.732 (44.00)
    E
    Bearing 1.429 (36.30) 2.055 (52.20)
    Rear Race 1.358 (34.50) 1.909 (48.50)
    F
    Bearing 1.362 (34.60) 2.055 (52.20)
    G
    Front Race 1.587 (40.30) 2.283 (58.00)
    Bearing 1.520 (38.60) 2.362 (60.00)
    Rear Race 1.520 (38.60) 2.283 (58.00)
    H
    Bearing 2.110 (53.60) 2.740 (69.60)
    I
    Bearing 1.327 (33.70) 1.898 (48.20)
    Rear Race 1.193 (30.30) 1.811 (46.00)
    J
    Bearing 2.110 (53.60) 2.740 (69.60) Or 2.763 (70.18)
    (1) Refer to illustration for component locations. See Fig 19.
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