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Automatic Transaxle Unit: Reassembly

  1. BEARING POSITION 
    Fig 1: Exploded View Of Automatic Transaxle
    G05240060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING DIAMETER SPECIFICATIONS

    Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.)
    A - 57.2 (2.252) / 84.96 (3.3449) 56.4 (2.220) / 83.0 (3.268)
    B - 37.73 (1.4854)/58.0 (2.283) -
    C - 33.85 (1.3327)/52.2 (2.055) -
    D 24.94 (0.982) 23.5 (0.925)/44.0 (1.732) -
    E - 36.3 (1.429) / 51.93 (2.044) 34.5 (1.358)/48.35 (1.904)
    F 34.35 (1.352)/56.57 (2.227) 32.45 (1.278)/56.48 (2.223) -
    G 40.15 (1.581)/59.25 (2.333) 38.65 (1.522)/59.79 (2.354) 38.65 (1.522)/59.25 (2.332)
    H - 53.6 (2.110) / 69.6 (2.740) -
    I 33.02 (1.300)/45.8 (1.803) 31.85 (1.254)/57.3 (2.256) -
    J - 24.79 (0.976) / 39.5 (1.555) 23.6 (0.929)/37.95 (1.494)
    K - 56.3 (2.216)/75.96 (2.991) -
  2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      NOTE: Make sure to insert the pipe to the stopper.
      Fig 2: Identifying Differential Gear Lube Apply Tube And Transaxle Apply Tube Clamp
      G05240061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Install 2 new O-rings to the 2 transaxle case No. 1 plugs.
    2. Install the 2 transaxle case No. 1 plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 3: Identifying O-Rings And Transaxle Case No 1 Plug
      G05240062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Coat a new oil seal ring with ATF and install it to the transaxle housing.
      Fig 4: Identifying Underdrive Output Shaft Oil Seal Ring
      G05240063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Coat the underdrive cylindrical roller bearing with ATF.
    2. Using SST and a press, install the underdrive cylindrical roller bearing.

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 5: Pressing Underdrive Cylindrical Roller Bearing
      G05240064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE:
      • Do not expand the end gap of the oil seal ring too much.
      • Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
        Fig 6: Identifying Oil Seal
        G05240065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NEEDLE ROLLER BEARING 
    1. Wrap vinyl tape around the SST 4.0 mm (0.157 in.) from the bottom of the SST until the thickness of the tape is about 5.0 mm (0.197 in.).

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: Clean SST to remove deposited oil, before wrapping vinyl tape.
    2. Coat the needle roller bearing with ATF.
      Fig 7: Wrapping Vinyl Tape Around SST
      G05240066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the needle-roller bearing to the transaxle case.

      SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      NOTE: When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.
      Fig 8: Identifying SST
      G05240067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring before installing.
    2. Coat the underdrive brake piston with ATF.
      Fig 9: Identifying O-Rings
      G05240068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the underdrive brake piston to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 10: Identifying Underdrive Brake Piston
      G05240069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
      Fig 11: Compressing Return Spring
      G05240070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
      • The snap ring should be fully engaged in the groove of the transaxle case.
  10. INSTALL BREATHER PLUG NO. 2 (ATM) 
  11. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Coat the counter drive gear bearing with ATF.
    2. Using SST and a press, install the bearing outer race.

      SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 

      Fig 12: Installing Bearing Outer Race
      G05240071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive pressure to the bearing.
      • Press-fit the bearing outer race until it contacts the transaxle case.
    3. Using a snap ring expander, install the snap ring.
      NOTE: The white mark side of the snap ring should face upward.
      Fig 13: Removing Snap Ring
      G05240072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COUNTER DRIVE GEAR 
    1. Coat the counter drive gear with ATF.
    2. Using SST and a press, install the tapered roller bearing to the counter drive gear.

      SST 09950-70010 (09951-07150), 09649-17010 

      NOTE: Do not apply excessive pressure to the bearing.
      Fig 14: Pressing Tapered Roller Bearing
      G05240073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the counter drive gear and bearing to the transaxle case.

      SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) 

      NOTE: Do not apply excessive pressure to the counter drive gear.
      Fig 15: Pressing Counter Drive Gear And Bearing To Transaxle Case
      G05240074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat 2 new O-rings with ATF.
    2. Install the 2 O-rings to the 1st and reverse brake piston.
      NOTE:
      • Make sure that the O-rings are not twisted or pinched when they are installed.
      • Apply sufficient ATF to the O-ring prior to assembling.
        Fig 16: Identifying O-Rings
        G05240075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
      NOTE: Be careful not to damage the O-ring.
      Fig 17: Identifying 1st And Reverse Brake Piston
      G05240076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00070 

    2. Using a snap ring expander, install the snap ring to the transaxle case.
      Fig 18: Compressing Return Spring
      G05240077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.
      • The snap ring should be fully engaged in the groove of the cylinder.
      • Fix the snap ring to the inside of the claw of the spring seat firmly.
  15. INSTALL FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
      NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.
      Fig 19: Identifying Snap Ring And Front Planetary Ring Gear
      G05240078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear assembly to the brake hub.
      Fig 20: Removing Front Planetary Gear Assembly
      G05240079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press-fit the front planetary gear assembly.

      SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) 

      NOTE:
      • Do not apply excessive pressure to the planetary gear assembly.
      • Press the inner race of the LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right).
        Fig 21: Fitting Front Planetary Gear Assembly
        G05240080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new washer as shown in the illustration.
      Fig 22: Identifying Washer
      G05240081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, install the nut.

      SST 09387-00030,09387-00080 

      Torque: 280 N*m (2,855 kgf*cm, 207 ft.*lbf) 

      NOTE: Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.
      Fig 23: Removing Nut
      G05240082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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 as specified, gradually tighten the nut until it reaches the specified value.

      SST 09387-00080 

      Standard: 

      Turning torque at 60 rpm 

      Bearing: 

      New Bearing: 

      Fig 24: Measuring Turning Torque Of Bearing
      G05240083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      0.51 to 1.02 N*m (5.2 to 10.4 kgf*cm, 4.5 to 9.0 in.*lbf) 

      Used Bearing: 

      0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

    6. Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.

      Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) 

    7. Using a chisel and hammer, stake the front lock washer.
      Fig 25: Staking Front Lock Washer
      G05240084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL INPUT SUN GEAR 
    1. Coat the 2 thrust bearings with ATF.
    2. Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly.
      Fig 26: Identifying Thrust Bearings, Bearing Race And Input Sun Gear
      G05240085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.
      • When installing the thrust bearings and front sun gears, be careful about the direction of the parts.
      • Install the bearing race on the side of the front sun gear. Be careful about the direction of the race.
      • Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

      Thrust bearing and bearing race diameter: mm (in.) 

      THRUST BEARING AND BEARING RACE DIAMETER

        Inside Outside
      Thrust Bearing, A 32.5 (1.28) 56.5 (2.224)
      Bearing Race, B 40.2 (1.583) 59.3 (2.335)
      Thrust Bearing, C 38.6 (1.520) 59.7 (2.35)
      Bearing Race, D 38.6 (1.520) 59.3 (2.335)
  18. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear assembly to the rear planetary ring gear.
      Fig 27: Identifying Rear Planetary Gear Assembly
      G05240086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.
      Fig 28: Installing Snap Ring
      G05240087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Coat the 6 discs with ATF.
    2. Install the 7 plates and 6 discs.
      NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
      Fig 29: Identifying Discs And Plates
      G05240088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 
    1. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.
      Fig 30: Measuring Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder
      G05240089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Pack clearance: 

      1.16 to 1.35 mm (0.0457 to 0.0531 in.) 

      HINT:

      Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.)

      FLANGE THICKNESS FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 1.8 (0.071) 5 2.2 (0.087)
      2 1.9 (0.075) 6 2.3 (0.091)
      3 2.0 (0.079) 7 2.4 (0.094)
      4 2.1 (0.083) 8 2.5 (0.098)
    3. Install the flange.
      Fig 31: Identifying Flange
      G05240090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL SECOND BRAKE PISTON ASSEMBLY 
    1. Install the second brake piston assembly to the transaxle case.
      Fig 32: Identifying Second Brake Piston Assembly
      G05240091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring and measure the inside diameter.

      Inside diameter: 

      Greater than 167 mm (6.57 in.) 

      Fig 33: Installing Snap Ring
      G05240092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the tapered snap ring is installed in the correct direction.
      • When the diameter does not meet the specified value, replace the snap ring with a new one.
      • After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
  22. INSTALL 1-WAY CLUTCH SLEEVE OUTER 
    1. Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.
      NOTE: Make sure that the outer sleeve is installed in the correct direction.
      Fig 34: Identifying 1-Way Clutch Sleeve Outer
      G05240093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL 1-WAY CLUTCH ASSEMBLY 
    1. Install the 1-way clutch inner race to the 1-way clutch.
      NOTE:
      • Make sure that the inner race is installed in the correct direction.
      • Confirm that the discrimination mark is visible.
        Fig 35: Identifying 1-Way Clutch Inner Race
        G05240094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the rotating direction of the 1-way clutch for the lock or free operation as shown in the illustration.
      Fig 36: Identifying Free Operation Of 1-Way Clutch
      G05240095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Bearing 53.6 (2.110) 69.4 (2.732)
      NOTE: Install the thrust bearing properly so that no-colored race will be visible.
      Fig 37: Identifying Thrust Needle Roller Bearing
      G05240096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL PLANETARY CARRIER THRUST WASHER NO. 1 
    1. Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, and install the washer onto the planetary sun gear assembly.
      NOTE: After installing, confirm that the projection should be fixed firmly in the hole of the planetary sun gear assembly.
      Fig 38: Installing Planetary Carrier Thrust Washer No. 1
      G05240097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Coat the planetary carrier thrust washer No. 2 with yellow petrolatum, and install the washer onto the rear planetary sun gear.
      Fig 39: Removing Rear Planetary Sun Gear Assembly
      G05240098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Race, A 33.0 (1.299) 45.4 (1.787)
      Bearing, B 31.85 (1.254) 45.2 (1.78)
      Fig 40: Identifying Bearing And Rear Planetary Sun Gear
      G05240099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear planetary sun gear assembly to the rear planetary gear.
      NOTE: When installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.
      Fig 41: Identifying Rear Planetary Sun Gear Assembly
      G05240100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs and 5 plates to the transaxle case.
    3. Temporarily install the snap ring.
      Fig 42: Identifying Discs And Plates
      G05240101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
    2. Select an appropriate flange so that the pack clearance will meet the specified value.

      Clearance: 

      0.62 to 0.91 mm (0.0244 to 0.0358 in.) 

      Fig 43: Measuring Distance Between Disc Surface And Snap Ring Surface
      G05240102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.) Flange thickness: mm (in.)

      FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 (0.118) 5 3.4 (0.134)
      2 3.1 (0.122) 6 3.5 (0.138)
      3 3.2 (0.126) 7 3.6 (0.142)
      4 3.3 (0.130) 8 -
    3. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
      NOTE: Secure the snap ring so that the ends are visible through the groove of the transaxle case.
      Fig 44: Identifying Snap Ring
      G05240103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY 
    1. Install the direct clutch hub to the planetary gear assembly.
      NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation.
    2. Coat the thrust bearing with ATF.
      Fig 45: Identifying Direct Clutch Hub And Planetary Gear Assembly
      G05240104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bearing race and the thrust bearing to the direct clutch hub.
      NOTE: Be careful not to drop the bearing when it is installed.

      Bearing and race diameter: mm (in.) 

      BEARING AND RACE DIAMETER

        Inside Outside
      Bearing, A 24.7 (0.972) 39.5 (1.555)
      Race, B 23.6 (0.929) 38.0 (1.496)
  29. INSTALL DIRECT CLUTCH ASSEMBLY 
    1. Coat the thrust bearing with ATF.
    2. Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
      NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
      Fig 46: Identifying Thrust Bearing And Direct Clutch Assembly
      G05240105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the connecting part of the transaxle case and the rear cover.
    4. 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 vernier calipers (Dimension C).
      Fig 47: Measuring Distance Between Transaxle Case And Straightedge
      G05240106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using vernier calipers and a straightedge, measure the dimension shown in the illustration.
    6. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.

      End play: 

      0.244 to 0.901 mm (0.0096 to 0.0355 in.) 

      Fig 48: Measuring Dimension
      G05240107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the no-colored race side is facing the direct clutch assembly.

      HINT:

      End play = Dimension D - Dimension C

      Bearing thickness and diameter: mm (in.) 

      BEARING THICKNESS AND DIAMETER

      Thickness Inside Outside
      3.6 (0.1417) 56.3 (2.217) 75.7 (2.980)
      3.8 (0.1496) 56.3 (2.217) 75.7 (2.980)
  30. INSTALL GOVERNOR APPLY GASKET NO. 1 
    1. Install 3 new governor apply gaskets No. 1 to the transaxle case.
      Fig 49: Locating Gaskets
      G05240108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BRAKE APPLY TUBE 
    1. Install the clamp to the brake apply tube.
      NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
    2. Install the clutch apply tube.
      Fig 50: Identifying Brake Apply Tube
      G05240109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the brake apply tube to the transaxle case with the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      NOTE: The tube should be securely inserted until it reaches the stopper.
      Fig 51: Locating Bolt, Clamp And Brake Apply Tube
      G05240110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, press the needle roller bearing into the transaxle rear cover.

      SST 09950-60010 (09951-00230, 09952-06010) 

      Press fit depth: 

      20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

      Fig 52: Pressing Needle Roller Bearing Into Transaxle Rear Cover
      G05240111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • The engraved mark side of the bearing should face upward.
      • Repeat the press fit until the specified value is obtained.
    2. Coat the needle roller bearing with ATF.
  33. INSTALL REAR CLUTCH OIL SEAL RING OUTER 
    1. Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 53: Installing Rear Clutch Oil Seal Ring Outer
      G05240112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Coat 4 new O-rings with ATF.
    2. Install the 4 O-rings to the 4 transaxle case No. 1 plugs.
    3. Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 54: Identifying O-Ring And Transaxle Case No. 1 Plugs
      G05240113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
    2. Apply FIPG to the cover.

      Seal Packing: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 55: Applying FIPG To Cover
      G05240114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the FIPG is applied in a bead (section diameter: ø1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.
    3. Apply liquid sealer to the "A" bolt threads.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    4. Install the 11 bolts.

      Torque: Bolt A 

      18.6 N*m (190 kgf*cm, 14 ft.*lbf) 

      Other bolts: 

      24.5 N*m (250 kgf*cm, 18 ft.*lbf) 

      Fig 56: Locating Bolts
      G05240115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL UNDERDRIVE CLUTCH DISC NO. 2 
    1. Coat the 4 discs with ATF.
    2. Install the 4 discs, 4 plates and flange to the transaxle case.
      NOTE: Be careful about the order of the discs, plates and flange.
      Fig 57: Identifying Discs, Plates And Flange
      G05240116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be fully engaged in the groove of the drum.
      Fig 58: Removing Snap Ring
      G05240117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 
    1. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 

      1.81 to 2.20 mm (0.0713 to 0.0866 in.) 

      Fig 59: Measuring Underdrive Brake Pack Clearance
      G05240118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Select an appropriate flange from the table below so that it will meet the specified value.

      Flange thickness: mm (in.) 

      FLANGE THICKNESS

      Mark Thickness Mark Thickness
      1 3.0 (0.118) 4 3.1 (0.122)
      2 3.2 (0.126) 5 3.3 (0.130)
      3 3.4 (0.134) - -
    2. Temporarily remove the snap ring and attach it to the flange.
    3. Reinstall the snap ring.
  38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch assembly to the 1-way clutch.
    2. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
      Fig 60: Checking Free Operation
      G05240119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    1. 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.
      Fig 61: Identifying Outer Race Retainer
      G05240120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 1-way clutch to the transaxle case.
      NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
      Fig 62: Identifying Mark On 1-Way Clutch Outer Race
      G05240121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.
      NOTE: The snap ring should be fully engaged in the groove of the transaxle case.
      Fig 63: Installing Snap Ring To Transaxle Case
      G05240122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 
    1. Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

      Bearing and bearing race diameter: mm (in.) 

      BEARING AND BEARING RACE DIAMETER

        Inside Outside
      Bearing 37.73 (1.4854) 58.0 (2.2835)
      Race 29.9 (1.1772) 55.5 (2.185)
      Fig 64: Identifying Bearing And Bearing Race
      G05240123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 
    1. Install the pawl pin and spring to the parking lock pawl.
      Fig 65: Identifying Pawl Pin, Spring And Parking Lock Pawl
      G05240124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
      Fig 66: Identifying Spring, Pawl Pin And Parking Lock Pawl
      G05240125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear assembly to the transaxle case.
      NOTE: Fully engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly and install them securely.
      Fig 67: Installing Underdrive Planetary Gear Assembly To Transaxle Case
      G05240126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the parking lock pawl shaft.
      Fig 68: Installing Parking Lock Pawl Shaft
      G05240127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the pawl shaft clamp with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 69: Identifying Bolt And Pawl Shaft Clamp
      G05240128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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.
      Fig 70: Measuring Gap Between Top Of Differential Drive Pinion
      G05240129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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)

      Fig 71: Identifying Dimension (1) And Dimension (2)
      G05240130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the thrust bearing race No. 1 to the transaxle case while checking its direction.

      Bearing race diameter: mm (in.) 

      BEARING RACE DIAMETER

        Inside Outside
      Bearing race 39,5 (1.555) 45.8 (1.803)
      Fig 72: Installing Multiple Disc Clutch Hub
      G05240131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.

      Thrust bearing and race diameter: mm (in.) 

      THRUST BEARING AND RACE DIAMETER

        Inside Outside
      Thrust Bearing 36.4 (1.433) 52.2 (2.055)
    3. Coat the needle roller bearing with ATF.
      Fig 73: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
      G05240132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the needle roller bearing to the multiple clutch hub.

      Bearing diameter: mm (in.) 

      BEARING DIAMETER

        Inside Outside
      Bearing 23.6 (0.929) 44 (1.732)
    5. Install the multiple clutch hub to the transaxle case.
      Fig 74: Identifying Needle Roller Bearing And Multiple Clutch Hub
      G05240133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FORWARD CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF.
    2. Install the thrust needle roller bearing to the forward clutch.

      Thrust bearing diameter: mm (in.) 

      THRUST BEARING DIAMETER

        Inside Outside
      Thrust Bearing 33.58 (1.3220) 51.9 (2.043)
      Fig 75: Identifying Thrust Needle Roller Bearing
      G05240134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install the thrust bearing properly so that the no-colored race or blue ink jet race will be visible.
    3. Install the forward clutch to the forward clutch assembly.
      NOTE:
      • Align the splines of all discs in the forward clutch with those of the multiple clutch hub to install them securely.
      • Be careful not to damage the inside of the bushing of the forward clutch hub during installation.
        Fig 76: Identifying Forward Clutch Assembly
        G05240135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OVERDRIVE BRAKE GASKET 
    1. Install 2 new overdrive brake gaskets.
      Fig 77: Installing Overdrive Brake Gaskets
      G05240136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Install the differential gear assembly to the transaxle case.
      Fig 78: Removing Differential Gear Assembly From Transaxle Case
      G05240137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL THRUST BEARING UNDERDRIVE RACE NO. 2 
    1. Install the thrust bearing underdrive race No. 2 to the underdrive planetary gear assembly.
      Fig 79: Identifying No. 2 Thrust Bearing Underdrive Race
      G05240138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. Coat the thrust needle-roller bearing with ATF.
    2. 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.
      Fig 80: Identifying Thrust Needle Roller Bearing And Underdrive Planetary Gear Assembly
      G05240139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.) 

      RACE THICKNESS

      F - E Thickness
      Less than 7.72 (0.3039) 3.5 (0.138)
      7.72 (0.3039) 3.8 (0.150)

      Bearing and bearing race diameter: mm (in.) 

      BEARING AND BEARING RACE DIAMETER

        Inside Outside
      Bearing 57.2 (2.252) 84.96 (3.345)
      Bearing race 56.4 (2.22) 83.0 (3.268)
  49. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump to the transaxle case with the 7 bolts.

      Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) 

      Fig 81: Locating Transaxle Case Bolts
      G05240140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the O-ring of the oil pump with ATF.
      NOTE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.
      Fig 82: Identifying O-Ring
      G05240141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
    2. Apply FIPG to the transaxle case.

      Seal Packing: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 83: Applying FIPG To Transaxle Case
      G05240142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 16 bolts.

      Torque: Bolt A 

      25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Bolt B 

      33 N*m (337 kgf*cm, 24 ft.*lbf) 

      Bolt C 

      29 N*m (295 kgf*cm, 21 ft.*lbf) 

      Fig 84: Installing Transaxle Housing
      G05240143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply seal packing or equivalent to bolts A and D.

      Seal packing: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 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.) 

      NOTE: Tighten the bolts within 10 minutes of sealant application.
  51. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.

      End play: 

      0.262 to 1.249 mm (0.0103 to 0.0492 in.) 

      Fig 85: Measuring Input Shaft End Play
      G05240144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. FIX AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Fix the transaxle assembly.
      Fig 86: Fixing Automatic Transaxle Assembly
      G05240145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat a new oil seal with MP grease.
    2. Install the oil seal to the transaxle case.

      SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) 

      Oil seal installation depth: 

      0 +- 0.5 mm (0 +- 0.197 in.) 

      Fig 87: Installing Oil Seal To Transaxle Case
      G05240146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod to the manual valve lever.
      Fig 88: Identifying Parking Lock Rod Sub-Assembly
      G05240147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Install a new spacer and the manual valve lever shaft to the transaxle case.
      NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.
      Fig 89: Installing Manual Valve Lever Sub-Assembly
      G05240148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, drive in a new pin.
      Fig 90: Driving Out Pin Using Pin Punch And Hammer
      G05240149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
      Fig 91: Turning Spacer And Lever Shaft
      G05240150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, install the retainer spring.
      NOTE: Hang the spring on the shaft firmly.
      Fig 92: Removing Manual Valve Lever Shaft Retainer Spring
      G05240151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL PARKING LOCK PAWL BRACKET 
    1. Install the parking lock pawl bracket with the 2 bolts.

      Torque: 20 N*m (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.
      Fig 93: Locating Parking Lock Pawl Bracket And Bolts
      G05240152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. 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.

      Fig 94: Locating Manual Detent Spring And Cover Bolts
      G05240153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

      20 N*m (205 kgf*cm, 15 ft.*lbf) 

      Bolt B 

      12 N*m (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 
    1. Coat a new O-ring with ATF, and 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.
      Fig 95: Locating O-Ring
      G05240154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

      Accumulator spring: 

      ACCUMULATOR SPRING SPECIFICATIONS

      Free Length Outer Diameter mm (in.) Color
      Inner 62.00 (2.4469) / 15.50 (0.610) Purple
      Outer 74.23 (2.9224)/ 21.70(0.854) Purple
      Fig 96: Locating Piston With ATF
      G05240155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Coat 2 new O-rings with ATF, and 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.
      Fig 97: Locating O-Rings
      G05240156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

      Accumulator spying: 

      ACCUMULATOR SPRING SPECIFICATIONS

      Free Length Outer Diameter mm (In.) Color
      60.96 (2.3999) / 14.10 (0.555) Yellow
      Fig 98: Locating Piston With ATF
      G05240157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL C-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, and 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.
      Fig 99: Locating O-Ring And C-3 Accumulator Piston
      G05240158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, and install it to the transaxle case.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.

      Accumulator spring: 

      ACCUMULATOR SPRING SPECIFICATIONS

      Free Length Outer Diameter mm (in.) Color
      72.20 (2.8425) / 19.0 (0.748) Colorless
      Fig 100: Installing Piston To Transaxle Case
      G05240159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spring to the C-3 accumulator piston.
      NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
      Fig 101: Identifying Spring And C-3 Accumulator Piston
      G05240160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL CHECK BALL BODY 
    1. Coat the check ball body with ATF.
    2. 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.
      Fig 102: Identifying Check Ball Body And Spring
      G05240161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL BRAKE DRUM GASKET 
    1. Coat a new brake drum 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.
      Fig 103: Locating Brake Drum Gasket
      G05240162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET 
    1. 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.
      Fig 104: Locating Transaxle Case 2nd Brake Gasket
      G05240163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL GOVERNOR APPLY GASKET NO. 1 
    1. 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.
      Fig 105: Locating Governor Apply Gasket No.1
      G05240164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSMISSION WIRE 
    1. 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 transmission wire to the transaxle case. Apply sufficient ATF to the O-ring before installation.
      Fig 106: Locating O-Ring With ATF
      G05240165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission wire retaining bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 107: Locating Transmission Wire Retaining Bolt
      G05240166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. CONNECT TRANSMISSION WIRE 
    1. Coat an O-ring of the ATF temperature sensor with ATF.
    2. Install the ATF temperature sensor with the lock plate and bolt.

      Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) 

    3. Connect the 7 solenoid connectors.
      Fig 108: Locating Solenoid Connectors
      G05240167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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 
    1. While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.
      Fig 109: Locating Transaxle Case Bolts
      G05240168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 11 N*m (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.) 

      NOTE:
      • 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 
    1. 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.
      Fig 110: Locating O-Ring
      G05240169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil strainer to the valve body with the 3 bolts.

      Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

      NOTE: Apply ATF to the bolts.
      Fig 111: Locating Bolts And Oil Strainer
      G05240170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install the 2 magnets to the oil pan.
    2. Apply seal packing or equivalent to new 18 bolts.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 112: Locating Magnets On Oil Pan
      G05240171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pan and a new oil pan gasket to the transaxle case with the 18 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      NOTE:
      • 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.
        Fig 113: Locating Bolts Of Oil Pan
        G05240172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL TRANSAXLE CASE NO. 1 PLUG 
    1. Coat 4 new O-rings with ATF, and install them to the 4 transaxle case No. 1 plugs.
    2. Install the 4 transaxle case No. 1 plugs to the transaxle case.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

      Fig 114: Identifying O-Rings And Transaxle Case No.1 Plugs
      G05240173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL SPEED SENSOR 
    1. Coat 2 new O-rings with ATF and install them to the 2 sensors.
    2. Install the 2 sensors to the transaxle case with the 2 bolts.

      Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) 

      Fig 115: Identifying Speed Sensor
      G05240174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF, and install it to the elbow.
    2. Install the elbow to the transaxle case.

      Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf) 

      Fig 116: Identifying O-Ring And Elbow
      G05240175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) 
    1. Coat a new O-ring with ATF, and install it to the union.
    2. Install the union to the transaxle case.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 117: Identifying O-Ring And Union
      G05240176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL BREATHER PLUG HOSE 
    1. Install the breather plug hose to the transaxle case firmly.
  76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the 2 adjusting bolts.
    2. Install a new nut stopper and nut.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

      Fig 118: Installing Bolts
      G05240177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the control shaft lever.
      Fig 119: Identifying Control Shaft Lever
      G05240178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
    5. Remove the control shaft lever.
      Fig 120: Turning Lever Counterclockwise
      G05240179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Align the groove with the neutral basic line.
    7. Tighten the 2 bolts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 121: Aligning Groove With Neutral Basic Line
      G05240180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a screwdriver, stake the nut with the nut stopper.
      Fig 122: Removing Lock Nut And Stopper
      G05240181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the control shaft lever, washer and nut.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 123: Installing Bolt
      G05240182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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