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Automatic Transaxle Unit: Reassembly

WARNING: This page is about a different variant/trim than selected.
  1. BEARING POSITION 

    Check each bearing position and installation direction.

    Fig 1: Identifying Bearing Position
    G06011783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    THRUST BEARING DIAMETER SPECIFICATION

    Mark Front Race Diameter Inside / Outside (mm (in.)) Thrust Bearing Diameter Inside / Outside (mm (in.)) Rear Race Diameter Inside / Outside (mm (in.))
    A - 53.0 (2.087) / 78.2 (3.079) 52.1 (2.051)/75.5 (2.972)
    B - 37.73 (1.4854) / 58.0 (2.284) 29.9 (1.177)/55.5 (2.185)
    C - 33.85 (1.3327)/52.2 (2.055) -
    D - 23.5 (0.925)/44.0 (1.732) -
    E - 36.3 (1.429)/52.2 (2.055) 34.5 (1.358)/48.5 (1.909)
    F 34.5 (1.358)/56.82 (2.2370) 32.4 (1.276)/56.62 (2.2291) -
    G 40.3 (1.587)/58.0 (2.284) 38.6 (1.520)/60.0 (2.362) 38.6 (1.520)/ 58.0 (2.284)
    H - 53.6 (2.110)/69.6 (2.740) -
    I 33.1 (1.303)/45.4 (1.787) 31.85 (1.2539)/45.2 (1.780) -
    J - 25.0 (0.984)/39.5 (1.555) 23.6 (0.929)/37.0 (1.457)
    K - 55.9 (2.201) / 76.0 (2.992) or 76.6 (3.016) -
  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 Transaxle Apply Tube Clamp And Differential Gear Lube Apply Tube
      G06011751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Install a new O-ring to each No. 1 transaxle case plug.
    2. Install the 2 No. 1 transaxle case plugs to the transaxle rear housing.

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

      Fig 3: Identifying No. 1 Transaxle Case Plugs With O-Rings
      G04976198Courtesy 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
      G06011750Courtesy 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, 09950-70010 (09951-00780, 09951-07100) 

      NOTE: Do not apply excessive pressure.
      Fig 5: Pressing Underdrive Cylindrical Roller Bearing
      G04976227Courtesy 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 case.
      NOTE:
      • Do not expand the gap of the oil seal ring excessively.
      • Securely engage the hooks. Confirm that the rings rotate smoothly.
        Fig 6: Identifying Underdrive Clutch Drum Oil Seal Rings
        G06011747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NEEDLE ROLLER BEARING 
    1. Wrap vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wrapped tape is about 5.0 mm (0.197 in.).
      NOTE: Clean SST to remove oil deposits before wrapping with vinyl tape.
      Fig 7: Wrapping Vinyl Tape Around SST
      G06011789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat a new needle roller bearing with ATF.
    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 the press.
      Fig 8: Pressing Needle Roller Bearing To Transaxle Case
      G04976230Courtesy 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:
      • Install the O-rings carefully so that they are not twisted or pinched.
      • Apply sufficient ATF to the O-rings prior to installation.
        Fig 9: Locating O-Rings
        G06011745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the underdrive brake piston with ATF.
    3. Install the underdrive brake piston to the transaxle case.
      NOTE: Be careful not to damage the O-rings.
      Fig 10: Identifying Underdrive Brake Piston
      G04976232Courtesy 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 

      Fig 11: Compressing Return Spring With Press
      G04976193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, install the snap ring to the transaxle case.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
      • The snap ring should be securely engaged in the groove of the transaxle case.
  10. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Install the snap ring to the transaxle case.
      Fig 12: Identifying Snap Ring
      G04976234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the bearing outer race (rear side) to the transaxle case.

      SST 09316-12010, 09950-60020 (09951-00810), 09950-70010 (09951-07150) 

      NOTE:
      • Ensure that the snap ring is securely installed.
      • Do not apply excessive pressure to the bearing outer race.
        Fig 13: Pressing Bearing Outer Race (Rear Side) To Transaxle Case
        G04976235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the bearing outer race (front side) to the transaxle case.

      SST 09316-12010, 09502-24010, 09523-36010, 09950-60020 (09951-00810), 09950-70010 (09951-07150) 

      NOTE:
      • Do not apply excessive pressure to the bearing outer race.
      • Install the bearing outer race with a press while holding the bearing outer race with SST (09502-24010, 09523-36010).
        Fig 14: Pressing Bearing Outer Race (Front Side) To Transaxle Case
        G04976236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 angular balls to the transaxle case.
  11. INSTALL COUNTER DRIVE GEAR 
    1. Coat the counter drive gear with ATF.
    2. Using SST and a press, install the tapered roller bearing inner race (front side) to the counter drive gear.

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

      NOTE: Do not apply excessive pressure to the bearing inner race.
      Fig 15: Pressing Tapered Roller Bearing Inner Race (Front Side) To Counter Drive Gear
      G05559408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, install the counter drive gear and bearing inner race (rear side) to the transaxle case.

      SST 09223-15030, 09527-17011, 09950-60020 (09951-00720), 09950-70010 (09951-07150) 

      NOTE: Do not apply excessive pressure to the counter drive gear and bearing inner race.
      Fig 16: Pressing Counter Drive Gear And Bearing Inner Race (Rear Side) To Transaxle Case
      G06044159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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:
      • Install the O-rings carefully so that they are not twisted or pinched.
      • Apply sufficient ATF to the O-rings prior to installation.
        Fig 17: Locating O-Rings
        G06011734Courtesy 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-rings.
  13. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the return spring.
      Fig 18: Identifying 1st And Reverse Brake Piston
      G06011800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the return spring and compress the return spring with a press.

      SST 09387-00070 

      Fig 19: Compressing Return Spring With Press
      G04976182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install the snap ring to the transaxle case.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      • After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
      • The snap ring should be securely engaged in the groove of the cylinder.
  14. 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 20: Identifying Front Planetary Ring Gear And Snap Ring With Brake Hub
      G06011731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary gear assembly to the brake hub.
      Fig 21: Identifying Front Planetary Gear Assembly And Brake Hub
      G04976243Courtesy 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 front planetary gear assembly.
      • Press the inner race of the counter drive angular ball bearing (front side), counter drive gear, and front planetary gear assembly to the position where no preload is applied to each tapered roller bearing (front and rear).
        Fig 22: Pressing Front Planetary Gear Assembly
        G06011804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a new washer as shown in the illustration.
      Fig 23: Identifying Washer
      G04976245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, install the nut.

      SST 09387-00030,09387-00080 

      Torque: 185 N*m (1886 kgf*cm, 136 ft.*lbf) 

      Fig 24: Removing/Installing Nut And Washer
      G04976178Courtesy 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. If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range.

      SST 09387-00080 

      Torque: 350 N*m (3569 kgf*cm, 258 ft.*lbf) (maximum limit) 

      Bearing Turning Torque: 0.19 to 0.4 N*m (1.9 to 4.1 kgf*cm, 1.7 to 3.5 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) to measure the turning torque.

      Fig 25: Measuring Turning Torque Of Bearing
      G04976247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a chisel and a hammer, stake the washer.
      Fig 26: Staking Washer
      G04976248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL INPUT SUN GEAR 
    1. Coat the 2 thrust bearings with ATF.
    2. Install the input sun gear, 2 thrust needle roller bearings, 2 No. 2 thrust bearing races, and No. 3 thrust bearing races to the transaxle case.
      NOTE: Ensure that the parts are installed in the correct order and direction.

      Thrust Bearing and Bearing Race Diameter 

      THRUST BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing Race, A 34.5 (1.358) 56.82 (2.2370)
      Thrust Bearing, B 32.4 (1.276) 56.62 (2.2291)
      Bearing Race, C 40.3 (1.587) 58.0 (2.284)
      Thrust Bearing, D 38.6 (1.520) 60.0 (2.362)
      Bearing Race, E 38.6 (1.520) 58.0 (2.284)
      Fig 27: Identifying Input Sun Gear
      G04976249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the rear planetary gear assembly to the brake hub.
      Fig 28: Identifying Rear Planetary Gear Assembly
      G06011724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, install the snap ring.
      NOTE: Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.
      Fig 29: Removing/Installing Snap Ring
      G04976173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL 1ST AND REVERSE BRAKE DISC 
    1. Coat the 5 discs with ATF.
    2. Install the 5 plates and 5 discs.
      NOTE: Be sure to install the plates and discs in the correct order.
      Fig 30: Identifying Plates And Discs
      G04976252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE  (See INSPECTION )
  20. INSTALL 2ND BRAKE PISTON 
    1. Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder.
      Fig 31: Coating 2nd Brake Piston With ATF
      G05000986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Install the 2nd brake piston return spring sub-assembly.
      NOTE: Ensure that all springs are fitted in the piston correctly.
      Fig 32: Identifying 2nd Brake Piston Return Spring Sub-Assembly
      G06011720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the piston return spring, and compress it with a press.

      SST 09387-00060 

    3. Using a screwdriver, install the snap ring.
      NOTE: Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      Fig 33: Removing/Installing Snap Ring
      G04976169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL 2ND BRAKE PISTON ASSEMBLY 
    1. Install the 2nd brake piston assembly to the transaxle case.
      Fig 34: Identifying Second Brake Piston Assembly
      G06044177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the snap ring and measure the inside diameter.

      Inside diameter: More than 167 mm (6.57 in.) 

      NOTE:
      • Make sure to install the tapered snap ring in the correct direction.
      • If the diameter does not meet the specified value, replace the snap ring with a new one.
      • After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the transaxle case.
        Fig 35: Removing/Installing Snap Ring
        G04976257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL ONE-WAY CLUTCH SLEEVE 
    1. Install the one-way clutch sleeve to the 2nd brake cylinder assembly.
      NOTE: Check the position and direction of the outer sleeve.
      Fig 36: Identifying One-Way Clutch Sleeve
      G06011818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER 
    1. Coat the No. 1 planetary carrier thrust washer with ATF, and install it onto the planetary sun gear assembly.
      NOTE: After installing the washer, confirm that the projections on the washer are securely fitted in the holes of the planetary sun gear assembly.
      Fig 37: Identifying No. 1 Planetary Carrier Thrust Washer
      G06011715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL ONE-WAY CLUTCH ASSEMBLY 
    1. Install the one-way clutch inner race to the one-way clutch.
      NOTE:
      • Check the direction of the inner race.
      • Confirm that the identification mark can be seen.
        Fig 38: Identifying One-Way Clutch Inner Race
        G06011713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
      Fig 39: Checking One-Way Clutch
      G04976261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the one-way clutch and thrust needle roller bearing to the one-way clutch sleeve outer.

      Bearing Diameter 

      BEARING DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing 53.6 (2.110) 69.6 (2.740)
      NOTE: Confirm that the thrust bearing is installed properly with the uncolored race visible.
      Fig 40: Identifying One-Way Clutch And Thrust Needle Roller Bearing
      G06011712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Coat the No. 2 planetary carrier thrust washer with ATF, and install it onto the rear planetary sun gear.
      Fig 41: Identifying No. 2 Planetary Carrier Thrust Washer And Rear Planetary Sun Gear
      G06011711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

      Bearing and Race Diameter 

      BEARING AND RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Race, A 33.1 (1.303) 45.4 (1.787)
      Bearing, B 31.85 (1.254) 45.2 (1.78)
      Fig 42: Identifying Race And Bearing
      G05559435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the rear planetary sun gear assembly to the rear planetary gear.
      NOTE: After installing the rear planetary sun gear assembly, confirm that the discs engage.
      Fig 43: Identifying Rear Planetary Sun Gear Assembly
      G06011709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Coat the 3 discs with ATF.
    2. Install the 3 discs and 3 plates to the transaxle case.
      Fig 44: Identifying Discs And Plates
      G04976266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the snap ring.
  28. INSPECT PACK CLEARANCE OF 2ND BRAKE  (See INSPECTION )
  29. 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.
    3. Install the bearing race and the thrust bearing to the direct clutch hub.
      Fig 45: Identifying Overdrive Direct Clutch Hub
      G06044188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When installing the bearing, hold the side of the overdrive clutch hub.

      Bearing and Race Diameter 

      BEARING AND RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing, A 25.0 (0.984) 39.5 (1.555)
      Race, B 23.6 (0.929) 37.0 (1.457)
  30. INSTALL OVERDRIVE DIRECT CLUTCH O-RING 
    1. Coat a new O-ring with ATF, and install it to the direct clutch drum.
      NOTE: Ensure that the O-ring is not twisted or pinched.
      Fig 46: Locating Overdrive Direct Clutch O-Ring
      G04976157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Coat the direct clutch drum with ATF, and install it to the intermediate shaft.
      NOTE:
      • Be careful not to damage the O-ring.
      • Be careful not to damage the lip seal of the direct clutch drum.
        Fig 47: Identifying Overdrive Direct Clutch Drum And Intermediate Shaft Sub-Assembly
        G06011829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL OVERDRIVE DIRECT CLUTCH PISTON 
    1. Coat the overdrive direct clutch piston with ATF, and install it to the overdrive direct clutch drum sub-assembly.
      NOTE: Be careful not to damage the lip seal of the direct clutch piston.
      Fig 48: Identifying Overdrive Direct Clutch Piston
      G06011830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Install the overdrive clutch return spring sub-assembly to the overdrive direct clutch drum sub-assembly.
      NOTE: When installing the spring sub-assembly, ensure that all springs are fitted in the piston correctly.
      Fig 49: Identifying Overdrive Clutch Return Spring And Overdrive Direct Clutch Drum
      G04976154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the clutch balancer with ATF.
    3. Install the clutch balancer to the overdrive direct clutch drum sub-assembly.
      NOTE:
      • Be careful not to damage the lip seal of the direct clutch balancer.
      • Ensure that the clutch balancer is not pinched and there are no defects on the sealing lip.
      • Apply sufficient ATF to the sealing lip prior to installation.
        Fig 50: Identifying Clutch Balancer And Overdrive Direct Clutch Drum Sub-Assembly
        G06011832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place SST on the clutch balancer and compress the piston return spring with a press.

      SST 09387-00020 

    5. Using a snap ring expander, install the snap ring to the direct clutch drum.
      NOTE:
      • Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
        Fig 51: Placing SST On Clutch Balancer And Compressing Spring With Press
        G04976152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Position the end gap of the snap ring in the piston as shown in the illustration.
      NOTE: Ensure that the end gap of the snap ring is not aligned with any of the stoppers.
      Fig 52: Identifying Stopper Illustration Position
      G06011834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL OVERDRIVE DIRECT CLUTCH DISC 
    1. Coat the 3 discs with ATF.
    2. Install the 3 plates, 3 discs and flange to the intermediate shaft.
      NOTE: Be sure to install the plates, discs and flange in the correct order.
      Fig 53: Identifying Plates, Discs And Flange
      G04976275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be securely engaged in the groove of the drum.
      Fig 54: Installing Snap Ring
      G04976276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Coat the 3 discs with ATF.
    2. Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft.
      NOTE:
      • Install the cushion plate with the mark on the white surface facing the plate.
      • Be sure to install the cushion plate, plates, discs and flange in the correct order.
        Fig 55: Identifying Cushion Plate, Plates, Discs And Flange
        G04976277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be securely engaged in the groove of the drum.
      Fig 56: Installing Snap Ring
      G04976278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSPECT PACK CLEARANCE OF DIRECT CLUTCH  (See INSPECTION )
  37. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH  (See INSPECTION )
  38. 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 discs in the direct clutch should be completely matched with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
      Fig 57: Identifying Direct Clutch Assembly And Thrust Bearing
      G06011698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the contact surfaces 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 a vernier caliper (Dimension C).
      Fig 58: Measuring Distance Between Transaxle Case And Straightedge
      G04976280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a vernier caliper 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 specified end play value and install it.

      End play: 0.199 to 0.970 mm (0.00783 to 0.0382 in.) 

      NOTE: Make sure that the uncolored race side is facing the direct clutch assembly.

      HINT:

      End play = Dimension D - Dimension C

      Fig 59: Measuring Dimension
      G04976281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bearing Thickness and Diameter 

      BEARING THICKNESS AND DIAMETER SPECIFICATION

      Thickness Inside (mm (in.)) Outside (mm (in.))
      3.6 (0.142) 55.9 (2.201) 76.0 (2.992)
      3.8 (0.150) 55.9 (2.201) 76.6 (3.016)
  39. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Install 3 new No. 1 governor apply gaskets to the transaxle case.
      Fig 60: Locating No. 1 Governor Apply Gasket
      G04976282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. 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 61: Installing Clamp To Brake Apply Tube
      G04976283Courtesy 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: Each pipe should be securely inserted until it reaches the stopper.
      Fig 62: Locating Bolt, Clamp And Brake Apply Tube
      G06011697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL NEEDLE ROLLER BEARING 
    1. Using SST and a press, install the needle roller bearing to the transaxle rear cover.

      SST 09950-60010 (09951 -00230, 09951-00360, 09952-06010) 

      Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) 

      NOTE:
      • Face the inscribed side of the bearing race up.
      • Keep pressing until the specified value is obtained.
        Fig 63: Pressing Needle Roller Bearing To Transaxle Rear Cover
        G05000888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the needle roller bearing with ATF.
  42. INSTALL REAR CLUTCH OIL SEAL RING 
    1. Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
      NOTE: The rear clutch oil seal rings should be securely engaged in the grooves of the drum.
      Fig 64: Identifying Rear Clutch Oil Seal Rings
      G06011694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Install a new O-ring to each No. 1 transaxle case plug.
    2. Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.

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

      Fig 65: Identifying No. 1 Transaxle Case Plugs
      G06011693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove any packing material and keep the contact surfaces of the transaxle rear cover and the transaxle case away from oil.
    2. Apply FIPG to the cover.

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

      NOTE: Apply FIPG in a continuous bead (width 1.2 mm (0.0472 in.)) along the sealing surface.
      Fig 66: Identifying FIPG Application Area
      G04976288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply adhesive to the threads of bolt A.

      Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent 

      Fig 67: Applying Adhesive To Threads Of Bolt A
      G06011849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 11 bolts.

      Torque: Bolt A 

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

      Other bolts 

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

  45. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Coat the 3 discs with ATF.
    2. Install the 3 discs, 3 plates and flange to the transaxle case.
      NOTE: Be sure to install the discs, plates and flange in the correct order.
      Fig 68: Identifying Discs, Plates And Flange
      G04976290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      NOTE: The snap ring should be securely engaged in the groove of the drum.
      Fig 69: Removing/Installing No. 2 Underdrive Clutch Disc Snap Ring
      G04976140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE  (See INSPECTION )
  47. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY  (See INSPECTION )
  48. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the outer race retainer to the one-way clutch.
      NOTE: Securely install the outer race retainer onto the tooth of the one-way clutch.
      Fig 70: Identifying Outer Race Retainer
      G06044213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the one-way clutch to the transaxle case.
      NOTE: Ensure that the outer race retainer and the mark on the transaxle case are aligned.
      Fig 71: Identifying Mark On Outer Race Retainer
      G06011853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.
      NOTE: The snap ring should be securely engaged in the groove of the transaxle case.
      Fig 72: Installing Snap Ring
      G04976294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL UNDERDRIVE CLUTCH DRUM O-RING 
    1. Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
      NOTE: Install the O-ring carefully so that it is not twisted or pinched.
      Fig 73: Locating Underdrive Clutch Drum O-Ring
      G04976430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL UNDERDRIVE CLUTCH PISTON SET 
    1. Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
      NOTE:
      • Be careful not to damage the O-ring.
      • Be careful not to damage the lip seal of the piston.
        Fig 74: Identifying Underdrive Clutch Piston Set
        G04976431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Install the return spring to the underdrive clutch drum.
      NOTE: After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.
    2. Coat the clutch balancer with ATF.
      Fig 75: Identifying Return Spring And Underdrive Clutch Drum
      G06044046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the clutch balancer to the underdrive clutch drum.
      NOTE: Be careful not to damage the lip seal of the clutch balancer.
      Fig 76: Identifying Clutch Balancer And Underdrive Clutch Drum
      G04976422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place SST on the clutch balancer and compress the piston return spring with a press.

      SST 09350-32014 (09351-32070) 

    5. Using a snap ring expander, install the snap ring to the underdrive clutch drum.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
        Fig 77: Compressing Spring With Press
        G04976421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Position the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
      NOTE: The end gap of the snap ring should not be aligned with any of the stoppers.
  52. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Coat the 3 discs with ATF.
      Fig 78: Identifying Gap Of Snap Ring
      G04976435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 plates, 3 discs, and flange to the underdrive clutch drum.
      NOTE: Ensure that the discs, plates, and flange are in the correct order.
      Fig 79: Identifying Plates, Discs And Flange
      G04976436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING 
    1. Using a screwdriver, install the No. 2 underdrive clutch flange hole snap ring.
    2. Check that the end gap of the snap ring is not aligned with one of the cutouts.
      NOTE: The snap ring should be securely engaged in the groove of the drum.
      Fig 80: Identifying No. 2 Underdrive Clutch Flange Hole Snap Ring
      G04976437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 
    1. Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch.

      Bearing and Race Diameter 

      BEARING AND RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing 37.73 (1.4854) 58.0 (2.284)
      Race 29.9 (1.177) 55.5 (2.185)
      Fig 81: Identifying Thrust Bearing And Bearing Race
      G04976295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the underdrive clutch assembly to the transaxle case.
      NOTE: When installing the underdrive clutch drum sub-assembly, do not damage the oil seal ring.
  55. INSTALL PARKING LOCK PAWL 
    1. Install the pawl pin and spring to the parking lock pawl.
      Fig 82: Identifying Pawl Pin And Spring With Parking Lock Pawl
      G04976296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the parking lock pawl, pin and spring to the transaxle case as shown in the illustration.
      Fig 83: Identifying Spring, Pawl Pin And Parking Lock Pawl
      G05000774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL UNDERDRIVE PLANETARY RING GEAR 
    1. Install a new snap ring to the outer race of the tapered roller bearing.

      HINT:

      If replacing the bearing, also replace the counter driven gear with a new one.

      Fig 84: Identifying Snap Ring
      G04976405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a piston ring compressor, squeeze the snap ring.
      Fig 85: Squeezing Snap Ring
      G04976406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the outer race of the angular ball bearing.

      SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) 

      NOTE: Do not damage the snap ring during installation of the outer race.
      Fig 86: Pressing Outer Race Of Angular Ball Bearing
      G04976407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the underdrive planetary ring gear to the counter driven gear.
      Fig 87: Identifying Underdrive Planetary Ring Gear And Counter Driven Gear
      G04976402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using snap ring pliers, install the snap ring.
      Fig 88: Removing/Installing Underdrive Planetary Ring Gear Snap Ring
      G04976401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using a press, press the angular bail bearing inner race (rear side) into the underdrive planetary gear.

      SST 09726-40010, 09950-60010 (09951 -00260), 09950-70010 (09951-07100) 

      Fig 89: Pressing Angular Bail Bearing Inner Race (Rear Side) Into Underdrive Planetary Gear
      G04976410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the counter driven gear with planetary ring gear to the underdrive planetary gear.
      Fig 90: Installing Counter Driven Gear With Planetary Ring Gear To Underdrive Planetary Gear
      G04976411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press in the angular ball bearing inner race (front side).

      SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) 

      NOTE: Rotate the counter driven gear while pressing.
      Fig 91: Pressing Angular Ball Bearing Inner Race (Front Side)
      G04976412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a press, press in the parking lock gear.

      SST 09316-20011, 09950-60010 (09951-00260), 09950-70010 (09951-07100) 

      NOTE: Rotate the counter driven gear while pressing.
      Fig 92: Pressing Parking Lock Gear
      G04976413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL DIFFERENTIAL DRIVE PINION 
    1. Using a press, press in the differential drive pinion.

      SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) 

      NOTE: Rotate the counter driven gear while pressing.
      Fig 93: Pressing Differential Drive Pinion
      G04976414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL CYLINDRICAL ROLLER BEARING RACE INNER 
    1. Using a press, press in the cylindrical roller bearing race inner.

      SST 09515-21010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) 

      NOTE: Rotate the counter driven gear while pressing.
      Fig 94: Pressing Cylindrical Roller Bearing Race Inner
      G04976415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL FRONT PLANETARY GEAR NUT 
    1. Clamp the underdrive planetary gear in a soft jaw vise.
      NOTE: Be careful not to damage the differential drive pinion.
    2. Using a socket wrench, install a new gear nut.

      Torque: 280 N*m (2855 kgf*cm, 207 ft.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 750 mm (29.53 in.).

      Fig 95: Removing/Installing Underdrive Planetary Gear Nut
      G04976397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a chisel and hammer, stake the gear nut.
      CAUTION: Be sure that there are no cracks on the nut.
      Fig 96: Staking Gear Nut
      G04976417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Install the underdrive planetary gear assembly to the transaxle case.
      NOTE: Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly.
      Fig 97: Identifying Underdrive Planetary Gear Assembly
      G06011669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the parking lock pawl shaft.
      Fig 98: Identifying Parking Lock Pawl Shaft
      G04976299Courtesy 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 99: Identifying Pawl Shaft Clamp
      G06011666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle case and housing (Dimension E).
      NOTE: Take a note of dimension E because it is necessary for the following process.
      Fig 100: Measuring Gap Between Top Of Differential Drive Pinion
      G04976301Courtesy 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 following formula:
      NOTE: Take a note of dimension F because it is necessary for the following process.

      HINT:

      Dimension F = Dimension (1) - Dimension (2)

      Fig 101: Measuring Places Of Transaxle Housing
      G04976302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the No. 1 thrust bearing race to the transaxle case in the correct direction.

      Bearing Race Diameter 

      BEARING RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing Race 34.5 (1.359) 48.5 (1.909)
      Fig 102: Identifying No. 1 Thrust Bearing Race
      G06011884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the thrust needle roller bearing and race with ATF, and install them onto the multiple disc clutch hub.

      Thrust Bearing Diameter 

      THRUST BEARING DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing 36.3 (1.429) 52.2 (2.055)
    3. Coat the needle roller bearing with ATF.
      Fig 103: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
      G06044246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the needle roller bearing to the multiple disc clutch hub.

      Bearing Diameter 

      BEARING DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing 23.5 (0.925) 44.0 (1.732)
    5. Install the multiple disc clutch hub to the transaxle case.
      Fig 104: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
      G06011886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL INPUT SHAFT OIL SEAL RING 
    1. Compress a new input shaft oil seal ring from both sides to adjust dimension A.

      Dimension A: 5 mm (0.197 in.) 

    2. Coat the oil seal ring with ATF and install it to the input shaft.
      NOTE: Do not expand the gap of the oil seal ring excessively. Securely engage the hooks.
      Fig 105: Installing Input Shaft Oil Seal Ring
      G04976386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Coat the forward clutch piston with ATF, and install it to the input shaft.
      NOTE: Be careful not to damage the lip seal of the forward clutch piston.
      Fig 106: Identifying Forward Clutch Piston
      G04976387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Install the return spring to the input shaft.
      NOTE: After installing the spring sub-assembly, check that all of the springs are fitted to the piston correctly.
      Fig 107: Identifying Return Spring And Input Shaft
      G04976379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the clutch balancer with ATF.
    3. Install the clutch balancer to the input shaft.
      NOTE:
      • Be careful not to damage the lip seal of the forward clutch balancer.
      • Install the clutch balancer carefully not to pinch or damage at the sealing lip.
      • Apply sufficient ATF to the sealing lip prior to installation.
        Fig 108: Identifying Clutch Balancer And Input Shaft
        G04976378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place SST on the clutch balancer, and compress the clutch balancer with a press.

      SST 09387-00020 

      Fig 109: Compressing Return Spring With Press
      G04976377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the snap ring with a snap ring expander.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    6. Position the end gap of the snap ring in the piston as shown in the illustration.
      NOTE: The end gap of the snap ring should not be aligned with any of the stoppers.
      Fig 110: Identifying Gap Of Snap Ring
      G04976391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Coat the 5 discs with ATF.
    2. Install the 5 plates, 5 discs, and flange to the input shaft.
      NOTE: Ensure that the discs, plates, and flange are in the correct order.
      Fig 111: Identifying Plates, Discs And Flange
      G04976392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring.
      Fig 112: Removing/Installing Snap Ring
      G04976375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check that the end gap of the snap ring is not aligned with one of the cutouts.
      NOTE: The snap ring should be securely engaged in the groove of the drum.
  67. INSPECT PACK CLEARANCE OF FORWARD CLUTCH  (See INSPECTION )
  68. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC  (See INSPECTION )
  69. INSTALL FORWARD CLUTCH ASSEMBLY 
    1. Coat the thrust needle roller bearing with ATF.
    2. Install the thrust needle roller bearing to the forward clutch assembly.

      Thrust Bearing Diameter 

      THRUST BEARING DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing 33.85 (1.3327) 52.2 (2.0551)
      NOTE: Confirm that the thrust bearing is installed properly with the uncolored race visible.
      Fig 113: Identifying Thrust Needle Roller Bearing
      G04976306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the forward clutch assembly to the multiple clutch hub assembly.
      NOTE:
      • Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.
      • Be careful not to damage the bushing inside the multiple clutch hub during installation.
        Fig 114: Identifying Forward Clutch Assembly
        G06011656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL OVERDRIVE BRAKE GASKET 
    1. Install 2 new overdrive brake gaskets.
      Fig 115: Identifying Overdrive Brake Gaskets
      G04976127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL DIFFERENTIAL GEAR ASSEMBLY 
    1. Install the differential gear assembly to the transaxle case.
      Fig 116: Identifying Differential Gear Assembly
      G06011654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.
      Fig 117: Identifying No. 2 Thrust Bearing Underdrive Race And Underdrive Planetary Gear Assembly
      G06011653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. 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 Dimensions E and F that ware measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate No. 2 underdrive planetary gear thrust bearing race which satisfies the specified end play value, and install it.

      End play: 0.198 to 0.693 mm (0.00779 to 0.02728 in.) 

      HINT:

      End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 in.) - No. 2 underdrive thrust bearing race thickness.

      Race Thickness: mm (in.) 

      RACE THICKNESS SPECIFICATION

      F - E (mm (in.)) Thickness (mm (in.))
      Less than 7.339 (0.28894) 3.5 (0.138)
      7.339 (0.28894) or more 3.8 (0.150)
      Fig 118: Identifying Thrust Needle Roller Bearing And Differential Gear Assembly
      G06011652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bearing and Bearing Race Diameter 

      BEARING AND BEARING RACE DIAMETER SPECIFICATION

        Inside (mm (in.)) Outside (mm (in.))
      Bearing 53.0 (2.087) 78.2 (3.079)
      Bearing race 52.1 (2.051) 75.5 (2.972)
  74. INSTALL OIL PUMP ASSEMBLY 
    1. Install the oil pump to the transaxle case with the 7 bolts.

      Torque: 22 N*m (225 kgf*cm, 16 ft.*lbf) 

      Fig 119: Locating Oil Pump Bolts
      G04976123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the O-ring of the oil pump with ATF.
      NOTE: Confirm that the input shaft rotates smoothly by hand after installing the oil pump.
      Fig 120: Identifying Oil Pump O-Ring
      G04976313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL TRANSAXLE HOUSING 
    1. Remove any FIPG material and keep the contact surfaces of the transaxle case and transaxle housing away from oil.
    2. Apply FIPG to the transaxle case.

      FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 121: Identifying FIPG Application Area
      G06043579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transaxle housing to the transaxle case with the 18 bolts.

      Torque: Bolt A 

      29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Bolt B 

      29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Bolt C 

      22 N*m (225 kgf*cm, 16 ft.*lbf) 

      Bolt D 

      10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt E 

      33 N*m (336 kgf*cm, 24 ft.*lbf) 

      Bolt F 

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

      Fig 122: Locating Transaxle Case With Bolts
      G06011904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply seal packing or equivalent to bolts C and F.

      Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent 

      Bolt length 

      Bolt B, C, D, F: 50 mm (1.969 in.) 

      Bolt A, E: 42 mm (1.654 in.) 

      NOTE: Apply seal packing to new bolts and tighten them within 10 minutes of application.
  76. INSPECT INPUT SHAFT END PLAY  (See INSPECTION )
  77. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle assembly onto wooden blocks.
      Fig 123: Identifying Transaxle Assembly Onto Wooden Blocks
      G04976316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Coat a new oil seal with MP grease.
    2. Using SST and a hammer, install the oil seal to the transaxle case.

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

      Oil seal drive in depth: -0.5 to 0.5 mm (-0.0197 to 0.0197 in.) 

      Fig 124: Tapping Manual Valve Lever Shaft Oil Seal
      G06011906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Install the parking lock rod to the manual valve lever.

      HINT:

      Align the dial with the notches on the manual valve lever and turn the dial 90° to install the parking lock rod.

      Fig 125: Identifying Parking Lock Rod Sub-Assembly
      G04976318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. 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 while installing the shaft to the transaxle case.
      Fig 126: Installing Manual Valve Lever Sub-Assembly
      G04976319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and a hammer, drive in a new pin.
      Fig 127: Tapping Transaxle Case Pin
      G04976118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Turn the spacer and the lever shaft to align the smaller hole of 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 128: Staking Spacer Through Small Hole
      G04976321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, install the retainer spring.
      NOTE: Securely attach the spring onto the shaft.
      Fig 129: Removing/Installing Manual Valve Lever Shaft Retainer Spring
      G04976114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. 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: Be sure that the parking rod is placed between the parking pawl and the guide of the parking bracket after the parking bracket is installed.
      Fig 130: Locating Parking Lock Pawl Bracket With Bolts
      G04976323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring sub-assembly with the 2 bolts.
      NOTE: Make sure to install the manual detent spring and cover in this order.

      HINT:

      Tighten bolt A first, then B.

      Torque: Bolt A 

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

      Bolt B 

      12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 131: Locating Manual Detent Spring Sub-Assembly With Bolts
      G04976324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt length: 

      Bolt A: 27 mm (1.06 in.) 

      Bolt B: 16 mm (0.630 in.) 

  84. INSTALL B-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
      NOTE:
      • Install the O-ring to the accumulator piston, being careful not to twist or pinch it.
      • Apply sufficient ATF to the O-ring prior to installation.
      • Be sure to confirm the installation position.
        Fig 132: Locating O-Ring
        G06044003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston and springs with ATF, and install them to the transaxle case.
      NOTE: Install the correct springs to the B-3 accumulator piston after confirming the color and dimension of the springs.

      Accumulator Spring 

      ACCUMULATOR SPRING LENGTH SPECIFICATION

      Free Length / Outer Diameter (mm (in.)) Color
      Inner: 62.00 (2.4409) /15.50 (0.610) Purple
      Outer: 74.23 (2.9224) / 21.70 (0.854) Purple
      Fig 133: Identifying Piston And Springs With ATF
      G04976326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Coat 2 new O-rings with ATF, and install them to the reverse clutch accumulator piston.
      NOTE:
      • Install the O-rings to the accumulator piston, being careful not to twist or pinch them.
      • Apply sufficient ATF to the O-rings prior to installation.
      • Be sure to confirm the installation positions.
        Fig 134: Locating Reverse Clutch Accumulator Piston O-Ring
        G05559498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston and spring with ATF, and install them to the transaxle case.
      NOTE: Install the correct spring to the reverse clutch accumulator piston after confirming the color or dimension of the spring.

      Accumulator Spring 

      ACCUMULATOR SPRING LENGTH SPECIFICATION

      Free Length / Outer Diameter (mm (in.)) Color
      60.96 (2.3999) /14.10 (0.555) Yellow
      Fig 135: Identifying Piston And Spring
      G04976328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL C-3 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
      NOTE:
      • Install the O-ring to the accumulator piston, being careful not to twist or pinch it.
      • Apply sufficient ATF to the O-ring prior to installation.
      • Be sure to confirm the installation position.
        Fig 136: Locating O-Ring
        G06011918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the piston with ATF, and install it to the transaxle case.
      Fig 137: Identifying Piston With AFT
      G04976330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the spring to the C-3 accumulator piston.
      NOTE: Install the correct spring to the C-3 accumulator piston after confirming the color and dimension of the spring.

      Accumulator Spring 

      ACCUMULATOR SPRING LENGTH SPECIFICATION

      Free Length / Outer Diameter (mm (in.)) Color
      72.20 (2.8425) /19.0 (0.748) No color
      Fig 138: Identifying C-3 Accumulator Piston Spring
      G04976107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL CHECK BALL BODY 
    1. Coat the check ball body with ATF.
    2. Install the check ball body and spring.
      NOTE: Ensure the spring is inserted into the check ball body and the parts are installed in the correct direction.
      Fig 139: Identifying Check Ball Body And Spring
      G04976106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL BRAKE DRUM GASKET 
    1. Coat a new brake drum gasket with ATF, and install it to the transaxle case.
      NOTE:
      • Do not damage the lip portion of the brake drum gasket when inserting the gasket to the case.
      • Apply sufficient ATF to the gasket prior to installation.
      • Be sure to install the part in the correct direction.
        Fig 140: Locating Brake Drum Gasket
        G04976105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. 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:
      • Do not damage the lip portion of the transaxle case 2nd brake gasket when inserting the gasket to the case.
      • Apply sufficient ATF to the gasket prior to installation.
      • Be sure to install the part in the correct direction.
        Fig 141: Locating Transaxle Case 2nd Brake Gasket
        G04976104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL NO. 1 GOVERNOR APPLY GASKET 
    1. Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
      NOTE:
      • Do not damage the lip portion of the No. 1 governor apply gasket when inserting the gasket to the case.
      • Apply sufficient ATF to the gasket prior to installation.
      • Be sure to install the part in the correct direction.
        Fig 142: Locating No. 1 Governor Apply Gasket
        G04976103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Check the manual valve lever position. Install the valve body to the transaxle case with the 17 bolts.

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

      Bolt length: 

      Bolt A: 25 mm (0.984 in.) 

      Bolt B: 57 mm (2.244 in.) 

      Bolt C: 41 mm (1.614 in.) 

      Fig 143: Locating Transaxle Case With Bolts
      G04976336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Push the valve body against the accumulator piston spring and the check ball body to install it.
      • When installing the valve body to the transaxle case, do not hold the solenoids.
      • Temporarily tighten the bolts marked (1) in the illustration first because they are positioning bolts.
  92. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the oil strainer.
      NOTE:
      • Install the O-ring carefully to avoid twists or pinches.
      • Apply sufficient ATF to the O-ring prior to installation.
        Fig 144: Locating Oil Strainer O-Ring
        G04976101Courtesy 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 prior to installation.
      Fig 145: Locating Oil Strainer Bolts
      G04976100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF, and install it to the transmission wire.
      NOTE: Install the O-ring carefully to avoid twists or pinches. Apply sufficient ATF to the O-ring prior to installation.
      Fig 146: Locating Transmission Wire O-Ring
      G06044289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission wire retaining bolt.

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

      Fig 147: Identifying Transmission Wire Connector
      G04976099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. CONNECT TRANSMISSION WIRE 
    1. Coat the ATF temperature sensor O-ring 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.
      NOTE:
      • Connect the connectors to A, B, C, D, E, F and G, starting with shorter connectors first.
      • Apply ATF to the bolt prior to installation.
        Fig 148: Locating Solenoid Connectors
        G06011930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install the 2 magnets to the oil pan.
      Fig 149: Identifying Transmission Oil Cleaner Magnets
      G04976096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply seal packing or equivalent to the 18 bolts.

      Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent 

      NOTE:
      • Apply seal packing to the bolts and tighten them within 10 minutes of application.
      • Completely remove any oil or grease from the gasket contact surfaces of the transaxle case and the oil pan before installing the oil pan to the case.
    3. Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts.

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

      NOTE:
      • Apply seal packing to the bolts and tighten them within 10 minutes of application.
      • Completely remove any oil or grease from the gasket contact surfaces of the transaxle case and the oil pan before installing the oil pan to the case.
    4. Install a new gasket to the drain plug.
    5. Install the drain plug.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

      Fig 150: Locating Oil Pan Bolts
      G04975941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.
    2. Install the 4 No. 1 transaxle case plugs to the transaxle case.

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

      Fig 151: Identifying O-Ring And No. 1 Transaxle Case Plugs
      G06011621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSTALL TRANSMISSION REVOLUTION SENSOR 
    1. Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.
      Fig 152: Identifying Speed Sensor With Bolts And O-Rings
      G06011934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply adhesive to the bolt threads.

      Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent 

    3. Install the 2 speed sensors to the transaxle case with the 2 bolts.

      Torque: Bolt A 

      8.8 N*m (90 kgf*cm, 78 in.*lbf) 

      Bolt B 

      11 N*m (112 kgf*cm, 8 ft.*lbf) 

  98. INSTALL OIL COOLER TUBE UNION (OUTLET 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: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 153: Identifying O-Ring And Union
      G06011619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. INSTALL OIL COOLER TUBE ELBOW (INLET OIL COOLER ELBOW) 
    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 (275 kgf*cm, 20 ft.*lbf) 

  100. INSTALL NO. 2 BREATHER PLUG 
    1. Coat a new O-ring with ATF.
      Fig 154: Identifying O-Ring And Elbow
      G06011936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hose and the O-ring to the breather plug.
    3. Install the No. 2 breather plug to the transaxle case.
      Fig 155: Identifying O-Ring And No. 2 Breather Plug
      G04976089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. 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.
      Fig 156: Locating Park/Neutral Position Switch Bolts
      G04975931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new nut stopper and nut.

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

      Fig 157: Locating Lock Plate Nut
      G04975927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the control shaft lever.
    4. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
      Fig 158: Identifying Control Shaft Lever Turn Position
      G06011940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the control shaft lever.
    6. Align the groove with the neutral basic line.
      Fig 159: Aligning Groove With Neutral Basic Line
      G06044302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Hold the switch in that position and tighten the 2 bolts.

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

    8. Using a screwdriver, stake the nut with the nut stopper.
      Fig 160: Unstaking Lock Plate
      G04975926Courtesy 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 161: Locating Control Shaft Lever Nut And Washer
      G06011613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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