Part 2

U151F AUTOMATIC TRANSAXLE UNIT:

REASSEMBLY (Continued)

21. INSTALL 2ND BRAKE PISTON ASSEMBLY

(a) Install the 2nd brake piston assembly to the transaxle case.

(b) Install the snap ring and measure the inside diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
- Make sure that the tapered snap ring is installed in the correct direction.
- When the diameter is not as specified, 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 ONE-WAY CLUTCH SLEEVE OUTER

(a) Install the one-way clutch sleeve outer to the 2nd brake cylinder assembly.
NOTE: Make sure that the outer sleeve is installed in the correct direction.

23. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the one-way clutch inner race to the one-way clutch.
- Make sure that the inner race is installed in the correct direction.
- Confirm that the discrimination mark can be seen.

(b) Check the rotating direction of one-way clutch for the lock or free operation as shown in the illustration.

NOTE: Install the thrust bearing properly so that no-colored race can be seen.

24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER

(a) Coat the No. 1 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear assembly.
NOTE: After installing, confirm that the projection should be firmly engaged in the hole of the planetary sun gear assembly.

25. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 2 planetary carrier thrust washer with yellow petrolatum, and install the washer onto the rear planetary sun gear.

(b) Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear.

(c) Install the rear planetary sun gear assembly to the rear planetary gear.
NOTE: After installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.

26. INSTALL 2ND BRAKE CLUTCH DISC

(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
27. INSPECT PACK CLEARANCE OF 2ND BRAKE

(a) Using vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance will be within the specified range.
Clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT: Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Flange thickness: mm (in.)

(c) Temporarily remove the snap ring, attach the selected flange, and reinstall the snap ring.
NOTE: Secure the snap ring so that the ends can be seen through the groove of the transaxle case.

28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY

(a) 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.

(b) Coat the thrust bearing with ATF.
(c) 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.)

29. INSTALL DIRECT CLUTCH ASSEMBLY

(a) Coat the thrust bearing with ATF.
(b) 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.

(c) Clean the connecting part of the transaxle case and the rear cover.
(d) 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).

(e) Using vernier calipers and a straightedge, measure the dimension shown in the illustration.
(f) Calculate the end play using the following formula. Select a thrust bearing which satisfies the end play and install the selected bearing.
End play:
0.244 to 0.901 mm (0.0096 to 0.0355 in.)
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.)

30. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 3 new No. 1 governor apply gaskets to the transaxle case.
31. INSTALL BRAKE APPLY TUBE

(a) 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.

(b) Install the clutch apply tube.

(c) Install the brake apply tube and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: The tube should be securely inserted until it reaches the stopper.

32. INSTALL NEEDLE ROLLER BEARING

(a) 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.)
- The engraved mark side of the bearing should face upward.
- Repeat press fitting until the specified value is obtained.

(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER

(a) 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.

34. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 No. 1 transaxle case plugs.
(c) Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
(b) Apply seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTE: Make sure that the seal packing is applied in a bead (section diameter: dia1.2) so that the entire sealing surface will be evenly sealed. The seal packing should also protrude slightly from the flange after the assembly of the parts has been completed.

(c) Apply liquid sealer to the "A" bolt threads.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the 11 bolts.
Bolt A - Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)
Other bolts: - Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates, and flange to the transaxle case.
NOTE: Make sure that discs, plate, and flange assembly are installed in the correct order.

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

37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

(a) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT: Select an appropriate flange from the table below so that it will be within the specified range.

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

(a) Install the underdrive clutch assembly to the one-way clutch.
(b) Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
39. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the one-way clutch.
NOTE: Secure the outer race retainer to the external tooth of the one-way clutch firmly.

(b) Install the one-way clutch to the transaxle case.
NOTE: Make sure that the mark on the one-way clutch outer race can be seen.

(c) 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.