Part 3

U151E AUTOMATIC TRANSAXLE UNIT:

REASSEMBLY (Continued)

40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

(b) 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

(a) Install the pawl pin and spring to the parking lock pawl.

(b) Temporarily install the parking lock pawl, shaft, and spring to the transaxle case as shown in the illustration.
42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the underdrive planetary gear assembly to the transaxle case.
- Fully engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.
- Check the number and position of the gear teeth.

(b) Install the parking lock pawl shaft.

(d) 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.

(e) 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)

43. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Install the No. 1 thrust bearing race to the transaxle case while checking its direction.

(b) Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.

(d) Install the needle roller bearing to the multiple clutch hub.

(e) Install the multiple clutch hub to the transaxle case.
44. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward clutch.

Thrust bearing diameter: mm (in.)

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

(c) Install the forward clutch to the forward clutch assembly.
- Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
- Be careful not to damage the bushing inside of the forward clutch hub during installation.

45. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear assembly to the transaxle case.
47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.
48. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play 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 No. 2 underdrive planetary gear thrust bearing race which satisfies the specified end play, and install the selected bearing race.
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.) - No. 2 underdrive thrust bearing race thickness.

Race thickness: mm (in.)

Bearing and bearing race diameter: mm (in.)

49. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22 Nm (226 kgf-cm, 16 ft-lbf)

(b) 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.

50. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Install the transaxle housing and 16 bolts to the transaxle case.
Bolt A - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
Bolt B - Torque: 33 Nm (337 kgf-cm, 24 ft-lbf)
Bolt C - Torque: 29 Nm (295 kgf-cm, 21 ft-lbf)
Bolt D - Torque: 28 Nm (286 kgf-cm, 21 ft-lbf)
HINT: Apply adhesive to bolts A and D.

Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
Bolt length
Bolt A, B
50 mm (1.969 in.)
Bolt C
42 mm (1.654 in.)
Bolt D
72 mm (2.835 in.)
NOTE: Tighten the bolts within 10 minutes of sealant application.

51. INSPECT INPUT SHAFT END PLAY

(a) Using a dial indicator, measure the input shaft end play.
End play:
0.262 to 1.249 mm (0.0103 to 0.0492 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY

(a) Fix the transaxle assembly on wooden blocks.
53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST: 09950-60010
09951-00230
SST: 09950-70010
09951-07100
Oil seal installation depth:
0.5 to -0.5 mm (0.02 to -0.02 in.)
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft to the transaxle case.
NOTE: Do not damage the oil seal when installing the shaft to the transaxle case.

(b) Using a pin punch and hammer, drive in a new pin.

(c) 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.
(d) Using a pin punch, stake the spacer through the small hole.
(e) Check that the spacer does not turn.
56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
NOTE: Hang the spring on the shaft firmly.

57. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (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.

58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) 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, and then bolt B.

Bolt A - Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
Bolt B - Torque: 12 Nm (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

(a) 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.

(b) 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.

60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

(a) 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.

(b) 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.