Part 1

U151F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube and transaxle apply tube clamp to the transaxle housing with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
NOTICE:
Make sure to insert the pipe to the stopper.

3. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 No. 1 transaxle case plugs.
(b) Install the 2 No. 1 transaxle case plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65in-lbf)
4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Coat a new oil seal ring with ATF and install it to the transaxle housing.
5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical roller bearing.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07100
NOTICE:
Do not apply excessive pressure to the bearing.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Coat 2 new oil seal rings with ATF and install them to the transaxle rear cover.
- Do not expand the end gap of the oil seal ring too much.
- Secure the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.

7. INSTALL NEEDLE ROLLER BEARING

(a) 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 approximately 5.0 mm (0.197 in.).
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTICE:
Clean the SST to remove deposited oil before wrapping vinyl tape.

(b) Coat the needle roller bearing with ATF.

(c) Using SST and a press, install the needle-roller bearing to the transaxle case.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTICE:
When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.

8. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the underdrive brake piston.
- Make sure that the O-rings are not twisted or pinched when they are installed.
- Apply sufficient ATF to the O-ring before installing.

(b) Coat the underdrive brake piston with ATF.

(c) Install the underdrive brake piston to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.

9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.
SST: 09387-00020
(b) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
- 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.
- Install the spring sub-assembly and check that all of the springs are fully engaged in the piston correctly.
- The snap ring should be fully engaged in the groove of the transaxle case.

10. INSTALL NO. 2 BREATHER PLUG
11. INSTALL COUNTER DRIVE GEAR BEARING

(a) Coat the counter drive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST: 09950-60020
09951-01030
SST: 09950-70010
09951-07150
SST: 09649-17010
NOTICE:
- Do not apply excessive pressure to the bearing.
- Press-fit the bearing outer race until it contacts the transaxle case.

(c) Using a snap ring expander, install the snap ring.
NOTICE:
The surface with a white mark of the snap ring should face upward.

12. INSTALL COUNTER DRIVE GEAR

(a) Coat the counter drive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST: 09950-70010
09951-07150
SST: 09649-17010
NOTICE:
Do not apply excessive pressure to the bearing.

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST: 09950-70010
09951-07150
SST: 09223-15030
SST: 09527-17011
SST: 09950-60020
09951-00750
NOTICE:
Do not apply excessive pressure to the counter drive gear.

13. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st and reverse brake piston.
NOTICE:
- Make sure that the O-rings are not twisted or pinched when they are installed.
- Apply sufficient ATF to the O-rings before assembling them.

(c) Coat the 1st and reverse brake piston with ATF and install it to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.

14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.
SST: 09387-00070
(b) Using a snap ring expander, install the snap ring to the transaxle case.
NOTICE:
- 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 to prevent the spring seat from being deformed.
- Do not expand the snap ring excessively.
- Install the spring sub-assembly and 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

(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
NOTICE:
Confirm that the snap ring is engaged in the groove of the brake hub correctly.

16. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear assembly.
SST: 09950-60010
09951-00500
SST: 09950-70010
09951-07100
- 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 pre-load should be applied to one pair of the tapered roller bearings (left and right).

(d) Using SST, install the nut.
SST: 09387-00030
SST: 09387-00080
Torque: 280 Nm (2854 kgf-cm, 207ft-lbf)
NOTICE:
Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.

(e) 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
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 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.).

(f) Tighten the nut gradually until the specified turning torque of the tapered roller bearing is measured.
Torque: 350 Nm (3569 kgf-cm, 258ft-lbf)

(g) Using a chisel and hammer, stake the front lock washer.
17. INSTALL INPUT SUN GEAR

(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race, and the input sun gear to the front planetary gear assembly.
NOTICE:
- Install the bearing race on the side of the front planetary carrier. Make sure that the race is installed in the correct direction.
- When installing the thrust bearing and front sun gears, make sure that they are installed in the correct direction.
- Install the bearing race on the side of the front sun gear. Make sure that the race is installed in the correct direction.
- 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.)

18. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear assembly to the rear planetary ring gear.

(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm that the snap ring is engaged in the groove of the 1st and reverse brake hub correctly.

19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Make sure that the plates, discs, and flange are installed as shown in the illustration.

20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

(a) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
(b) Select an appropriate flange so that the pack clearance will be within the specified range.
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.)

(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.
NOTICE:
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.

NOTICE:
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.
NOTICE:
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.
NOTICE:
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.
NOTICE:
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.
NOTICE:
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.
NOTICE:
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.
NOTICE:
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.)
NOTICE:
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.
NOTICE:
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, 48in-lbf)
NOTICE:
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.
NOTICE:
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, 65in-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
NOTICE:
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, 14ft-lbf)
Other bolts: - Torque: 25 Nm (250 kgf-cm, 18ft-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.
NOTICE:
Make sure that discs, plate, and flange assembly are installed in the correct order.

(c) Using a screwdriver, install the snap ring.
NOTICE:
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.