Part 2
AUTOMATIC TRANSAXLE UNIT20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
a. Using a vernier caliper, 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 meet the specified value.
Standard pack clearance: 1.16 to 1.35 mm (0.0457 to 0.0531 inch)
HINT: Piston stroke = Dimension A - Flange thickness
Standard flange thickness:
c. Install the flange.
21. INSTALL SECOND BRAKE PISTON ASSEMBLY
a. Install the second brake piston to the transaxle case.
b. Install the snap ring and measure the inside diameter.
Inside diameter: Greater than 167 mm (6.57 inch)
NOTICE:
^ Make sure that the taper snap ring is installed in the correct direction.
^ When the diameter does not meet the specified value, replace the snap ring with a new one.
^ After installing the snap ring, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER
a. Install the 1-way clutch sleeve outer to the 2nd brake cylinder.
NOTICE: Make sure that the outer sleeve is installed in the correct direction.
23. INSTALL 1-WAY CLUTCH ASSEMBLY
a. Install the 1-way clutch inner race to the 1-way clutch.
NOTICE:
^ Make sure that the inner race is installed in the correct direction.
^ Confirm that the discrimination mark is visible.
b. Check that the 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration.
If the result is not as specified, replace the 1-way clutch.
c. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer.
Standard bearing diameter:
NOTICE: Install the thrust bearing properly so that the non-colored race will be visible.
24. INSTALL NO. 1 PLANETARY CARRIER THRUST WASHER
a. Coat the planetary carrier thrust washer with yellow petrolatum, and install the washer onto the planetary sun gear.
NOTICE: After installing the washer, confirm that the projection of the washer is fixed firmly in the hole of the planetary sun gear.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
a. Coat the 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.
Standard bearing diameter:
c. Install the rear planetary sun gear to the rear planetary gear.
NOTICE: After installing the rear planetary sun gear, 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 plates and 4 discs to the transaxle case.
NOTICE: Make sure that the plates and discs are installed as shown in the illustration.
c. Temporarily install the snap ring.
27. INSPECT PACK CLEARANCE OF 2ND BRAKE
a. Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).
b. Select an appropriate flange so that the pack clearance will meet the specified value.
Standard clearance: 0.62 to 0.91 mm (0.0244 to 0.0358 inch)
HINT: Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 inch)
Standard flange thickness:
c. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
NOTICE: Secure the snap ring so that the ends are visible through the groove of the transaxle case.
28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY
a. Install the direct clutch hub to the planetary gear.
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.
Standard bearing and race diameter:
29. INSTALL DIRECT CLUTCH ASSEMBLY
a. Coat the thrust bearing with ATF.
b. Install the direct clutch and thrust bearing to the rear planetary sun gear.
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 a vernier caliper (Dimension C).
e. Using a vernier caliper and straightedge, measure the dimension shown in the illustration (Dimension D).
f. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing.
Standard end play: 0.244 to 0.901 mm (0.0096 to 0.0355 inch)
NOTICE: Make sure that the non-collared race side is facing the direct clutch.
HINT: End play = Dimension D - Dimension C
Standard bearing thickness and diameter:
30. INSTALL NO. 1 GOVERNOR APPLY GASKET
a. Install 3 new 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 to the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
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)
Standard depth: 20.55 to 21.25 mm (0.8091 to 0.8366 inch)
NOTICE:
^ The engraved mark side of the bearing should face upward.
^ Continue pressing 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 plugs.
c. Install the 4 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
35. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY
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 FIPG 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: diameter 1.2 mm (0.047 inch)) so that the entire sealing surface will be evenly sealed. The seal packing should also protrude slightly from the flange after the installation of the cover has been completed.
c. Apply adhesive to the threads of bolt A.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
d. Install the cover with the 11 bolts.
Torque:
19 Nm (194 kgf-cm, 14 ft. lbs.) for bolt A
25 Nm (255 kgf-cm, 18 ft. lbs.) for other bolts
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: Be careful of the order of the discs, plate and flange.
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).
Standard pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 inch)
HINT: Select an appropriate flange from the table so that it will meet the specified value.
Standard flange thickness:
b. Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
c. Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
a. Install the underdrive clutch to the 1-way clutch.
b. Check that the underdrive 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration.
If the result is not as specified, replace the underdrive 1-way clutch.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
a. Install the outer race retainer to the 1-way clutch.
NOTICE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.
b. Install the 1-way clutch to the transaxle case.
NOTICE: Make sure that the mark on the 1-way clutch outer race is visible.
c. Using a screwdriver, install the snap ring to the transaxle case.
NOTICE: The snap ring should be fully engaged in the groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Coat the bearing and bearing race with petrolatum, and install them onto the underdrive clutch.
Standard bearing and bearing race diameter:
b. Install the underdrive clutch to the transaxle case.
NOTICE: Do not damage the oil seal when installing the underdrive clutch drum.
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 to the transaxle case.
NOTICE:
^ Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear and install them securely.
^ Check the position and number of the grooves on each end face of the differential drive pinion gear.
b. Install the parking lock pawl shaft.
c. Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
d. Using a straightedge and vernier caliper 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).
NOTICE: 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.
NOTICE: Record dimension F for the following process.
HINT: Dimension F = Dimension (1) - Dimension (2)
43. INSTALL MULTIPLE DISC CLUTCH HUB
a. Install the thrust bearing race to the transaxle case while checking its direction.
Standard bearing race diameter:
b. Coat the thrust needle roller bearing and race with yellow petrolatum, and install them onto the multiple disc clutch hub.
Standard thrust bearing and race diameter:
c. Coat the needle roller bearing with ATF.
d. Install the needle roller bearing to the multiple clutch hub.
Standard bearing diameter:
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.
Standard thrust bearing diameter:
NOTICE: Install the thrust bearing properly so that the non-collared race or blue ink jet race will be visible.
c. Install the forward clutch to the transaxle case.
NOTICE:
^ 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 to the transaxle case.
NOTICE: Check the position and number of the grooves on each end face of the differential ring gear.
47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
a. Install the thrust bearing underdrive race to the underdrive planetary gear.