Part 2

A245E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY CONTINUED

28. INSPECT HEIGHT OF COUNTER SHAFT (Transaxle Unit)

29. INSTALL COUNTER DRIVE GEAR BEARING
(a) Install the new counter drive gear bearing to the counter drive gear.
(b) Install the new snap ring to the counter drive gear bearing.
SST: 09350-32014
09351-32120
30. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, install the counter drive gear.
SST: 09350-32014
09351-32150
09351-32130
31. INSTALL INTERMEDIATE SHAFT SUB-ASSEMBLY

(a) Install the intermediate shaft sub-assembly to the transaxle case.

(b) Using SST to hold the counter drive gear, install the new counter drive gear nut.
SST: 09960-10010
09962-01000
09963-01000
Torque: 180 Nm (1,835 kgf-cm, 133 ft-lbf)
32. INSPECT DRIVE GEAR PRELOAD (Transaxle Unit)

33. TIGHTEN COUNTER DRIVE GEAR NUT
34. INSTALL COUNTER DRIVEN GEAR

(a) Install the thrust needle roller bearing to the transaxle case.
Bearing:
mm (in.)

(b) Using SST and a press, press in the counter driven gear.
SST: 09350-32014
09351-32100
09351-32140

(c) Using SST to hold the counter shaft assembly, tighten a new counter driven gear nut.
SST: 09350-32014
09351-32032
Torque: 180 Nm (1,835 kgf-cm, 133 ft-lbf)
35. INSPECT END PLAY OF COUNTER SHAFT (Transaxle Unit)

36. TIGHTEN COUNTER DRIVEN GEAR NUT

(a) Using a pin punch and hammer, stake the counter driven gear nut.
37. INSTALL REAR TRANSMISSION CASE COVER

(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the rear transmission case cover or transaxle case.
(b) Apply FIPG sealant to the transmission case cover rear.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Install and tighten the 13 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

HINT: Each bolt length is indicated in the illustration.

Bolt length:
Bolt A
25 mm (0.98 in.)
Bolt B
32 mm (1.26 in.)
38. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY (Transaxle Unit)

39. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat the 2 new O-rings with ATF and install 2 new O-rings to the 1st and reverse brake piston.

(b) Place the 1st and reverse brake piston into the bore of the case, facing the spring seats upward.

NOTE: Be careful not to damage the O-rings.

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

(a) Install the 1st and reverse brake return spring sub-assembly and snap ring in place.

(b) Place SST on the 1st and reverse brake return spring sub-assembly, and compress the 1st and reverse brake return spring sub-assembly with a press.
SST: 09350-32014
09351-32040
(c) Using snap ring pliers, install the snap ring.

HINT: Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is aligned with the spring retainer claw.

41. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Install the 1st and reverse brake clutch discs and plates in order.

HINT: 6 plates and 6 discs.

Install in order:
D = Disc P = Plate
P - D - P - D - P - D - P - D - P - D - P - D

(b) Install the outer flange with the flat side facing downward.

(c) Using a screwdriver, install the snap ring to the transaxle case.

HINT: Be sure the snap ring end gap is not aligned with one of the cutouts.

42. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (Transaxle Unit)

43. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the intermediate shaft sub-assembly.
Bearing and race:
mm (in.)

(b) Coat the No. 2 planetary carrier thrust washer with petroleum jelly and install it on to the rear planetary gear assembly.

HINT: Make sure that the different lug shapes match the corresponding openings on the gear.

(c) Align the spline of the rear planetary gear assembly with the flukes of the discs and install the rear planetary gear assembly in to the 1st and reverse brake discs.

(d) Check the part "A" of the rear planetary gear assembly is below the upper surface of the flange.
SST: 09350-32014
09351-32050

(e) Place the No. 2 1 way clutch assembly into the case, with the shiny side facing upward.
(f) Install the No. 2 1 way clutch assembly onto the inner race while turning the rear planetary gear assembly clockwise with SST.
SST: 09350-32014
09351-32050
(g) Check that the rear planetary gear assembly turns freely clockwise and locks if turned counterclockwise.

(h) Coat the No. 2 planetary carrier thrust washer with petroleum jelly and install it on to the rear planetary gear assembly.

(i) Be sure the end gap of the snap ring is not aligned with one of the cutouts.
44. INSTALL 2ND BRAKE CLUTCH DISC

(a) Install the flange with the flat side facing upward.

(b) Install the 3 discs and 3 plates in order to the transaxle case.
Install in order:
D = Disc P = Plate
D - P - D - P - D - P
45. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.
46. INSTALL 2ND COAST BRAKE BAND GUIDE PLATE

(a) Install the 2nd coast brake band guide plate and brake band guide plate retainer so that its tip touches the transaxle case.
(b) Install the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
47. INSTALL SECOND BRAKE PISTON ASSEMBLY

(a) Align the groove of the drum with the bolt and place the 2nd brake piston assembly in to the transaxle case.

(b) Place both ends of the snap ring in the groove, and then set the snap ring in to the transaxle case.
(c) While compressing the piston return springs over the drum with hammer handles, install the snap ring.

HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.

48. INSPECT 2ND BRAKE PISTON (Transaxle Unit)

49. INSTALL 1 WAY CLUTCH ASSEMBLY

(a) Using a screwdriver, align the flukes of the discs in the 2nd brake.

(b) Align the spline of the 1 way clutch assembly with the flukes of the discs and install the 1 way clutch assembly to the 2nd brake discs.
50. INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE (Transaxle Unit)

51. INSTALL SUN GEAR INPUT DRUM ASSEMBLY

(a) Coat the No. 3 planetary carrier thrust washer with petroleum jelly and install it on the planetary sun gear sub-assembly.

(b) By turning the planetary sun gear sub-assembly clockwise, install it in to the 1 way clutch assembly.
52. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Coat the thrust needle roller bearing with petroleum jelly and install it on to the front planetary gear assembly.
Bearing:
mm (in.)

(b) Install the front planetary gear assembly.
53. INSTALL FRONT PLANETARY RING GEAR

(a) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them onto the front planetary gear assembly.
Bearing and race:
mm (in.)

(b) Install the front planetary ring gear to the transaxle case.

HINT: If the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.

(c) Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the tip of ring gear flange.
Bearing and race:
mm (in.)

54. INSTALL 2ND COAST BRAKE BAND ASSEMBLY

(a) Place the 2nd coast brake band assembly in to the transaxle case.
(b) Install the pin to the transaxle case.
55. INSTALL INPUT SHAFT ASSEMBLY

(a) Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch assembly.
Assembled bearing and race:
mm (in.)

(b) Coat the clutch drum thrust washer with petroleum jelly and install it onto the direct clutch drum with the oil groove facing upward.

(d) Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

HINT: If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.

(e) Place the direct clutch assembly and forward clutch assembly in to the transaxle case.
(f) While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install them.

(g) Check the distance between A and B.
Distance:
Approx. 3 mm (0.118 in.)