Part 2

U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY (Continued)

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.)

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.

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

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, 48 in-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.)

NOTICE:
* 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, 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

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 adhesive 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.

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.

39. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the one-way clutch.

NOTICE:
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.

NOTICE:
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.

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 petroleum jelly, and install them onto the underdrive clutch.

(b) Install the underdrive clutch assembly to the transaxle case.

NOTICE:
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.

NOTICE:
* 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.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(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).

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 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.

(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.

NOTICE:
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.

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 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.

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.

NOTICE:
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

Seal Bead Width:

1.2 mm (0.047 in.)

(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.)

NOTICE:
Apply adhesive to the bolts and tighten them within 10 minutes of application.

HINT
Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.