Part 3

U151E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - Continued

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.

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.

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.

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. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY

(a) Support 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.

NOTICE:
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.

NOTICE:
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.)

NOTICE:
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.

NOTICE:
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.

NOTICE:
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.

NOTICE:
Install the springs to each accumulator piston, checking the identification color or each spring.

Accumulator spring:

60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF and install them to the reverse accumulator piston.

NOTICE:
Install the springs to each accumulator piston, checking the identification color or each spring.

Accumulator spring:

61. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF and install it to the C-3 accumulator piston.

NOTICE:
Install the springs to each accumulator piston, checking the identification color or each spring.

Accumulator spring:

NOTICE:
Install the springs to each accumulator piston, checking the identification color or each spring.

62. INSTALL CHECK BALL BODY

(a) Coat the check ball body with ATF.

(b) Install the check ball body and spring.

NOTICE:
Be sure to place the spring in the hole in the check ball body. Make sure that they are installed in the correct direction.

63. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF and install it to the transaxle case.

NOTICE:
Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.

64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF and install it to the transaxle case.

NOTICE:
Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.

65. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new No. 1 governor apply gasket with ATF and install it to the transaxle case.

NOTICE:
Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Make sure that they are installed in the correct direction.

66. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF and install it to the transmission wire.

NOTICE:
Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation.

(b) Install the bolt that retains the transmission wire.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

67. CONNECT TRANSMISSION WIRE

(a) Coat an O-ring of the ATF temperature sensor with ATF.

(b) Install the ATF temperature sensor with the lock plate and bolt.

Torque : 6.6 Nm (67 kgf-cm, 58 in-lbf)

(c) Connect the 7 solenoid connectors.

NOTICE:
* Connect the connectors A, B, C, D, E, F, G, in the order from the shortest to longest.
* Apply ATF to the bolt.

68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

Bolt length:

Bolt A
25 mm (0.984 in.)

Bolt B
57 mm (2.244 in.)

Bolt C
41 mm (1.614 in.)

NOTICE:
* Push the valve body against the accumulator piston spring and the check ball body to install the valve body.
* When installing the valve body to the transaxle case, do not hold the solenoids.
* Temporarily tighten the bolts marked (1) in the illustration first because they are positioning bolts.

69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the oil strainer.

NOTICE:
Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation.

(b) Install the oil strainer and 3 bolts to the valve body.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

NOTICE:
Apply ATF to the bolts.

70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 magnets to the oil pan.

(b) Apply adhesive to 18 new bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts.

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

NOTICE:
* Apply adhesive to the bolts and tighten them within 10 minutes of application.
* Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.

71. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs to the transaxle case.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)

72. INSTALL SPEED SENSOR

(a) Coat 2 new O-rings with ATF and install them to the 2 sensors.

(b) Install the 2 sensors to the transaxle case with the 2 bolts.

Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)

73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Coat a new O-ring with ATF and install it to the elbow.

(b) Install the elbow to the transaxle case.

Torque : 27 Nm (276 kgf-cm, 20 ft-lbf)

74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION)

(a) Coat a new O-ring with ATF and install it to the union.

(b) Install the union to the transaxle case.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

75. INSTALL BREATHER PLUG HOSE

(a) Install the breather plug hose to the transaxle case firmly.

76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch to the manual valve shaft.

(b) Temporarily install the 2 bolts.

(c) Install a new lock plate and tighten the nut.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

(d) Temporarily install the control shaft lever.

(e) Turn the lever counterclockwise until it stops and then turn it clockwise 2 notches.

(f) Remove the control shaft lever.

(g) Align the groove with the neutral basic line.

(h) Hold the switch in position and tighten the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(i) Using a screwdriver, bend the tabs of the lock plate.

(j) Install the control shaft lever, washer and nut.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

77. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.

(b) Install the bolt and speedometer driven hole cover sub-assembly to the transaxle assembly.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)