Part 1

U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

HINT
Check bearing position and installation direction.

1. INSTALL COUNTER DRIVE GEAR BEARING

HINT
Perform this procedure only when the counter drive gear bearing or transaxle case sub-assembly is replaced.

(a) Using SST and a press, install a new counter drive gear bearing and snap ring to the transaxle case sub-assembly.

SST : 09950-60020

09951-01030

SST : 09950-70010

09951-07100

2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat the lip of a new manual valve lever shaft oil seal with a small amount of MP grease.

(b) Using SST and a hammer, tap in the manual valve lever shaft oil seal.

SST : 09950-60010

09951-00230

SST : 09950-70010

09951-07100

Oil seal tap in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:
Check that the oil seal is installed in the correct direction.

3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

(a) Install the manual valve lever shaft sub-assembly to the transaxle case sub-assembly.

NOTICE:
Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft sub-assembly to the transaxle case sub-assembly.

(b) Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case sub-assembly.

4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Align the slot with the notches on the manual valve lever shaft sub-assembly and install the parking lock rod sub-assembly.

5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring sub-assembly and manual detent spring cover to the transaxle case sub-assembly with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

NOTICE:
Make sure to install the manual detent spring sub-assembly first and then the manual detent spring cover.

6. INSTALL NO. 3 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

NOTICE:
Ensure that the 2 O-rings are not twisted.

(b) Temporarily install the No. 3 brake piston to the transaxle case sub-assembly.

Text in Illustration

NOTICE:
After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned.

(d) Press the No. 3 brake piston into the transaxle case sub-assembly.

NOTICE:
Make sure that the lip of the No. 3 brake piston is not twisted and does not get caught in the transaxle case sub-assembly.

HINT
Use the installation surface of the return spring to press the piston into the transaxle case sub-assembly.

(e) Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.

(f) Install the brake piston return spring to the transaxle case sub-assembly.

Text in Illustration

NOTICE:
Install the brake piston return spring as shown in the illustration.

(g) Place SST on the brake piston return spring and compress the brake piston return spring with a press.

Text in Illustration

SST : 09387-00070

NOTICE:
Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.

(h) Using a screwdriver, install the snap ring to the transaxle case sub-assembly as shown in the illustration.

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.
* Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.

7. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, install a new counter drive gear bearing inner race (front side) to the counter drive gear.

SST : 09387-00020

(b) Using SST, install a new counter drive gear bearing inner race (rear side) and counter drive gear to the transaxle case sub-assembly.

SST : 09223-15030

SST : 09527-17011

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07100

NOTICE:
There should not be any clearance between the counter drive gear bearing inner race (front side) and counter drive gear.

8. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Using SST and a press, press in a new front planetary gear assembly to the transaxle case sub-assembly.

SST : 09223-15030

SST : 09527-17011

SST : 09951-01100

9. INSTALL NO. 2 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 2 brake piston.

NOTICE:
Ensure that the 2 O-rings are not twisted.

(b) Install the No. 2 brake piston to the transaxle case sub-assembly.

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

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

(a) Install the 1st and reverse brake return spring to the transaxle case sub-assembly.

(b) Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring with a press.

SST : 09387-00060

NOTICE:
Stop the press when the 1st and reverse brake return spring is flush with the snap ring groove. This prevents the 1st and reverse brake return spring from being deformed.

(c) Using a screwdriver, install the snap ring to the transaxle case sub-assembly as shown in the illustration.

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

11. INSTALL NO. 2 BRAKE DISC

(a) Install the 4 No. 2 brake discs, 4 No. 2 brake plates, and No. 2 brake flange to the transaxle case sub-assembly.

Text in Illustration

NOTICE:
Make sure that the discs, plates, and flange are installed in the correct order.

(b) Using a screwdriver, install the snap ring to the transaxle case sub-assembly.

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

12. INSPECT CLEARANCE OF NO. 2 BRAKE Transaxle Unit

13. INSTALL PLANETARY RING GEAR FLANGE

(a) Install the planetary ring gear flange to the planetary ring gear.

Text in Illustration

(b) Using a screwdriver, install the snap ring to the planetary ring gear.

NOTICE:
Confirm that the snap ring is correctly located in the groove of the planetary ring gear.

14. INSTALL ONE-WAY CLUTCH ASSEMBLY

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

Text in Illustration

(b) Install the one-way clutch assembly to the planetary ring gear.

NOTICE:
Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration.

(c) Coat the thrust needle roller bearing with ATF, and install it onto the front planetary gear assembly.

Text in Illustration

Bearing Diameter

NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(d) Install the one-way clutch assembly with the planetary ring gear to the transaxle case sub-assembly.

NOTICE:
Make sure that there is no clearance between the retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer will be deformed.

(e) Using a screwdriver, install the snap ring to the transaxle case sub-assembly.

NOTICE:
* Confirm that the snap ring is correctly located in the groove of the transaxle case sub-assembly.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case sub-assembly as shown in the illustration.

15. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)

(a) Using SST and a hammer, install a new differential drive pinion tapered roller bearing LH (outer race) to the transaxle case sub-assembly.

SST : 09950-60010

09951-00630

SST : 09950-70010

09951-07100

NOTICE:
Be sure to install the differential drive pinion tapered roller bearing so that there is no clearance between the bearing outer race and the transaxle case sub-assembly. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

16. INSTALL PARKING LOCK PAWL

(a) Install the parking lock pawl to the transaxle case sub-assembly with the parking lock pawl shaft.

Text in Illustration

(b) Install the parking lock pawl pin to the transaxle case sub-assembly.

(c) Install the torsion spring to the parking lock pawl.

NOTICE:
Make sure that one end of the spring is secured in the hole of the transaxle case sub-assembly and the other end is positioned on the parking lock pawl as shown in the illustration.

17. INSTALL PARKING LOCK SLEEVE

(a) Install the parking lock sleeve to the transaxle case sub-assembly.

18. INSTALL PAWL STOPPER PLATE

(a) Install the pawl stopper plate to the transaxle case sub-assembly with the 2 bolts.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

19. INSTALL NO. 1 TRANSMISSION CASE PLATE

(a) Clean and degrease the bolt and the installation hole in the transaxle case sub-assembly.

(b) Apply adhesive to 2 or 3 threads on the ends of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the No. 1 transmission case plate to the transaxle case sub-assembly with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

HINT
Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case sub-assembly as shown in the illustration.

20. INSTALL PAWL SHAFT CLAMP

(a) Install the pawl shaft clamp to the transaxle case sub-assembly with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

21. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)

(a) Using SST and a press, install a new differential drive pinion tapered roller bearing RH (inner race) to the counter driven gear sub-assembly.

SST : 09950-60010

09951-00490

NOTICE:
Be sure to install the differential drive pinion tapered roller bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

22. INSTALL DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (INNER RACE)

(a) Using SST and a press, install a new differential drive pinion tapered roller bearing LH (inner race) to the counter driven gear sub-assembly.

SST : 09950-60010

09951-00400

NOTICE:
Be sure to install the differential drive pinion tapered roller bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

23. INSTALL COUNTER DRIVEN GEAR

(a) Install the counter driven gear to the transaxle case sub-assembly.