Part 2

U140F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - Continued

26. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.

(b) Install the 2 plugs to the transaxle rear cover.

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

27. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Using SST and a press, press in the bearing.

SST : 09950-60010

09951-00230

09952-06010

Standard depth:

12.05 to 12.75 mm (0.4744 to 0.5020 in.)

NOTICE:
* Face the inscribed mark side of the bearing race up.
* Repeat the press-fit until the specified value is obtained.

(b) Apply adhesive to the 2 screws.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Using a T30 ''TORX'' socket wrench, install the transaxle rear cover plate with the 2 screws.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

(e) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.

(f) Apply FIPG to the cover.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(g) Coat the needle roller bearing with ATF.

(h) Apply adhesive to the threads of the bolts labeled A.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(i) Install the 11 bolts.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf) for bolt A.

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

SST : 09950-60010

09951-00230

09952-06010

28. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

(a) Install the 3 discs and 3 plates to the transaxle.

Install in order:

P - D - P - D - P - D

HINT
D = Disc

P = Plate

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

(c) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392kPa, 4.0 kgf/cm2, 57 psi).

Standard pack clearance:

1.59 to 2.20 mm (0.0626 to 0.0866 in.)

HINT
Select an appropriate flange from the table below so that it will meet the specified value.

Standard flange thickness:

(d) Temporarily remove the snap ring and attach the flange. Restore the snap ring.

29. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Transaxle Unit

30. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the 1-way clutch.

(b) Install the 1-way clutch to the transaxle.

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.

31. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.

Standard race diameter:

(b) Install the underdrive clutch to the transaxle.

32. INSTALL UNDERDRIVE PLANETARY GEAR

(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.

NOTICE:
Engage all the discs of underdrive clutch and the hub splines of the underdrive planetary gear firmly and assemble them securely.

(d) Install the parking lock pawl shaft.

(e) Install the pawl shaft clamp with the bolt.

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

(f) 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 contact surface of the transaxle and housing (Dimension D).

NOTICE:
Make a note of dimension D as it is necessary for the following process.

(g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.

NOTICE:
Make a note of dimension E as it is necessary for the following process.

HINT
Dimension E = Dimension (1) - Dimension (2)

33. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Install the bearing race to the transaxle while checking its direction.

Standard bearing race diameter:

(b) Coat the thrust bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.

Standard thrust bearing and race diameter:

Standard bearing diameter:

(d) Install the forward clutch hub to the transaxle.

34. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Install the thrust bearing to the forward clutch.

Standard bearing diameter:

NOTICE:
Install the thrust bearing properly so that the race "B" will be visible.

(b) Install the forward clutch to the multiple clutch hub.

NOTICE:
Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

35. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets.

36. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear to the transaxle.

37. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the thrust bearing race to the underdrive planetary gear.

38. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it.

End play:

0.498 to 0.993 mm (0.0196 to 0.0390 in.)

HINT
End play = Dimension E - Dimension D - thrust bearing thickness 3.28mm (0.1291 in.) - underdrive thrust bearing race thickness.

Standard race thickness:

Standard bearing and bearing race diameter:

39. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump to the transaxle with the 7 bolts.

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(b) Coat the O-ring of the oil pump with ATF.

40. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to get oil on the contacting surface of the transaxle housing.

(b) Apply seal packing to the transaxle.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or equivalent

(c) Install the transaxle housing to the transaxle with the 18 bolts.

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf) for bolt A

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf) for bolt B and C

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt D

HINT
Each bolt length is indicated below.

Bolt length:

50 mm (1.969 in.) for bolt A, B and D

42 mm (1.654 in.) for bolt C

NOTICE:
Because the bolt labeled A are seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or Equivalent

41. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.

(b) Install the 2 plugs to the transaxle housing.

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

42. INSPECT INPUT SHAFT END PLAY Transaxle Unit

43. FIX AUTOMATIC TRANSAXLE ASSEMBLY