Automatic Transaxle Unit: Reassembly
- BEARING POSITION
Standard bearing position
STANDARD BEARING POSITION CHARTMark Front Race Diameter Inside / Outside Thrust Bearing Diameter Inside / Outside Rear Race Diameter Inside / Outside A - 53.0 mm (2.087 in.) / 78.2 mm (3.079 in.) 52.1 mm (2.051 in.) / 75.5 mm (2.972 in.) B - 37.73 mm (1.4854 in.) / 58.0 mm (2.283 in.) 29.9 mm (1.177 in.) / 55.5 mm (2.185 in.) C - 33.85 mm (1.3327 in.) / 52.2 mm (2.055 in.) - D - 23.5 mm (0.925 in.) / 44.0 mm (1.732 in.) - E - 36.3 mm (1.492 in.) / 52.2 mm (2.055 in.) 34.5 mm (1.358 in.) / 48.5 mm (1.909 in.) F - 34.6 mm (1.362 in.) / 52.2 mm (2.055 in.) - G 40.3 mm (1.587 in.) / 58.0 mm (2.283 in.) 38.6 mm (1.520 in.) / 60.0 mm (2.362 in.) 38.6 mm (1.520 in.) / 58.0 mm (2.283 in.) H - 53.6 mm (2.110 in.) / 69.6 mm (2.740 in.) - I - 33.7 mm (1.327 in.) / 48.2 mm (1.898 in.) 30.3 mm (1.193 in.) / 46.0 mm (1.811 in.) J - 53.6 mm (2.110 in.) / 70.18 mm (2.763 in.) or 69.6 mm (2.740 in.) - - INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
- Install the apply tube and apply tube clamp onto the transaxle housing with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTE: Make sure to insert the tube to the stopper.
- Install the apply tube and apply tube clamp onto the transaxle housing with the bolt.
- INSTALL NO. 2 BREATHER PLUG
- INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
- Using a screwdriver, install the hole snap ring into the transaxle.
- INSTALL COUNTER DRIVE GEAR
- Using SST and a press, press the 2 counter drive gear bearings outer races into the transaxle.NOTE:
- Press-fit the bearing race until it contacts the snap ring.
- Do not apply excessive pressure.
SST 09950-60020 (09951-00890, 09951 -07150), 09950-70010 (09951-07150)
- Using SST and a press, press the tapered roller bearing onto the counter drive gear.
SST 09649-17010
- Using SST and a press, press the counter drive gear and bearing into the transaxle.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
NOTE: Do not apply excessive pressure.
- Using SST and a press, press the 2 counter drive gear bearings outer races into the transaxle.
- INSTALL 1ST AND REVERSE BRAKE PISTON
- Coat 2 new O-rings with ATF.
- Install the 2 O-ring onto the 1st and reverse brake piston.
- Coat the 1st and reverse brake piston with ATF, and install it into the transaxle.
- Install the 1st and reverse brake return spring onto the 1st and reverse brake piston.
- Using SST, a press and snap ring expander, press the piston return spring and snap ring onto the transaxle.
SST 09387-00070
NOTE:- Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deform.
- Do not expand the snap ring excessively.
- INSTALL FRONT PLANETARY RING GEAR
- Using a screwdriver, install the front planetary ring gear and brake hub snap ring into the brake hub.
- INSTALL FRONT PLANETARY GEAR ASSEMBLY
- install the front planetary gear into the brake hub.
- Using SST and a press, press-fit the front planetary gear.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)
NOTE: Do not apply excessive pressure to it. - Install the front planetary gear lock washer, as shown in the illustration.
- Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (2855 kgf*cm, 207 ft.*lbf)
- Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
Torque: Standard turning torque at 60 rpm
0.5 to 1.0 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) for new
0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf) for used
- Using a chisel and hammer, stake the front planetary gear lock washer.
- INSTALL INPUT SUN GEAR
- Install the 2 thrust bearings, bearing race and front planetary sun gear into the planetary gear.
Standard bearing race diameter
STANDARD BEARING RACE DIAMETERItem Inside Outside Bearing 34.6 mm (1.362 in.) 52.2 mm (2.055 in.) Race 40.3 mm (1.587 in.) 58.0 mm (2.283 in.) Bearing 38.6 mm (1.520 in.) 60.0 mm (2.362 in.)
- Install the 2 thrust bearings, bearing race and front planetary sun gear into the planetary gear.
- INSTALL REAR PLANETARY GEAR ASSEMBLY
- Coat the bearing race with ATF, and install it onto the rear planetary gear.
Standard bearing race diameter
STANDARD BEARING RACE DIAMETERItem Inside Outside Race 38.6 mm (1.520 in.) 58.0 mm (2.283 in.) - Install the planetary carrier thrust washer onto the planetary gear.
- Install the rear planetary gear onto the rear planetary ring gear.
- Using screwdrivers, install the snap ring onto the brake hub.
- Coat the bearing race with ATF, and install it onto the rear planetary gear.
- INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
- Install the 5 plates and 5 discs.
Install in order:
P-D-P-D-P-D-P-D-P-D
HINT:
P = Plate
D = Disc
- Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
- Select an appropriate flange so that the piston stroke will meet the specified value.
Pack clearance:
1.02 to 1.21 mm (0.0402 to 0.0476 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
STANDARD FLANGE THICKNESSMark Thickness Mark Thickness 1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.) 2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.) 3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.) 4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.) - Install the flange.
- Install the 5 plates and 5 discs.
- INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE
- INSTALL 1-WAY CLUTCH SLEEVE OUTER
- Install the 1-way clutch outer sleeve into the 2nd brake cylinder.NOTE: Check the positioning direction of the outer sleeve.
- Install the 1-way clutch outer sleeve into the 2nd brake cylinder.
- INSTALL 1-WAY CLUTCH ASSEMBLY
- Install the inner race into the 1-way clutch.NOTE: Check the direction of the inner race.
- Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in illustration.
- Install the 1-way clutch and bearing onto the 1-way clutch outer race sleeve.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.) NOTE: Install the thrust bearing properly so that no colored race will be visible.
- Install the inner race into the 1-way clutch.
- INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
- Coat the No. 1 planetary carrier thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.
- Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing 33.8 mm (1.331 in.) 48.2 mm (1.898 in.) - Install the rear planetary sun gear onto the rear planetary gear.
- INSTALL 2ND BRAKE CLUTCH DISC
- Install the 3 discs and 3 plates onto the transaxle.
Install in order:
P-D-P-D-P-D
HINT:
P = Plate
D = Disc
- Temporarily install the snap ring.
- Using vernier calipers, measure the distance between the disc surface and snap ring surface.
- Select an appropriate flange so that the piston stroke will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
STANDARD FLANGE THICKNESSMark Thickness Mark Thickness 0 2.9 mm (0.114 in.) 5 3.4 mm (0.134 in.) 1 3.0 mm (0.118 in.) 6 3.5 mm (0.138 in.) 2 3.1 mm (0.122 in.) 7 3.6 mm (0.142 in.) 3 3.2 mm (0.126 in.) 8 3.7 mm (0.146 in.) 4 3.3 mm (0.130 in.) - - - Temporarily remove the snap ring, attach the selected flange and restore the snap ring.NOTE: Secure the snap ring so that the gap is visible through the groove of the transaxle case.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Install the 3 discs and 3 plates onto the transaxle.
- INSTALL DIRECT CLUTCH
- Install the bearing race onto the direct clutch.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.) - Install the direct clutch and thrust needle roller bearing onto the rear planetary sun gear.NOTE: The disc in the direct clutch should completely align with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.
- Clean the connector part of the transaxle case and rear cover.
- 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 B).
- Measure the 2 places on the rear cover as shown in the illustration and calculate dimension C using the following formula.
HINT:
Dimension C = Dimension (1) - Dimension (2)
- Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play:
0.198 to 0.936 mm (0.00800 to 0.03685 in.)
NOTE: Make sure that the colored race side is facing the direct clutch assembly.HINT:
End play = Dimension C - Dimension B
Standard bearing thickness and diameter
STANDARD BEARING THICKNESS AND DIAMETERThickness Inside Outside 3.58 mm (0.1409 in.) 53.6 mm (2.110 in.) 69.6 mm (2.740 in.) 3.88 mm (0.1528 in.) 53.6 mm (2.110 in.) 70.18 mm (2.763 in.)
- Install the bearing race onto the direct clutch.
- INSTALL NO. 1 GOVERNOR APPLY GASKET
- Install 2 new apply gaskets onto the transaxle.
- INSTALL FRONT CLUTCH APPLY TUBE
- Install the clamp onto the front clutch apply tube.NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
- Install the clamp onto the front clutch apply tube.
- INSTALL BRAKE APPLY TUBE
- Install the clamp onto the brake apply tube.NOTE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.
- Install the 2 apply tubes into the transaxle with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTE: Each pipe should be securely inserted until it reaches the stopper.
- Install the clamp onto the brake apply tube.
- INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY
- Using SST and a press, press in the bearing.
SST 09950-60010 (09951-00230, 09951-00350)
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
NOTE:- Face the inscribed mark side of the bearing race up.
- Repeat the press-fit until the specified value is obtained.
- Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
- Using a T30 "TORX" socket, install the transaxle rear cover plate with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
- Coat 2 new oil seal rings with ATF, and install them onto the transaxle rear cover.
- Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.
- Apply seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
- Coat the needle roller bearing with ATF.
- Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
- Install the 11 bolts.
Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other bolt
- Using SST and a press, press in the bearing.
- INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
- Install 2 new oil seals onto the transaxle.
- INSTALL UNDERDRIVE BRAKE PISTON
- Wind vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
SST 09550-60010 (09951-00320)
NOTE: Clean SST to remove any oil deposits before winding a vinyl tape. - Using SST and a press, press the needle-roller bearing into the transaxle until the wound vinyl tape contacts the transaxle case.
SST 09550-60010 (09951-00320), 09950-70010 (09951-07100), 09387-00020
- Coat 2 new O-rings with ATF, and install them onto the underdrive brake piston.
- Install the underdrive brake piston into the transaxle.
- Wind vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
- INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
- Install the underdrive brake return spring into the underdrive brake piston.
- Using SST, a snap ring expander and press, press the return spring and install the snap ring into the transaxle.
SST 09387-00020
NOTE: Do not apply excessive pressure.
- INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
- Install the 3 discs and 3 plates into the transaxle.
Install in order:
P-D-P-D-P-D
HINT:
D = Disc
P = Plate
- Using a screwdriver, install the snap ring.
- Using a dial indicator, measure the underdrive brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2
, 57 psi).
Standard piston stroke:
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 meet the specified value.
Standard flange thickness
STANDARD FLANGE THICKNESSMark Thickness Mark Thickness Y 2.8 mm (0.110 in.) C 3.4 mm (0.134 in.) A 3.0 mm (0.118 in.) D 3.6 mm (0.142 in.) B 3.2 mm (0.126 in.) - - - Temporarily remove the snap ring and attach the flange. Restore the snap ring.
- Install the 3 discs and 3 plates into the transaxle.
- INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
- Install the outer race retainer onto the 1-way clutch.
- Install the underdrive clutch assembly onto the 1-way clutch. Rotate the underdrive clutch to check the rotating direction for the lock or free operation.
- Install the 1-way clutch into the transaxle.NOTE: Make sure that the mark on the 1-way clutch outer race is visible.
- Using a screwdriver, install the snap ring into the transaxle.
- INSTALL UNDERDRIVE CLUTCH
- Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
Standard race diameter
STANDARD RACE DIAMETERItem Inside Outside Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.283 in.) Race 29.9 mm (1.177 in.) 55.5 mm (2.185 in.) - Install the underdrive clutch assembly into the transaxle.
- Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
- INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
- Install the parking lock pawl pin and torsion spring onto the parking lock pawl.
- Temporarily install the parking lock pawl, shaft and spring into the transaxle case as shown in the illustration.
- Install the underdrive planetary gear assembly into the transaxle.NOTE: Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly firmly and assemble them securely.
- Install the parking lock pawl shaft.
- Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- 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).NOTE: Note down the dimension D as it is necessary for the following process.
- As shown in the illustration, measure the 2 places of the transaxle housing. Calculate dimension E using the formula.NOTE: Note down dimension E as it is necessary for the following process.
HINT:
Dimension E = Dimension (1) - Dimension (2)
- INSTALL MULTIPLE DISC CLUTCH HUB
- Install the bearing race into the transaxle while checking its direction.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing race 34.5 mm (1.358 in.) 48.5 mm (1.909 in.) - Coat the thrust needle roller bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.
Standard thrust bearing and race diameter
STANDARD THRUST BEARING AND RACE DIAMETERItem Inside Outside Bearing 36.3 mm (1.429 in.) 52.25 mm (2.055 in.) - Install the input shaft thrust bearing onto the multiple clutch hub.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing 23.5 mm (0.925 in.) 44.0 mm (1.732 in.) - Install the forward clutch hub into the transaxle.
- Install the bearing race into the transaxle while checking its direction.
- INSTALL FORWARD CLUTCH ASSEMBLY
- Install the input shaft thrust bearing onto the forward clutch.
Standard bearing diameter
STANDARD BEARING DIAMETERItem Inside Outside Bearing 33.85 mm (1.3327 in.) 52.2 mm (2.055 in.) NOTE: Install the thrust bearing properly so that the race "B" will be visible. - Install the forward clutch onto the multiple clutch hub.NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
- Install the input shaft thrust bearing onto the forward clutch.
- INSTALL OVERDRIVE BRAKE GASKET
- Install 2 new overdrive brake gaskets into the transaxle.
- INSTALL FRONT DIFFERENTIAL ASSEMBLY
- Install the differential assembly into the transaxle.
- INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
- Install the thrust bearing race onto the underdrive planetary gear.
- INSTALL THRUST NEEDLE ROLLER BEARING
- Calculate the end play value using the following formula and value of Dimensions D and E that were measured when installing the 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.
Standard end play:
0.498 to 0.993 mm (0.0194 to 0.0390 in.)
HINT:
End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in.) - underdrive thrust bearing race thickness.
Standard race thickness
STANDARD RACE THICKNESSE-D Thickness Less then 7.34 mm (0.2890 in.) 3.5 mm (0.138 in.) 7.34 mm (0.2890 in.) 3.8 mm (0.150 in.) Standard bearing and bearing race diameter
STANDARD BEARING AND BEARING RACE DIAMETERItem Inside Outside Bearing 53.0 mm (2.087 in.) 78.2 mm (3.079 in.) Bearing race 52.1 mm (2.051 in.) 75.5 mm (2.972 in.)
- Calculate the end play value using the following formula and value of Dimensions D and E that were measured when installing the 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.
- INSTALL OIL PUMP ASSEMBLY
- Install the oil pump into the transaxle with the 7 bolts.
Torque: 22 N*m (225 kgf*cm, 16 ft.*lbf)
- Install the oil pump into the transaxle with the 7 bolts.
- INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
- Install a new oil seal ring onto the transaxle housing.
- INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
- Using SST and a press, press in the underdrive cylindrical roller bearing.
SST 09950-60020, 09950-70010 (09951 -07100, 09951-07100)
NOTE: Do not apply excessive pressure to it.
- Using SST and a press, press in the underdrive cylindrical roller bearing.
- INSTALL TRANSAXLE HOUSING
- Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing.
- Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
- Install the transaxle housing onto the transaxle with the 18 bolts.
Torque:
22 N*m (220 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (300 kgf*cm, 21 ft.*lbf) for bolt B and C
10 N*m (102 kgf*cm, 7.4 ft.*lbf) for bolt D
Each bolt length is indicated below.
BOLT LENGTH CHARTBolt Length Head A 50 mm (1.969 in.) 12 mm (0.47 in.) B 50 mm (1.969 in.) 12 mm (0.47 in.) C 42 mm (1.654 in.) 12 mm (0.47 in.) D 50 mm (1.969 in.) 10 mm (0.39 in.) NOTE: Because the bolt A and D is a seal bolt, apply the 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
- INSPECT INPUT SHAFT END PLAY (See INSPECTION )
- FIX AUTOMATIC TRANSAXLE ASSEMBLY
- INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
- Coat a new oil seal with ATF, and install it into the transaxle.
- INSTALL PARKING LOCK ROD SUB-ASSEMBLY
- Install the parking lock rod onto the manual valve lever.
- INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
- Install a new spacer and manual valve lever shaft into the transaxle.
- Using a pin punch and hammer, tap in a new pin.
- Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
- Using a pin punch, stake the spacer through the small hole.
- Check that the spacer does not turn.
- INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
- Using needle-nose pliers, install the retainer spring.
- INSTALL PARKING LOCK PAWL BRACKET
- Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
Bolt length:
25 mm (0.984 in.)
- Install the parking lock pawl bracket with the 2 bolts.
- INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
- Install the manual detent spring with the 2 bolts.NOTE: Make sure to install the manual detent spring and cover in this order.
Torque:
20 N*m (204 kgf*cm, 15 ft.*lbf) for bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
HINT:
Each bolt length is indicated below.
Bolt length:
27 mm (1.063 in.) for bolt A
16 mm (0.630 in.) for bolt B
- Install the manual detent spring with the 2 bolts.
- INSTALL B-3 ACCUMULATOR PISTON
- Coat a new O-ring with ATF, and install it onto the B-3 accumulator piston.
- Coat the accumulator B-3 piston and spring with ATF, and install them to the transaxle.
Standard accumulator spring
STANDARD ACCUMULATOR SPRINGSpring Free length Outer diameter Color B-3 Inner 60.24 mm (2.3716 in.) 15.9 mm (0.626) Yellowish green B-3 Outer 74.61 mm (2.9374 in.) 21.7 mm (0.854 in.) Blue
- INSTALL C-1 ACCUMULATOR PISTON
- Coat 2 new O-rings with ATF, and install them onto the C-1 accumulator piston.
- Coat the accumulator C-1 piston with ATF, and install it into the transaxle.
Standard accumulator spring
STANDARD ACCUMULATOR SPRINGSpring Free length Outer diameter Color C-1 81.53 mm (3.2098 in.) 18.5 mm (0.728 in.) Pink
- INSTALL C-3 ACCUMULATOR PISTON
- Coat a new O-ring with ATF, and install it onto the C-3 accumulator piston.
- Coat the C-3 accumulator piston with ATF, and install it into the transaxle.
- Install the compression spring from the C-3 accumulator piston.
- INSTALL CHECK BALL BODY
- Install the check ball body and spring.
- INSTALL BRAKE DRUM GASKET
- Coat a new brake drum gasket with ATF, and install it into the transaxle.
- INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
- Coat a new transaxle case 2nd brake gasket with ATF, and install it into the transaxle.
- INSTALL NO. 1 GOVERNOR APPLY GASKET
- Coat a new No. 1 governor apply gasket with ATF, and install it into the transaxle.
- INSTALL TRANSMISSION WIRE
- Coat a new O-ring with ATF and install it onto the transmission wire.
- Pass the transmission wire through the transaxle case.
- Install the transmission wire with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- INSTALL TRANSMISSION VALVE BODY ASSEMBLY
- Align the groove of the manual valve with the pin of the lever.
- Install the transmission valve body assembly with the 17 bolts.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
NOTE:- Push the valve body against the accumulator piston springs and check ball body to install the valve body.
- First, temporarily tighten the bolts marked with (1) in the illustration because they are positioning bolts.
Bolt length:
25 mm (0.984 in.) for Bolt A
41 mm (1.614 in.) for Bolt B
45 mm (1.771 in.) for Bolt C
- Coat the O-ring on the ATF temperature sensor with ATF.
- Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
- Connect the 5 shift solenoid valve connectors.
- INSTALL VALVE BODY OIL STRAINER ASSEMBLY
- Coat a new O-ring with ATF, and install it into the valve body oil strainer assembly.
- Install the valve body oil strainer assembly with the 3 bolts.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
- INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
- Install the 2 oil cleaner magnets onto the automatic transaxle oil pan sub-assembly, as shown in the illustration.
- Install the automatic transaxle oil pan sub-assembly and a new oil pan gasket with the 18 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
- INSTALL NO. 1 TRANSAXLE CASE PLUG
- Coat 8 new O-rings with ATF, and install them into the 8 No. 1 transaxle case plugs.
- Install the 4 No. 1 transaxle case plugs onto the transaxle case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- Install the 2 No. 1 transaxle case plugs onto the transaxle housing.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- Install the 2 No. 1 transaxle case plugs onto the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
- INSTALL SPEED SENSOR NT
- Coat a new O-ring with ATF, and install it into the speed sensor NT.
- Install the speed sensor NT with the bolt.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
- INSTALL SPEED SENSOR NC
- Coat a new O-ring with ATF, and install it into the speed sensor NC.
- Install the speed sensor NC with the bolt.
Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)
- INSTALL INLET OIL COOLER TUBE UNION
- Coat a new O-ring with ATF, and install it into the inlet oil cooler tube union.
- Install the inlet oil cooler tube union into the transaxle case.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
- INSTALL OUTLET OIL COOLER TUBE UNION
- Coat a new O-ring with ATF, and install it into the outlet oil cooler tube union.
- Install the outlet oil cooler tube union into the transaxle case.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
- INSTALL BREATHER PLUG HOSE
- Install the breather plug hose to the breather plug.
- INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Install the park/neutral position switch assembly onto the manual valve lever shaft.
- Provisionally install the 2 bolts.
- Replace the lock plate with a new one and tighten the manual valve shaft nut.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
- Provisionally install the control shaft lever.
- Turn the control shaft lever counterclockwise until it stops, then turn it clockwise 2 notches.
- Remove the control shaft lever.
- Align the groove with the neutral basic line.
- Hold the switch in this position and tighten the 2 bolts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Using a screwdriver, stake the nut with the lock plate.
- Install the control shaft lever with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)