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Automatic Transaxle Unit: Reassembly

  1. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install a new front drive pinion rear tapered roller bearing in to the differential case.

      SST 09710-30031 (09710-03161) 

      Fig 1: Identifying Front Drive Pinion Rear Tapered Roller Bearing
      G05193875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the plate washer onto the transaxle case.
    3. Using SST and a press, press a new front drive pinion rear tapered roller bearing outer race in to the transaxle case.

      SST 09350-32014 (09351-32111, 09351-32130) 

      Fig 2: Pressing Front Drive Pinion Rear Tapered Roller Bearing Outer Race
      G05193876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING 
    1. Install the speedometer drive gear to the differential case.
      Fig 3: Installing Speedometer Drive Gear To Differential Case
      G05193877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the new front drive pinion front tapered roller bearing in to the differential case.

      SST 09350-32014 (09351-32090, 09351-32130) 

      Fig 4: Identifying Front Drive Pinion Front Tapered Roller Bearing
      G05193878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, press a new front drive pinion front tapered roller bearing outer race in to the transaxle housing.

      SST 09350-32014 (09351-32111, 09351-32130) 

      Fig 5: Pressing Front Drive Pinion Front Tapered Roller Bearing Outer Race
      G05193879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, drive in a new transaxle case oil seal.

      SST 09350-32014 (09351-32111, 09351-32130) 

      Fig 6: Installing Transaxle Case Oil Seal
      G05193880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of transaxle case oil seal with MP grease.
  4. INSTALL TRANSAXLE HOUSING OIL SEAL 
    1. Using SST and a hammer, drive in a new transaxle housing oil seal.

      SST 09350-32014 (09351-32130, 09351-32150) 

      Fig 7: Installing Transaxle Housing Oil Seal
      G05193881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the lip of transaxle housing oil seal with MP grease.
  5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST and a press, install the underdrive cylindrical roller bearing to the transaxle housing.

      SST 09350-32014 (09351-32140) 

      Fig 8: Installing Underdrive Cylindrical Roller Bearing To Transaxle Housing
      G05234226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the roller bearing retainer with a new seal washer and the bolt to the transaxle housing.

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      Fig 9: Installing Roller Bearing Retainer Bolt
      G05193883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Using a plastic hammer, install the differential gear lube apply tube to the transaxle housing.
      NOTE: Be careful not to bend or damage the tube.
      2. Fig 10: Installing Differential Gear Lube Apply Tube
      G05234228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL TRANSMISSION LUBE APPLY TUBE 
    1. Using a plastic hammer, install the transmission lube apply tube to the transaxle housing.
      NOTE: Be careful not to bend or damage the tube.
  8. INSTALL TRANSAXLE APPLY TUBE CLAMP N0.2 
    1. Install the transaxle apply tube clamp No. 2 with the bolt to the transaxle housing.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      2. Fig 11: Installing Transaxle Apply Tube Clamp Bolt
      G05193834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TRANSAXLE APPLY TUBE CLAMP NO.1 
    1. Install the 2 transaxle apply tube clamps No. 1 with the 2 bolts to the transaxle housing.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  10. INSTALL COUNTER DRIVEN GEAR CYLINDRICAL ROLLER BEARING 
    1. Using SST and a press, install the counter driven gear cylindrical roller bearing to the transaxle case.

      SST 09350-32014 (09351-32090) 

      2. Fig 12: Installing Counter Driven Gear Cylindrical Roller Bearing To Transaxle Case
      G05234230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL TRANSMISSION CASE PLATE NO.3 
    1. Install the transmission case plate No. 3 with the bolt to the transaxle case.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  12. INSTALL B-4 ACCUMULATOR PISTON 
    1. Coat a new O-ring with ATF and install them to the B-4 accumulator piston.
    2. Install the B-4 accumulator piston and compression spring to the transaxle case.
      Fig 13: Installing B-4 Accumulator Piston
      G05193832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clean the threads of the screws and case with white gasoline.
    4. Install a new transmission case plate No. 2 gasket and transmission case plate No. 2 in place to the transaxle case.
    5. Install and tighten the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 14: Tightening Transmission Case Plate Bolts
      G05193831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply adhesive or equivalent to the 7 screws.

      Adhesive: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    7. Using a "TORX" wrench, install the 7 screws.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 15: Tightening Screws
      G05193830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL CAM GUIDE SLEEVE 
    1. Install the cam guide sleeve to the transaxle case.
      Fig 16: Identifying Cam Guide Sleeve To Transaxle Case
      G05193829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL PARKING LOCK SLEEVE 
    1. Install the spring guide sleeve with the protruding portion facing up.
      Fig 17: Identifying Spring Guide Sleeve With Protruding Portion Facing Up
      G05193828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL PARKING LOCK PAWL 
    1. Place the pawl stopper plate on the protruding portion of the lock sleeve to the transaxle case.
      Fig 18: Identifying Parking Lock Pawl
      G05193892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the spring guide sleeve and torsion spring with the 2 bolts.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 19: Identifying Spring Guide Sleeve Bolts
      G05193893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the parking lock pawl to the transaxle case.
      Fig 20: Installing Parking Lock Pawl To Transaxle Case
      G05193894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the parking lock pawl shaft and pawl shaft clamp with a bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 21: Installing Parking Lock Pawl Shaft And Pawl Shaft Clamp
      G05193895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL UNDERDRIVE BRAKE PISTON 
    1. Coast 2 new O-rings with ATF and Install the 2 O-rings to the underdrive brake piston.
      Fig 22: Installing O-Rings To Underdrive Brake Piston
      G05193896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the underdrive brake piston into the case with the cup side up, being careful not to damage the O-rings.
      Fig 23: Placing Underdrive Brake Piston Into Case
      G05193897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the underdrive brake return spring sub-assembly to the transaxle case.
      Fig 24: Identifying Underdrive Brake Return Spring
      G05193898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL UNDERDRIVE CLUTCH DISC NO.2 
    1. Install the 3 plates, 3 underdrive clutch discs No. 2 and flange in order.

      Install in order: 

      D = Disc P = Plate F = Flange P - D - P - D - P - D - F 

      HINT:

      Install the flange with the flat side facing downward.

      Fig 25: Identifying Plates And Underdrive Clutch Discs
      G05193821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the flange, and compress the flange with a press.

      SST 09350-32014 (09351-32070 

      Fig 26: Installing Underdrive Clutch Flange Hole Snap Ring To Transaxle Case
      G05193900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the underdrive clutch flange No. 2 hole snap ring to the transaxle case.

      HINT:

      Be sure the end gap of the snap ring is not aligned with one of the cutouts.

  19. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE (See  INSPECTION   ) 
  20. INSTALL OVERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Coat 2 new overdrive clutch drum oil seal rings with ATF and install the 2 overdrive clutch drum oil seal rings to the transaxle case.
      Fig 27: Installing Overdrive Clutch Drum Oil Seal Rings To Transaxle Case
      G05193901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY 
    1. Install the underdrive 1 way clutch assembly to the transaxle case.
      Fig 28: Installing Underdrive 1 Way Clutch Assembly To Transaxle Case
      G05193902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL UNDERDRIVE 1 WAY CLUTCH RETAINER 
    1. In the place shown in the illustration (the space between the 1 way clutch outer race and case), push the underdrive 1 way clutch retainer in until you hear a "click".
    Fig 29: Identifying Underdrive 1 Way Clutch Retainer
    G05193903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY 
    1. Coat the underdrive clutch drum thrust washer with petroleum jelly and install it on to underdrive 1 way clutch assembly.
    2. Align the flukes of discs in the underdrive brake.
    3. Install the underdrive clutch drum sub-assembly.
    4. Turn the underdrive clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.
      Fig 30: Turning Underdrive Clutch Assembly
      G05193904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the assembled bearing and race, with the thrust needle roller bearing facing upward.

      Assembled bearing and race: 

      mm (in.) 

      Fig 31: Identifying Assembled Bearing And Race
      G05193905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Assembled bearing and race 43.9 mm (1.728 In.) 31.0 mm (1.220 in.)
  24. INSPECT HEIGHT OF CLUTCH ASSEMBLY (See  INSPECTION   ) 
  25. INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH (See  INSPECTION   ) 
  26. INSTALL UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Remove the underdrive planetary sun gear from the counter shaft assembly.
    2. Remove the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race.
      Fig 32: Identifying Underdrive Input Shaft Needle Roller Bearing
      G05234250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the underdrive planetary sun gear sub-assembly to the transaxle case.
      4. Fig 33: Installing Underdrive Planetary Sun Gear
      G05193907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat the underdrive input shaft needle roller bearing and underdrive input shaft thrust bearing race with petroleum jelly and install it on the transaxle case.
  27. INSTALL COUNTER SHAFT ASSEMBLY 
    1. Align the flukes of the discs in the underdrive clutch.
    2. Install the needle roller bearing with the bearing facing upward.

      Bearing and race: 

      mm (in.) 

      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Bearing 43.9 mm (1.728 In.) 31.0 mm (1.220 in.)
      Race 41.8 mm (1.646 In.) 30.0 mm (1.181 In.)
    3. Install the counter shaft assembly to the transaxle case.
      4. Fig 34: Installing Counter Shaft Assembly To Transaxle Case
      G05193908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT HEIGHT OF COUNTER SHAFT (See  INSPECTION   ) 
  29. INSTALL COUNTER DRIVE GEAR BEARING 
    1. Install the new counter drive gear bearing to the counter drive gear.
    2. Install the new snap ring to the counter drive gear bearing.

      SST 09350-32014 (09351-32120) 

  30. INSTALL COUNTER DRIVE GEAR 
    1. Using SST and a press, install the counter drive gear.

      SST 09350-32014 (09351-32150, 09351-32130) 

      Fig 35: Installing Counter Drive Gear
      G05193909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL INTERMEDIATE SHAFT SUB-ASSEMBLY 
    1. Install the intermediate shaft sub-assembly to the transaxle case.
      Fig 36: Installing Intermediate Shaft Sub-Assembly To Transaxle Case
      G05193910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST to hold the counter drive gear, install the new counter drive gear nut.

      SST 09960-10010 (09962-01000, 09963-01000) 

      Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) 

      Fig 37: Installing Counter Drive Gear Nut
      G05193911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSPECT DRIVE GEAR PRELOAD (See  INSPECTION   ) 
  33. TIGHTEN COUNTER DRIVE GEAR NUT 
  34. INSTALL COUNTER DRIVEN GEAR 
    1. Install the thrust needle roller bearing to the transaxle case.

      Bearing: 

      mm (in.) 

      BEARING SPECIFICATIONS

        Outer diameter Inner diameter
      Bearing 58.0 mm (2.283 in.) 41.0 mm (1.614 In.)
      Fig 38: Identifying Thrust Needle Roller Bearing
      G05193912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, press in the counter driven gear.

      SST 09350-32014 (09351-32100, 09351-32140) 

      Fig 39: Pressing Counter Driven Gear
      G05193913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST to hold the counter shaft assembly, tighten a new counter driven gear nut.

      SST 09350-32014 (09351-32032) 

      Torque: 180 N*m (1,835 kgf*cm, 133 ft.*lbf) 

      Fig 40: Tightening Counter Driven Gear Nut
      G05193914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSPECT END PLAY OF COUNTER SHAFT (See  INSPECTION   ) 
  36. TIGHTEN COUNTER DRIVEN GEAR NUT 
    1. Using a pin punch and hammer, stake the counter driven gear nut.
      Fig 41: Staking Counter Driven Gear Nut
      G05193915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL TRANSMISSION CASE COVER REAR 
    1. Remove any packing material and be careful not to get oil on the contacting surfaces of the transmission case cover rear or transaxle case.
    2. Apply FIPG sealant to the transmission case cover rear.

      FIPG: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 42: Identifying FIPG Sealant On Transmission Case Cover Rear
      G05193916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install and tighten the 13 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      HINT:

      Each bolt length is indicated in the illustration.

      Bolt length: 

      Bolt A: 

      25 mm (0.98 in.) 

      Bolt B: 

      32 mm (1.26 in.) 

      Fig 43: Identifying Transmission Case Cover Bolts
      G05193917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY (See  INSPECTION   ) 
  39. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. Coat the 2 new O-rings with ATF and install 2 new O-rings to the 1st & reverse brake piston.
      Fig 44: Identifying O-Rings To 1st And Reverse Brake Piston
      G05193918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the 1st & reverse brake piston into the bore of the case, facing the spring seats upward.
      NOTE: Be careful not to damage the O-rings.
      Fig 45: Placing 1st & Reverse Brake Piston Into Bore
      G05193919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Install the 1st & reverse brake return spring sub-assembly and snap ring in place.
      Fig 46: Identifying 1st And Reverse Brake Return Spring
      G05193802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place SST on the 1st & reverse brake return spring sub-assembly, and compress the 1st & reverse brake return spring sub-assembly with a press.

      SST 09350-32014 (09351-32040) 

      Fig 47: Compressing 1st And Reverse Brake Return Spring
      G05193801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using snap ring pliers, install the snap ring.

      HINT:

      Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is aligned with the spring retainer claw.

  41. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Install the 1st & reverse brake clutch discs and plates in order.

      HINT:

      6 plates and 6 discs.

      Install in order: 

      D = Disc P = Plate 

      P - D - P - D - P - D - P - D - P - D - P - D 

      Fig 48: Identifying 1st & Reverse Brake Clutch Discs And Plates
      G05193800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the outer flange with the flat side facing downward.
      Fig 49: Identifying Outer Flange
      G05193923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transaxle case.

      HINT:

      Be sure the snap ring end gap is not aligned with one of the cutouts.

      4. Fig 50: Installing Snap Ring
      G05193924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE (See  INSPECTION   ) 
  43. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the intermediate shaft sub-assembly.

      Bearing and race: 

      mm (in.) 

      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Race 37.6 mm (1.480 in.) 24.1 mm (0.949 In.)
      Bearing 37.6 mm (1.480 In.) 22.1 mm (0.870 In.)
      Fig 51: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
      G05193925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.

      HINT:

      Make sure that the different lug shapes match the corresponding openings on the gear.

      Fig 52: Installing Planetary Carrier Thrust Washer To Rear Planetary Gear Assembly
      G05234270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the spline of the rear planetary gear assembly with the flukes of the discs and install the rear planetary gear assembly in to the 1st & reverse brake discs.
      Fig 53: Installing Rear Planetary Gear Assembly
      G05193927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Check the part "A" of the rear planetary gear assembly is below the upper surface of the flange.

      SST 09350-32014 (09351-32050) 

      Fig 54: Identifying Rear Planetary Gear Assembly
      G05234272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the 1 way clutch No. 2 assembly into the case, with the shiny side facing upward.
    6. Install the 1 way clutch No. 2 assembly onto the inner race while turning the rear planetary gear assembly clockwise with SST.

      SST 09350-32014 (09351-32050) 

      Fig 55: Installing 1 Way Clutch Assembly Onto Inner Race
      G05193929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the rear planetary gear assembly turns freely clockwise and locks if turned counterclockwise.
    8. Coat the planetary carrier thrust washer No. 2 with petroleum jelly and install it on to the rear planetary gear assembly.
      Fig 56: Identifying Planetary Carrier Thrust Washer
      G05234274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Be sure the end gap of the snap ring is not aligned with one of the cutouts.
      Fig 57: Identifying Snap Ring End Gap Position
      G05193931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL 2ND BRAKE CLUTCH DISC 
    1. Install the flange with the flat side facing upward.
      Fig 58: Installing Flange
      G05193932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 2nd brake clutch discs and 3 plates in order to the transaxle case.

      Install in order: 

      D = Disc P = Plate 

      D - P - D - P - D - P 

      Fig 59: Identifying 2nd Brake Clutch Discs And Plates
      G05193933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Install each of the 2nd brake piston return spring sub-assembly over the protrusions in the transaxle case.
      Fig 60: Installing 2nd Brake Piston Return Spring
      G05234278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL 2ND COAST BRAKE BAND GUIDE PLATE 
    1. Install the 2nd coast brake band guide plate and brake band guide plate retainer so that its tip touches the transaxle case.
    2. Install the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 61: Installing 2nd Coast Brake Band Guide Plate Retainer Bolt
      G05193935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL SECOND BRAKE PISTON ASSEMBLY 
    1. Align the groove of the drum with the bolt and place the 2nd brake piston assembly in to the transaxle case.
      Fig 62: Aligning Groove Of Drum With Bolt
      G05193936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place both ends of the snap ring in the groove, and then set the snap ring in to the transaxle case.
      3. Fig 63: Setting Snap Ring Into Transaxle Case
      G05193937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

      HINT:

      Be sure the end gap of the snap ring is not aligned with one of the cutouts.

  48. INSPECT 2ND BRAKE PISTON (See  INSPECTION   ) 
  49. INSTALL 1 WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, align the flukes of the discs in the 2nd brake.
      Fig 64: Aligning Flukes Of Discs In 2nd Brake
      G05234282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the spline of the 1 way clutch assembly with the flukes of the discs and install the 1 way clutch assembly to the 2nd brake discs.
      Fig 65: Aligning Spline Of 1 Way Clutch Assembly With Flukes
      G05234283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE (See  INSPECTION   ) 
  51. INSTALL SUN GEAR INPUT DRUM ASSEMBLY 
    1. Coat the planetary carrier thrust washer No. 3 with petroleum jelly and install it on the planetary sun gear sub-assembly.
      Fig 66: Identifying Planetary Carrier Thrust Washer
      G05193940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. By turning the planetary sun gear sub-assembly clockwise, install it in to the 1 way clutch assembly.
      Fig 67: Turning Planetary Sun Gear Sub-Assembly Clockwise
      G05193941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Coat the thrust needle roller bearing with petroleum jelly and install it on to the front planetary gear assembly.

      Bearing: 

      mm (in.) 

      BEARING SPECIFICATIONS

        Outer diameter Inner diameter
      Bearing 45.0 mm (1.772 In.) 28.1 mm (1.106 In.)
      Fig 68: Identifying Thrust Needle Roller Bearing
      G05234286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front planetary gear assembly.
      Fig 69: Identifying Front Planetary Gear Assembly
      G05234287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL FRONT PLANETARY RING GEAR 
    1. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them onto the front planetary gear assembly.

      Bearing and race: 

      mm (in.) 

      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Race 35.0 mm (1.378 In.) 19.0 mm (0.748 In.)
      Bearing 38.0 mm (1.496 In.) 22.0 mm (0.866 In.)
      Fig 70: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
      G05193944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front planetary ring gear to the transaxle case.

      HINT:

      If the front planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with or under the shoulder of the intermediate shaft.

      Fig 71: Installing Front Planetary Ring Gear To Transaxle Case
      G05234289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the thrust needle roller bearing and thrust bearing race with petroleum jelly and install them on to the tip of ring gear flange.

      Bearing and race: 

      mm (in.) 

      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Race 39.5 mm (1.555 In.) 26.0 mm (1.024 In.)
      Bearing 42.0 mm (1.654 In.) 25.8 mm (1.016 In.)
      Fig 72: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
      G05193946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL 2ND COAST BRAKE BAND ASSEMBLY 
    1. Place the 2nd coast brake band assembly in to the transaxle case.
    2. Install the pin to the transaxle case.
      Fig 73: Installing Pin To Transaxle Case
      G05193783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL INPUT SHAFT ASSEMBLY 
    1. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch assembly.

      Assembled bearing and race: 

      mm (in.) 

      BEARING AND RACE SPECIFICATIONS

        Outer diameter Inner diameter
      Assembled bearing and race 46.0 mm (1.811 in.) 30.7 mm (1.209 in.)
      Fig 74: Identifying Thrust Needle Roller Bearing And Input Shaft Assembly
      G05193948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the clutch drum thrust washer with petroleum jelly and install it onto the direct clutch drum with the oil groove facing upward.
      Fig 75: Identifying Clutch Drum Thrust Washer
      G05193949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, align the flukes of the discs in the direct clutch.
      Fig 76: Aligning Flukes Of Discs In Direct Clutch
      G05193950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

      HINT:

      If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.

      Fig 77: Meshing Hub With Flukes Of Direct Clutch
      G05193951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place the direct clutch assembly and forward clutch assembly in to the transaxle case.
      6. Fig 78: Placing Direct Clutch Assembly And Forward Clutch Assembly Into Transaxle Case
      G05193952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. While rotating the forward clutch assembly to mesh the front planetary ring gear and discs, install them.
    7. Check the distance between A and B.

      Distance: 

      Approx. 3 mm (0.118 in.) 

      Fig 79: Checking Distance Between A And B
      G05234297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL 2ND COAST BRAKE PISTON 
    1. Coat the 2 new O-rings with ATF and install the 2 O-rings to the 2nd coast brake cover.
      Fig 80: Identifying O-Rings
      G05234298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the compression spring, 2nd coast brake piston and 2nd coast brake cover in to the bore.
      Fig 81: Identifying Compression Spring, 2nd Coast Brake Piston And 2nd Coast Brake
      G05193779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the snap ring.

      SST 09350-32014 (09351-32050) 

      Fig 82: Installing Snap Ring
      G05193777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSPECT PISTON STROKE OF 2ND COAST BRAKE (See  INSPECTION   ) 
  58. INSTALL GOVERNOR PRESSURE TUBE 
    1. Using a plastic hammer, install the governor pressure tube to the transaxle case.
      NOTE: Be careful not to bend or damage the tube.
      Fig 83: Installing Governor Pressure Tube To Transaxle Case
      G05193957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL TRANSAXLE APPLY TUBE CLAMP NO.3 
    1. Install the transaxle apply tube clamp No. 3 with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 84: Installing Transaxle Apply Tube Clamp Bolt
      G05193775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL OIL PUMP ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil pump assembly.
      Fig 85: Identifying O-Ring To Oil Pump Assembly
      G05193959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place the oil pump assembly through the input shaft, and align the bolt holes of the pump body with those of the transaxle case.
      3. Fig 86: Placing Oil Pump Assembly
      G05193960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the input shaft through the direct clutch drum.
      NOTE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.
    4. Install the 6 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 87: Installing Oil Pump Assembly Bolts
      G05193961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSPECT INPUT SHAFT ASSEMBLY (See  INSPECTION   ) 
  62. INSPECT INPUT SHAFT ENDPLAY (See  INSPECTION   ) 
  63. INSTALL GOVERNOR APPLY GASKET NO.2 
    1. Install the governor apply gasket No. 2 to the transaxle case.
    Fig 88: Installing Governor Apply Gasket To Transaxle Case
    G05193771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL TRANSMISSION CASE PLATE NO.1 
    1. Install the transmission case plate No. 1 with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  65. INSTALL FRONT DIFFERENTIAL ASSEMBLY 
    1. Install the front differential assembly to the transaxle case.
      Fig 89: Installing Front Differential Assembly To Transaxle Case
      G05193770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSAXLE HOUSING 
    1. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
    2. Apply FIPG to the transaxle housing.

      FIPG: 

      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent 

      Fig 90: Applying FIPG On Transaxle Housing
      G05193964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply adhesive to the bolt B threads.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

    4. Install the 17 bolts.

      Torque: 30 N*m (304 kgf*cm, 22 ft.*lbf) 

      HINT:

      Each bolt length is indicated in the illustration.

      Bolt length: 

      Bolt A: 

      30 mm (1.18 in.) 

      Fig 91: Identifying Transaxle Housing Bolts
      G05234309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt B: 

      35 mm (1.38 in.) 

  67. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Using SST, rotate the differential in both directions to snug the bearing down.

      SST 09564-32011 

      Fig 92: Rotating Differential In Both Directions To Snug Bearing Down
      G05193966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a torque wrench, measure the preload of the side bearing.

      SST 09564-32011 

      Torque: New bearing preload (at starting) 0.8 to 1.4 N*m (8 to 14 kgf*cm, 7.1 to 12.4 in.*lbf) 

      Used bearing preload (at starting) 0.4 to 0.7 N*m (4 to 7 kgf*cm, 3.5 to 6.2 in.*lbf) 

      If the preload is not within the specified range, remove the differential from the transaxle case. Re-select the transaxle case side adjusting shim according to the following table.

      Adjusting shim thickness: 

      mm (in.) 

      SHIM THICKNESS CHART

      Thickness Thickness Thickness
      2.00 mm (0.0787 In.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.)
      2.15 mm (0.0846 In.) 2.20 mm (0.0866 In.) 2.25 mm (0.0886 in.)
      2.30 mm (0.0906 In.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.)
      2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 In.)
      2.60 mm (0.1024 In.) 2.65 mm (0.1043 In.) 2.70 mm (0.1063 In.)
      2.75 mm (0.1083 In.) 2.80 mm (0.1102 In.) 2.85 mm (0.1122 In.)
      2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 In.)

      HINT:

      The preload will change about 0.3 to 0.4 N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) according to a change in shim thickness of 0.05 mm (0.0020 in.)

  68. INSTALL MANUAL VALVE LEVER SHAFT 
    1. Using a 14 mm (0.55 in.) socket wrench and hammer, drive in a new manual valve lever shaft oil seal.
      2. Fig 93: Installing Manual Valve Lever Shaft Oil Seal
      G05193967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply MP grease to the seal lip.
    3. Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.
    4. Slide in the manual valve lever shaft and install the washer plate, a new spacer and manual valve lever sub-assembly.
      Fig 94: Installing Washer Plate, New Spacer And Manual Valve Lever Sub-Assembly
      G05193968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the retainer spring.

      HINT:

      Make sure there is a washer between the retaining spring and case.

      Fig 95: Installing Retainer Spring
      G05193766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a pin punch and hammer, drive in the slotted spring pin.
      7. Fig 96: Driving In Slotted Spring Pin
      G05193970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Position the spacer and stake it.
  69. INSTALL ACCUMULATOR PISTON AND SPRING 
    1. Coat 8 new O-rings with ATF and install them to the accumulator pistons 2 each.
    2. Install the accumulator pistons and compression springs to the transaxle case as shown in the illustration.
      SPRING FREE LENGTH CHART

      Spring Free length Color
      (1) C3 (Outer) 68.4 mm (2.693 in.) Yellow
      (2) C3 (Inner) 50 mm (1.968 in.) Yellow
      (3) B2 64.68 mm (2.546 in.) Light blue
      (4) C2 70.45 mm (2.773 in.) Purple
      (5) 01 (Outer) 60.39 mm (2.378 in.) Pink
      Fig 97: Identifying Accumulator Pistons And Springs
      G05234315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL BRAKE DRUM GASKET 
    1. Install a new brake drum gasket until it makes contact with the 2nd brake drum.
      Fig 98: Installing Brake Drum Gasket
      G05193972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL GOVERNOR APPLY GASKET NO.1 
    1. Install the new governor apply gasket No. 1 to the transaxle case.
      Fig 99: Installing Governor Apply Gasket To Transaxle Case
      G05193758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSTALL CHECK BALL BODY 
    1. Install the check ball body and compression spring to the transaxle case.
      Fig 100: Installing Check Ball Body And Compression Spring To Transaxle Case
      G05193757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF and install the transmission wire to the transaxle case.
      Fig 101: Installing Transmission Wire To Transaxle Case
      G05193756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 102: Locating Transmission Wire Bolt
      G05234320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Connect the manual valve connecting rod to the manual valve lever.
      Fig 103: Installing Manual Valve Connecting Rod To Manual Valve Lever
      G05193977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission valve body assembly with the 17 bolts.

      HINT:

      Each bolt length is indicated in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt length: 

      Bolt A: 

      20 mm (0.79 in.) 

      Bolt B: 

      28 mm (1.10 in.) 

      Bolt C: 

      50 mm (1.97 in.) 

      Fig 104: Identifying Transmission Valve Body Assembly Bolts
      G05193978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the solenoid connectors.
      Fig 105: Locating Solenoid Connectors
      G05193752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Install the manual detent spring sub-assembly and manual detent spring cover with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 106: Locating Manual Detent Spring Sub-Assembly Bolt
      G05193751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Install the valve body oil strainer assembly and a new oil strainer gasket with the 3 bolts.

      HINT:

      Each bolt length is indicated in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Bolt length: 

      Bolt A: 

      12 mm (0.47 in.) 

      Bolt B: 

      20 mm (0.79 in.) 

      Fig 107: Identifying Valve Body Oil Strainer Bolts
      G05193981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL TRANSMISSION OIL CLEANER MAGNET 
    1. Install the 2 transmission oil cleaner magnets to the automatic oil pan sub-assembly.
      Fig 108: Identifying Transmission Oil Cleaner Magnets
      G05193982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan sub-assembly and install them to the transaxle.
    2. Tighten the 18 bolts.

      Torque: 5.3 N*m (54 kgf*cm, 47 in.*lbf) 

      Fig 109: Tightening Automatic Transaxle Oil Pan Bolts
      G05193983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL OIL COOLER TUBE UNION 
    1. Coat 2 new O-rings with ATF and install 2 new O-rings to the 2 oil cooler tube unions.
    2. Install the 2 oil cooler tube unions to the transaxle case.

      Torque: 30 N*m (304 kgf*cm, 22 ft.*lbf) 

      Fig 110: Identifying Oil Cooler Tube Union
      G05193748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park / neutral position switch assembly to the manual valve lever shaft.
    2. Place a new lock washer and tighten the nut.

      Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

    3. Temporarily install the 2 bolts.
      Fig 111: Identifying Park/Neutral Position Switch Assembly Nut And Bolts
      G05193747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the transmission control shift lever.
    5. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
      6. Fig 112: Turning Transmission Control Shift Lever Counterclockwise
      G05193986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the transmission control shift lever.
    7. Align the groove with neutral basic line.
      8. Fig 113: Identifying Park/Neutral Position Switch Groove And Neutral Basic Line
      G05193987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the 2 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    9. Using a screwdriver, stake the nut with the lock washer.
      10. Fig 114: Staking Nut With Lock Washer
      G05193988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL TRANSMISSION CONTROL SHAFT LEVER 
    1. Install the transmission control shaft lever with the nut and washer.

      Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

  82. INSTALL TRANSAXLE CASE NO.1 PLUG 
    1. Install the transaxle case No. 1 plug and a new CD-ring to the transaxle case.
  83. INSTALL BREATHER PLUG NO.1 (ATM) 
    1. Install the breather plug No. 1 and a new O-ring to the transaxle case.
  84. INSTALL BREATHER PLUG HOSE 
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