Part 3

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

Part 3

33. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE

(a) Install the thrust bearing race onto the underdrive planetary gear.
34. INSTALL THRUST NEEDLE ROLLER BEARING

(a) 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 bearing and bearing race diameter

35. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump into the transaxle with the 7 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)
36. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING

(a) Install a new oil seal ring onto the transaxle housing.
37. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Using SST and a press, press in the underdrive cylindrical roller bearing.
SST: 09950-60020
SST: 09950-70010
09951-07100
09951-07100
NOTICE: Do not apply excessive pressure to it.

38. INSTALL TRANSAXLE HOUSING

(a) Remove any packing material and be careful not to get oil on the contacting surfaces 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

(c) Install the transaxle housing onto the transaxle with the 18 bolts.
Torque: 22 Nm (220 kgf-cm, 16 ft-lbf) for bolt A
Torque: 29 Nm (300 kgf-cm, 21 ft-lbf) for bolt B and C
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf) for bolt D
Each bolt length is indicated below.:

NOTICE: 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
39. INSPECT INPUT SHAFT END PLAY Transaxle Unit

40. FIX AUTOMATIC TRANSAXLE ASSEMBLY
41. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with ATF, and install it into the transaxle.
42. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod onto the manual valve lever.
43. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft into the transaxle.

(b) Using a pin punch and hammer, tap in a new pin.

(c) 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.
(d) Using a pin punch, stake the spacer through the small hole.
(e) Check that the spacer does not turn.
44. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
45. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Bolt length:
25 mm (0.984 in.)
46. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring with the 2 bolts.
NOTICE: Make sure to install the manual detent spring and cover in this order.

Torque: 20 Nm (204 kgf-cm, 15 ft-lbf) for bolt A
Torque: 12 Nm (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
47. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it onto the B-3 accumulator piston.

(b) Coat the accumulator B-3 piston and spring with ATF, and install them to the transaxle.
Standard accumulator spring:

48. INSTALL C-1 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them onto the C-1 accumulator piston.

(b) Coat the accumulator C-1 piston with ATF, and install it into the transaxle.
Standard accumulator spring:

49. INSTALL C-3 ACCUMULATOR PISTON

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

(b) Coat the C-3 accumulator piston with ATF, and install it into the transaxle.

(a) Install the check ball body and spring.
51. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, and install it into the transaxle.
52. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it into the transaxle.
53. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new No. 1 governor apply gasket with ATF, and install it into the transaxle.
54. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF and install it onto the transmission wire.
(b) Pass the transmission wire through the transaxle case.

(c) Install the transmission wire with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
55. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Align the groove of the manual valve with the pin of the lever.

(b) Install the transmission valve body assembly with the 17 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)

NOTICE:
- 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
(c) Coat the O-ring on the ATF temperature sensor with ATF.

(d) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)
(e) Connect the 5 shift solenoid valve connectors.
56. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF, and install it into the valve body oil strainer assembly.

(b) Install the valve body oil strainer assembly with the 3 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 oil cleaner magnets onto the automatic transaxle oil pan sub-assembly, as shown in the illustration.

(b) Install the automatic transaxle oil pan sub-assembly and a new oil pan gasket with the 18 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
58. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 8 new O-rings with ATF, and install them into the 8 No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs onto the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)

(d) Install the 2 No. 1 transaxle case plugs onto the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)

59. INSTALL SPEED SENSOR NT
(a) Coat a new O-ring with ATF, and install it into the speed sensor NT.
(b) Install the speed sensor NT with the bolt.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
60. INSTALL SPEED SENSOR NC
(a) Coat a new O-ring with ATF, and install it into the speed sensor NC.
(b) Install the speed sensor NC with the bolt.
Torque: 8.8 Nm (90 kgf-cm, 78 in-lbf)
61. INSTALL INLET OIL COOLER TUBE UNION

(a) Coat a new O-ring with ATF, and install it into the inlet oil cooler tube union.
(b) Install the inlet oil cooler tube union into the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
62. INSTALL OUTLET OIL COOLER TUBE UNION

(a) Coat a new O-ring with ATF, and install it into the outlet oil cooler tube union.
(b) Install the outlet oil cooler tube union into the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
63. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the breather plug.
64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch assembly onto the manual valve lever shaft.
(b) Provisionally install the 2 bolts.
(c) Replace the lock plate with a new one and tighten the manual valve shaft nut.
Torque: 6.9 Nm (70 kgf-cm, 61 in-lbf)

(d) Provisionally install the control shaft lever.

(e) Turn the control shaft lever counterclockwise until it stops, 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 this position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)

(i) Using a screwdriver, stake the nut with the lock plate.

(j) Install the control shaft lever with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)