Part 2

U341E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

Part 2

40. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the No. 2 thrust washer to the rear planetary gear assembly.
(b) Install the one-way clutch assembly to the rear planetary sun gear assembly.
41. INSPECT ONE-WAY CLUTCH ASSEMBLY

(a) Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
42. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING

(a) Install the thrust bearing and a washer to the rear planetary sun gear.
43. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Install the rear planetary sun gear assembly.
44. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING

(a) Install the thrust bearing to the rear planetary sun gear.
45. INSTALL DIRECT CLUTCH HUB

(a) Install the direct clutch hub.
46. INSTALL THRUST NEEDLE ROLLER BEARING

(a) Install the No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race to the direct clutch hub.
47. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC

(a) Install the 2 discs, No. 2 flanges and flange to the transaxle case.
48. INSTALL INTERMEDIATE SHAFT ASSEMBLY

(a) Install the intermediate shaft assembly to the transaxle case.
49. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE

(a) As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers. (Dimension A)

(b) As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and straight edge using vernier calipers. (Dimension B)
Calculate the piston stroke value using the following formula. Select a flange which meets the piston stroke value and install it.
Pack clearance:
2.091 to 2.491 mm (0.0823 to 0.0981 in.)
NOTICE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different flange thicknesses.

Flange thickness:

50. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the intermediate shaft.
51. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Install the transaxle rear cover with the 11 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(b) Using a dial indicator, measure the intermediate shaft end play.
Standard clearance:
0.204 to 0.966 mm (0.008 to 0.038 in.)
If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.
HINT: There are 2 different trust needle roller bearing thicknesses.

(a) Install 4 new gaskets to the transaxle case.
53. INSTALL REAR TRANSAXLE COVER ASSEMBLY

(a) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
54. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

(a) Install the forward clutch hub sub-assembly onto the transaxle case.
55. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the forward clutch hub.
56. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the input shaft assembly.
57. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the input shaft assembly to the transaxle case.
58. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new gaskets to the transaxle case.
59. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear assembly to the transaxle case.
60. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump with the 7 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
61. INSPECT INPUT SHAFT ASSEMBLY

(a) Make sure that the input shaft turns smoothly.
62. INSPECT INPUT SHAFT END PLAY

(a) Measure the end play in the axial direction.
End play:
0.374 to 1.292 mm (0.0147 to 0.0509 in.)
If the end play is not as specified, replace the forward clutch hub thrust needle roller bearing and the stator shaft thrust needle bearing.
63. INSTALL TRANSAXLE HOUSING

(a) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt B - Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
64. INSTALL C-2 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the C-2 accumulator piston.
NOTICE: Do not damage the O-rings.

(b) Install the spring and C-2 accumulator piston.
Accumulator spring:

65. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the C-3 accumulator piston.
NOTICE: Do not damage the O-rings.

(b) Install the spring and C-3 accumulator piston.
Accumulator spring:

66. INSTALL B-2 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the B-2 accumulator piston.
NOTICE: Do not damage the O-rings.

(b) Install the spring and B-2 accumulator piston.
Accumulator spring:

67. INSTALL CHECK BALL BODY

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

(a) Install a new brake drum gasket.
69. INSTALL TRANSAXLE CASE GASKET

(a) Coat a new transaxle case gasket with Toyota Genuine ATF WS or equivalent, and install it to the transaxle case.
70. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with Toyota Genuine ATF WS or equivalent, and install it to the transaxle case.
71. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the transmission wire.

(b) Insert the transmission wire to the transaxle.

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

(b) Temporarily install the valve body with the 13 bolts.
Bolt length:
Bolt A: 32 mm (1.26 in.)
Bolt B: 22 mm (0.87 in.)
Bolt C: 55 mm (2.17 in.)
Bolt D: 45 mm (1.77 in.)

(c) Temporarily install the detent spring and detent spring cover with the 2 bolts.
Bolt length:
Bolt A: 14 mm (0.55 in.)
Bolt B: 45 mm (1.77 in.)
(d) Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.
(e) Tighten the 15 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)

(f) Connect the 5 solenoid connectors.
(g) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 11 Nm (110 kgf-cm, 8 ft-lbf)
Bolt length:
55 mm (2.17 in.)
73. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the oil strainer.

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

(a) Install the 2 magnets to the oil pan.
(b) Install a new oil pan gasket to the oil pan.

(c) Install the oil pan with the 19 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
75. INSTALL BREATHER PLUG
(a) Install the breather plug to the transaxle case.
76. INSTALL BREATHER PLUG HOSE

(a) Install the breather plug hose to the breather plug.
77. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 5 new O-rings with Toyota Genuine ATF WS or equivalent, and install them to the No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs to the transaxle housing and transaxle case.
Torque: 7.4 Nm (76 kgf-cm, 66 in-lbf)

(c) Install the No. 1 transaxle case plug to the transaxle case.
Torque: 7.4 Nm (76 kgf-cm, 66 in-lbf)
78. INSTALL OIL COOLER TUBE UNION
(a) Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 2 oil cooler tube unions.

(b) Install the 2 oil cooler tube unions to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
79. INSTALL SPEED SENSOR
(a) Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the speed sensor.

(b) Install the speed sensor to the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
80. 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 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 and washer.
Torque: 13 Nm (129 kgf-cm, 9 ft-lbf)
81. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
(a) Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it to the speedometer driven hole cover sub-assembly.

(b) Install the speedometer driven hole cover sub-assembly to the transaxle housing.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)