Part 2

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - Continued

26. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

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

(b) 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.

NOTICE:
Make sure that the mark on the 1-way clutch outer race is visible.

(d) Using a screwdriver, install the snap ring into the transaxle.

27. INSTALL UNDERDRIVE CLUTCH

(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 assembly into the transaxle.

28. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the parking lock pawl pin and torsion spring onto the parking lock pawl.

(b) Temporarily install the parking lock pawl, shaft and spring into the transaxle case as shown in the illustration.

NOTICE:
Engage all the discs of the underdrive clutch and hub splines of the underdrive planetary gear assembly 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:
Note down the 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 dimension E using the formula.

NOTICE:
Note down dimension E as it is necessary for the following process.

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

29. INSTALL MULTIPLE DISC CLUTCH HUB

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

Standard bearing diameter:

(b) 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 bearing diameter:

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

30. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Install the input shaft thrust bearing onto 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 onto 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.

31. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets into the transaxle.

32. INSTALL FRONT DIFFERENTIAL ASSEMBLY

(a) Install the differential assembly into the transaxle.

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.

50. INSTALL CHECK BALL BODY

(a) Install the check ball body and spring.