Part 1

U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

HINT
Check the position and installation direction of each bearing.

1. INSTALL COUNTER DRIVE GEAR BEARING

HINT
Perform this procedure only when the counter drive gear bearing or transaxle case is replaced.

(a) Using SST and a press, install a new counter drive gear bearing (outer race) and snap ring to the transaxle case.

SST : 09950-60020

09951-01030

SST : 09950-70010

09951-07100

2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat the lip of a new manual valve lever shaft oil seal with a small amount of MP grease.

(b) Using SST and a hammer, tap in the manual valve lever shaft oil seal.

SST : 09950-60010

09951-00230

SST : 09950-70010

09951-07100

Oil seal tap in depth:

-0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

NOTICE:
Check that the manual valve lever shaft oil seal is installed in the correct direction.

3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

(a) Install the manual valve lever shaft to the transaxle case.

NOTICE:
Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft to the transaxle case.

(b) Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case.

4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Align the slot with the notches on the manual valve lever shaft and install the parking lock rod.

5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring and manual detent spring cover to the transaxle case with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

NOTICE:
Make sure to install the manual detent spring first, and then install the manual detent spring cover.

6. INSTALL NO. 3 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

NOTICE:
Make sure that the 2 O-rings are not twisted.

(b) Temporarily install the No. 3 brake piston to the transaxle case.

NOTICE:
Be careful not to damage the O-ring.

(c) Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts.

Text in Illustration

NOTICE:
After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned.

(d) Press the No. 3 brake piston into the transaxle case.

HINT
Use the installation surface of the return spring to press the piston into the transaxle case.

(e) Remove the 2 bolts and pawl stopper plate from the transaxle case.

(f) Install the brake piston return spring to the transaxle case.

Text in Illustration

NOTICE:
Install the brake piston return spring as shown in the illustration.

(g) Place SST on the brake piston return spring and compress the brake piston return spring with a press.

Text in Illustration

SST : 09387-00070

NOTICE:
* Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.
* Be careful not to damage the No. 3 brake piston.

HINT
Wrap the tip of the screwdriver with protective tape before use.

(h) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.

NOTICE:
* Confirm that the snap ring is correctly seated in the groove of the transaxle case.
* Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.

7. INSTALL COUNTER DRIVE GEAR

(a) Using SST and a press, install a new counter drive gear bearing inner race (front side) to the counter drive gear.

SST : 09387-00020

(b) Using SST, install a new counter drive gear bearing inner race (rear side) and counter drive gear to the transaxle case.

SST : 09223-15030

SST : 09527-17011

SST : 09950-60020

09951-00810

SST : 09950-70010

09951-07100

NOTICE:
There should not be any clearance between the counter drive gear bearing inner race (front side) and counter drive gear.

8. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Using SST and a press, install a new front planetary gear assembly to the transaxle case.

SST : 09223-15030

SST : 09527-17011

SST : 09951-01100

9. INSTALL NO. 2 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 2 brake piston.

NOTICE:
Make sure that the 2 O-rings are not twisted.

(b) Install the No. 2 brake piston to the transaxle case.

NOTICE:
Be careful not to damage the O-rings.

10. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Install the 1st and reverse brake return spring to the transaxle case.

(b) Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring with a press.

SST : 09387-00060

NOTICE:
Stop the press when the 1st and reverse brake return spring is flush with the snap ring groove. This prevents the 1st and reverse brake return spring from being deformed.

(c) Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration.

Text in Illustration

Text in Illustration

NOTICE:
Make sure that the discs, plates and flange are installed in the correct order.

(b) Using a screwdriver, install the snap ring to the transaxle case.

Text in Illustration

NOTICE:
* Confirm that the snap ring is correctly seated in the groove of the transaxle case.
* Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration.
* Be careful not to damage the transaxle case.

HINT
Wrap the tip of the screwdriver with protective tape before use.

12. INSPECT CLEARANCE OF NO. 2 BRAKE Transaxle Unit

13. INSTALL PLANETARY RING GEAR FLANGE

(a) Install the planetary ring gear flange to the planetary ring gear.

(b) Using a screwdriver, install the snap ring to the planetary ring gear.

NOTICE:
Confirm that the snap ring is correctly seated in the groove of the planetary ring gear.

14. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the one-way clutch assembly.

(b) Install the one-way clutch assembly to the planetary ring gear.

NOTICE:
Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration.

(c) Coat the thrust needle roller bearing with ATF and install it to the front planetary gear assembly.

Text in Illustration

Bearing Diameter

NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(d) Install the one-way clutch assembly together with the planetary ring gear to the transaxle case.

NOTICE:
Make sure that there is no clearance between the retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer will be deformed.

(e) Using a screwdriver, install the snap ring to the transaxle case.

Text in Illustration

NOTICE:
Make sure that one end of the spring is secured in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.

16. INSTALL PARKING LOCK SLEEVE

(a) Install the parking lock sleeve to the transaxle case.

17. INSTALL PAWL STOPPER PLATE

(a) Install the pawl stopper plate to the transaxle case with the 2 bolts.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

18. INSTALL NO. 1 TRANSMISSION CASE PLATE

(a) Clean and degrease the bolt and the installation hole in the transaxle case.

(b) Apply adhesive to 2 or 3 threads at the end of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the No. 1 transmission case plate to the transaxle case with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

HINT
Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case as shown in the illustration.

19. INSTALL PAWL SHAFT CLAMP

(a) Install the pawl shaft clamp to the transaxle case with the bolt.

Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)

20. INSTALL COUNTER DRIVEN GEAR BEARING RH (INNER RACE)

(a) Using SST and a press, install a new counter driven gear bearing RH (inner race) to the counter driven gear.

SST : 09950-60010

09951-00490

NOTICE:
Be sure to install the counter driven gear bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

21. INSTALL COUNTER DRIVEN GEAR BEARING RH (OUTER RACE)

(a) Install the shim to the transaxle housing.

(b) Using SST, install a new counter driven gear bearing RH (outer race) to the transaxle housing.

SST : 09950-60020

09951-00710

SST : 09950-70010

09951-07100

NOTICE:
Be sure to install the counter driven gear bearing RH (outer race) so that there is no clearance between the bearing outer race, shim and the transaxle housing. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

22. INSTALL COUNTER DRIVEN GEAR BEARING LH (INNER RACE)

(a) Using SST and a press, install a new counter driven gear bearing LH (inner race) to the counter driven gear.

SST : 09950-60010

09951-00400

NOTICE:
Be sure to install the counter driven gear bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

23. INSTALL COUNTER DRIVEN GEAR BEARING LH (OUTER RACE)

(a) Using SST and a hammer, install a new counter driven gear bearing LH (outer race) to the transaxle case.

SST : 09950-60010

09951-00630

SST : 09950-70010

09951-07100

NOTICE:
Be sure to install the counter driven gear bearing so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.

24. INSTALL COUNTER DRIVEN GEAR

(a) Install the counter driven gear to the transaxle case.

25. INSTALL COUNTER DRIVE GEAR NUT

(a) Turn the manual valve lever shaft counterclockwise to set it to the P position as shown in the illustration.

(b) Using SST, install a new counter drive gear nut.

SST : 09387-00130

Torque : 150 Nm (1530 kgf-cm, 111 ft-lbf)

(c) Turn the manual valve lever shaft 2 notches clockwise to set it to the N position as shown in the illustration.

(d) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm.

SST : 09387-00130

Turning torque:

0.1 to 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf)

If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range.

Maximum torque:

180 N*m (1835 kgf*cm, 133 ft.*lbf)

(e) Using SST and a hammer, stake the counter drive gear nut.

SST : 09930-00010

26. INSTALL FRONT DIFFERENTIAL CASE

(a) Install the front differential case to the transaxle case.

27. INSTALL NO. 1 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

NOTICE:
Make sure that the 2 O-rings are not twisted.

(b) Install the No. 1 brake piston to the oil pump assembly.

NOTICE:
Be careful not to damage the O-rings.

28. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the 3 2nd brake piston return springs to the oil pump assembly.

NOTICE:
Make sure that the 3 2nd brake piston return springs are installed to the protrusions on the oil pump assembly.

29. INSTALL NO. 1 BRAKE DISC

(a) Install the 3 No. 1 brake discs, 3 No. 1 brake plates and No. 1 brake flange to the oil pump assembly.

Text in Illustration

NOTICE:
* Make sure that the discs, plates and flange are installed in the correct order.
* Be sure to install the flange in the correct direction.

(b) Place SST on the No. 1 brake flange and compress the No. 1 brake flange with a press.

SST : 09387-00070

SST : 09495-65040

NOTICE:
Stop the press when the 2nd brake piston return spring is flush with the snap ring groove. This prevents the 2nd brake piston return spring from being deformed.

(c) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration.

NOTICE:
* Confirm that the snap ring is correctly seated in the groove of the oil pump assembly.
* Make sure to align the protruding part of the snap ring with the indented part (#1) of the oil pump and gear body assembly shown in the illustration to install the snap ring.

(d) Install the brake snap ring stopper to the oil pump assembly.

NOTICE:
Be sure to install the brake snap ring stopper in the correct direction.

(e) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration.

NOTICE:
* Confirm that the snap ring is correctly seated in the groove of the oil pump.
* Make sure to align the protruding part of the snap ring with the indented part (#2) of the oil pump assembly shown in the illustration to install the snap ring.

(f) Check that the brake snap ring stopper can be turned by hand.

Text in Illustration

NOTICE:
If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not be completely seated in the groove on the oil assembly pump. Remove and reinstall the snap ring and brake snap ring stopper.

30. INSPECT CLEARANCE OF NO. 1 BRAKE Transaxle Unit