Part 2
U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY (Continued)
31. INSTALL UNDERDRIVE PLANETARY SUN GEAR
(a) Coat the thrust needle roller bearing with ATF and install it to the oil pump 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.
(b) Install the underdrive planetary sun gear to the oil pump assembly.
32. INSTALL INPUT SHAFT SUB-ASSEMBLY
(a) Coat 3 new oil seal rings with ATF and install them to the input shaft.
Text in Illustration
NOTICE:
Do not expand the gap of the oil seal ring too much.
(b) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the input shaft.
Bearing and Race Diameter
NOTICE:
Be sure to install the thrust needle roller bearing in the correct direction.
(c) Install the input shaft to the oil pump assembly.
33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY
(a) Using snap ring pliers, install the snap ring to the underdrive planetary gear assembly.
(b) Using a snap ring expander, install the planetary sun gear to the underdrive planetary gear assembly with the snap ring expanded.
34. INSTALL NO. 3 BRAKE HUB
(a) Coat the thrust needle roller bearing with ATF and install it to the underdrive planetary gear assembly.
Text in Illustration
Bearing and Race Diameter
NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.
(b) Coat the thrust bearing race with ATF and install it to the No. 3 brake hub.
(c) Install the No. 3 brake hub to the underdrive planetary gear assembly.
35. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Install the underdrive planetary gear assembly to the oil pump assembly.
36. INSTALL NO. 3 BRAKE DISC
(a) Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the oil pump assembly.
Text in Illustration
NOTICE:
Make sure that the discs, plates and flanges are installed in the correct order.
(b) Using a screwdriver, install the snap ring to the oil pump assembly.
NOTICE:
* Confirm that the snap ring is correctly seated in the groove of the oil pump assembly.
* Make sure that the snap ring ends are positioned as shown in the illustration (A).
37. INSPECT CLEARANCE OF NO. 3 BRAKE Transaxle Unit
38. INSTALL OIL PUMP ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the transaxle case.
Text in Illustration
(b) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the counter drive gear nut.
Bearing and Race Diameter
NOTICE:
Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.
(c) Coat a new O-ring with ATF and install it to the oil pump assembly.
(d) Install the oil pump assembly to the transaxle case with the 7 bolts.
Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
(e) Coat a new O-ring with ATF and install it to the oil pump assembly.
39. INSTALL TRANSAXLE HOUSING OIL SEPARATOR
(a) Clean and degrease the 3 bolts and the installation holes in the transaxle housing.
(b) Apply adhesive to 2 or 3 threads at the ends of the 3 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the transaxle housing oil separator to the transaxle housing with the 3 bolts.
Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
40. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube to the transaxle housing.
NOTICE:
Insert the differential gear lube apply tube into the transaxle housing until it makes contact with the stopper.
(b) Clean and degrease the bolt and the installation hole in the transaxle housing.
(c) Apply adhesive to 2 or 3 threads at the end of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the clamp to the differential gear lube apply tube with the bolt.
Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
NOTICE:
There should be clearance of the differential lube apply tube and apply tube clamp.
41. ADJUST COUNTER DRIVEN GEAR PRELOAD
(a) Remove the seal packing material from the contact surfaces of the transaxle housing and case.
(b) Install the transaxle housing to the transaxle case with the 20 bolts.
Bolt A - Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
except Bolt A - Torque : 31 Nm (312 kgf-cm, 23 ft-lbf)
(c) Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.
SST : 09564-33010
Turning torque:
Differential side bearing preload + 3.14 to 6.19 N*m (32.02 to 63.12 kgf*cm, 27.80 to 54.78 in.*lbf)
If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing (outer race) so that the turning torque is within the specified range.
Shim Thickness
(d) Remove the 20 bolts and transaxle housing.
42. INSTALL TRANSAXLE HOUSING
(a) Clean and degrease the contact surfaces of the transaxle housing and case.
NOTICE:
Make sure that there is no ATF on the contact surfaces.
(b) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTICE:
* Apply FIPG in a continuous line (width: 1.2 mm (0.0472 in.)) along the sealing surface.
* After applying FIPG, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 20 minutes.
(c) Install the transaxle housing to the transaxle case with the 17 bolts.
Torque : 31 Nm (312 kgf-cm, 23 ft-lbf)
(d) Clean and degrease the 3 bolts and the installation holes in the automatic transaxle.
(e) Apply adhesive to 2 or 3 threads at the ends of the 3 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(f) Install the 3 bolts.
Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
43. INSPECT CLEARANCE OF NO. 1 CLUTCH Transaxle Unit
44. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the rear multiple disc clutch assembly.
Text in Illustration
Bearing and Race Diameter
NOTICE:
Install the rear planetary sun gear thrust needle roller bearing properly so that the temper colored side of the race will be visible.
(b) Install the rear planetary sun gear assembly to the rear multiple disc clutch assembly.
(c) Using a snap ring expander, install the snap ring to the rear multiple disc clutch assembly.
(d) Coat a new O-ring with ATF and install it to the rear multiple disc clutch assembly.
NOTICE:
Make sure that the O-ring is not twisted.
(e) Coat a new oil seal ring with ATF and install it to the rear multiple disc clutch assembly.
45. INSPECT CLEARANCE OF NO. 2 CLUTCH Transaxle Unit
46. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY
(a) Coat the thrust needle roller bearing with ATF and install it to the transaxle case.
Text in Illustration
Bearing Diameter
(b) Install the rear multiple disc clutch assembly to the transaxle case.
47. INSPECT INTERMEDIATE SHAFT END PLAY Transaxle Unit
48. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY
(a) Using SST and a hammer, install a new needle roller bearing to the rear transaxle cover.
SST : 09950-60010
09951-00220
SST : 09950-70010
09951-07100
Installation depth:
21.5 to 21.9 mm (0.847 to 0862 in.)
(b) Clean and degrease the 2 screws and the installation holes in the rear transaxle cover.
(c) Apply adhesive to 2 or 3 threads at the ends of the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Using a T30 "TORX" socket wrench, install the rear transaxle cover plate to the rear transaxle cover with the 2 screws.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(e) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the rear transaxle cover.
Text in Illustration
Bearing and Race Diameter
(f) Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover.
(g) Coat 3 new O-rings with ATF and install them to the transaxle case.
(h) Remove the seal packing material from the contact surfaces of the rear transaxle cover and transaxle case.
NOTICE:
Make sure that there is no ATF on the contact surfaces.
(i) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent.
NOTICE:
* Apply FIPG in a continuous line (width: 1.2 mm (0.0472 in.)) along the sealing surface.
* After applying FIPG, install the rear transaxle cover to the transaxle case within 3 minutes and tighten the bolts within 20 minutes.
(j) Install the rear transaxle cover to the transaxle case with the 12 bolts.
Torque : 23 Nm (231 kgf-cm, 17 ft-lbf)
(k) Clean and degrease the 2 bolts and the installation holes in the transaxle case.
(l) Apply adhesive to 2 or 3 threads at the ends of the 2 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(m) Install the 2 bolts.
Torque : 17 Nm (172 kgf-cm, 12 ft-lbf)
49. INSTALL REAR TRANSAXLE COVER PLUG
(a) Coat 3 new O-rings with ATF and install them to the 3 rear transaxle cover plugs.
NOTICE:
Make sure that the 3 O-rings are not twisted.
(b) Install the 3 rear transaxle cover plugs to the rear transaxle cover.
Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)
50. INSTALL REFILL PLUG
(a) Install a new gasket to the refill plug.
(b) Install the refill plug to the rear transaxle cover sub-assembly.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
51. INSPECT INPUT SHAFT END PLAY Transaxle Unit
52. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat 2 new No. 1 governor apply gaskets with ATF.
(b) Install the 2 No. 1 governor apply gaskets to the transaxle case.
53. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Coat the O-ring of the transmission valve body assembly wire with ATF.
(b) Insert the pin of the manual valve lever into the groove on the end of the manual valve and install the transmission valve body assembly to the automatic transaxle with the 11 bolts.
Text in Illustration
Bolt Length
for Bolt A, B, C - Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)
for Bolt D - Torque : 9.6 Nm (98 kgf-cm, 85 in-lbf)
NOTICE:
* When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and automatic transaxle to interfere with each other.
* First, temporarily install the bolts marked *a in the illustration because they are positioning bolts.
54. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the valve body oil strainer assembly.
NOTICE:
Make sure that the O-ring is not twisted.
(c) Install the valve body oil strainer to the transmission valve body assembly with the 2 bolts.
Torque : 9.6 Nm (98 kgf-cm, 85 in-lbf)
55. INSTALL TRANSMISSION OIL CLEANER MAGNET
(a) Install the 2 transmission oil cleaner magnets to the automatic transaxle oil pan as shown in the illustration.
Text in Illustration
56. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET
(a) Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan.
57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
(a) Install the automatic transaxle oil pan together with the automatic transaxle oil pan gasket to the automatic transaxle with the 17 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
NOTICE:
Completely remove any oil or grease from the contact surfaces of the transaxle case and the oil pan with the gasket before installation.
(b) Clean and degrease the 2 bolts and the installation holes in the transaxle case.
(c) Apply adhesive to 2 or 3 threads at the end of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the 2 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
58. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE
(a) Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle oil pan.
Torque : 0.8 Nm (8 kgf-cm, 7 in-lbf)
59. INSTALL OVERFLOW PLUG
(a) Using a 6 mm hexagon socket wrench, install the overflow plug and a new gasket to the automatic transaxle oil pan.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
60. INSTALL NO. 2 TRANSAXLE CASE PLUG
(a) Clean and degrease the 3 No. 2 transaxle case plugs and the installation holes in the transaxle housing.
(b) Apply adhesive to 2 or 3 threads at the ends of the 3 No. 2 transaxle case plugs.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install 3 new gaskets to the 3 No. 2 transaxle case plugs.
(d) Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs together with the gaskets to the transaxle housing.
Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)
61. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 3 new O-rings with ATF and install them to the 3 No. 1 transaxle case plugs.
NOTICE:
Make sure that the 2 O-rings are not twisted.
(b) Install the 3 No. 1 transaxle case plugs to the transaxle case.
Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)
62. INSTALL OIL COOLER TUBE UNION (INLET)
(a) Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet).
NOTICE:
Make sure that the O-ring is not twisted.
(b) Install the oil cooler tube union (inlet) to the transaxle case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
63. INSTALL OIL COOLER TUBE UNION (OUTLET)
(a) Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet).
NOTICE:
Make sure that the O-ring is not twisted.
(b) Install the oil cooler tube union (outlet) to the transaxle case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Temporarily install the park/neutral position switch assembly to the transaxle case with the 2 bolts.
NOTICE:
Before installing the park/neutral position switch assembly, remove any dirt or rust on the control shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.
(b) Align the protrusions of the park/neutral position switch assembly as shown in the illustration.
Text in Illustration
(c) Tighten the 2 bolts
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTICE:
After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned.
65. INSTALL TRANSMISSION CONTROL SHAFT LEVER
(a) Install the transmission control shaft lever to the manual valve lever shaft with the washer and nut.
Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)
66. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the No. 2 breather plug.
NOTICE:
Make sure that the O-ring is not twisted.
(b) Install the No. 2 breather plug to the breather plug hose.
(c) Install the No. 1 breather plug to the breather plug hose.
(d) Install the transmission breather plug hose to the transaxle case.