Part 2

REASSEMBLY (continued)

26. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.

27. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 inch)

HINT: Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 inch)

Flange thickness: mm (inch):

(c) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

NOTICE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY
(a) Install the direct clutch hub to the planetary gear assembly.

NOTICE: Be careful not to damage the bush inside of the overdrive clutch hub during installing.

(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct clutch hub.

NOTICE: Installing the bearing, hold the part on the side of the overdrive clutch hub.

Bearing and race diameter: mm (inch):

29. INSTALL DIRECT CLUTCH ASSEMBLY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.

NOTICE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed.

(c) Clean the connector part of the transaxle case and the rear cover.
(d) As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between transaxle case and the straight edge using vernier calipers (Dimension C).

(e) Using vernier calipers and a simple straightedge, measure the position shown in the illustration.
(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play: 0.244 - 0.901 mm (0.0096 - 0.0355 inch)

NOTICE: Make sure that the no colored race side is facing the direct clutch assembly.

HINT: End play = Dimension D - Dimension C

Bearing thickness and diameter: mm (inch):

30. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the transaxle case.

31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.

NOTICE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

(b) Install the clutch apply tube.

(c) Install the brake apply tube and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Each pipe should be securely inserted until it reaches the stopper.

32. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing to the transaxle rear cover.
Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 inch)

NOTICE:
^ Face the inscribed mark side of the bearing race up.
^ Repeat the press fit until the specified value is obtained.

(b) Coat a needle roller bearing with ATF.

33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover.

NOTICE: The snap ring should be fixed certainly in the groove of the drum.

34. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 4 new O-ring to the 4 transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)

35. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY
(a) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case.
(b) Apply FIPG to the cover.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE: Concerning about the amount of the FIPG application, the amount should be controlled to from even sealing film on entire flange surface and have slight protrusion of the FIPG all around of the connecting area. The FIPG shall be applied continuously on the flange.

(Reference value of the section diameter: [diameter]1.2)

(c) Apply liquid sealer to the "A" bolt threads.
Sealant: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Install the 11 bolts.
Torque:
Bolt A 19 Nm (190 kgf-cm, 14 ft. lbs.)
Other bolt: 25 Nm (255 kgf-cm, 18 ft. lbs.)

36. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle case.

NOTICE: Be careful about the order of discs, plate and flange assembly.

(c) Using a screwdriver, install the snap ring.

NOTICE: The snap ring should be fixed certainly in the groove of the drum.

37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
(a) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 inch)

HINT: Select an appropriate flange from the table so that it will meet the specified value.

Flange thickness: mm (inch):

(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.

38. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way clutch.
(b) Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.

39. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.

NOTICE: Fix the outer race retainer to the external tooth of the one way clutch surely.

(b) Install the 1-way clutch to the transaxle case.

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

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

NOTICE: The snap ring should be fixed certainly in the groove of the transaxle case as the gap exists except in the lock of teeth.

40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.

Bearing and bearing race diameter: mm (inch):

(b) Install the underdrive clutch assembly to the transaxle case.

NOTICE: Installing the underdrive clutch drum subassembly, be sure not to damage the oil seal ring.

41. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.

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

42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Install the underdrive planetary gear assembly to the transaxle case.

NOTICE: Engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly firmly and assemble them securely.

(b) Install the parking lock pawl shaft.

(d) Using a straight edge 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 case and housing (Dimension E).

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

(e) As shown in the illustration, measure the 2 places of the transaxle housing, calculate the dimension F using the formula.

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

HINT: Dimension F = Dimension (1) - Dimension (2)

43. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case while checking its direction.

Bearing race diameter: mm (inch):

(b) Coat the thrust needle roller bearing and race with yellow petrolatum, install them onto the multiple disc clutch hub.

Thrust bearing and race diameter: mm (inch):

(d) Install the needle roller bearing to the multiple clutch hub.

Bearing diameter: mm (inch):

(e) Install the multiple clutch hub to the transaxle case.

44. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward clutch.

Thrust bearing diameter: mm (inch):

NOTICE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.

(c) Install the forward clutch to the forward clutch assembly.

NOTICE:
^ Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
^ Be careful not to damage the bush inside of the forward clutch hub during installing.

45. INSTALL OVERDRIVE BRAKE GASKET
(a) Install the 2 new overdrive brake gaskets.

46. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assembly to the transaxle case.

47. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2
(a) Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly.

48. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following formula and values of Dimension E and F that ware measured when installing 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.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 inch)

HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 inch) - underdrive thrust bearing race No. 2 thickness.

Race thickness: mm (inch):

Bearing and bearing race diameter: mm (inch):

49. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.0 Nm (226 kgf-cm, 16 ft. lbs.)

(b) Coat the O-ring of oil pump with ATF.

NOTICE: Confirm the input shaft rotates smoothly with the manual operation after assembling the oil pump.

50. INSTALL TRANSAXLE HOUSING
(a) Remove any parking material and be careful not to get oil on the contacting surface of the transaxle case or transaxle housing.
(b) Apply FIPG to the transaxle case.
FIPG: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(c) Install the transaxle housing and 16 bolts to the transaxle case.
Torque:
Bolt A 25 Nm (255 kgf-cm, 18 ft. lbs.)
Bolt B 33 Nm (337 kgf-cm, 24 ft. lbs.)
Bolt C 29 Nm (295 kgf-cm, 21 ft. lbs.)
Bolt D 22 Nm (226 kgf-cm, 16 ft. lbs.)

HINT: Apply seal packing or equivalent to the bolt A and bolt D.

Seal packing: Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent
Bolt length
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)
Bolt D: 72 mm (2.835 inch)

NOTICE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.