Part 2

U340E AUTOMATIC TRANSAXLE UNIT: REASSEMBLY (Continued)

38. INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING
(a) Using a screwdriver, install a snap ring onto the transaxle case.

39. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install No. 2 thrust washer onto the rear planetary gear assembly.
(b) Install 1-way clutch assembly onto the rear planetary sun gear assembly.

40. INSPECT 1-WAY CLUTCH ASSEMBLY
(a) Hold the rear planetary sun gear and turn the 1-way clutch and check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

41. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
(a) Install the thrust bearing and a washer onto the rear planetary sun gear.

42. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Install the rear planetary sun gear assembly.

43. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
(a) Install the thrust bearing onto the rear planetary sun gear.

44. INSTALL DIRECT CLUTCH HUB
(a) Install the direct clutch hub.

45. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Install No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race onto the direct clutch hub.

46. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC
(a) Install the 2 discs, 2 plates and flange onto the transaxle case.

47. INSTALL INTERMEDIATE SHAFT ASSEMBLY
(a) Install the intermediate shaft assembly onto the transaxle case.
48. 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.)
NOTE: If the clearance is outside the specifications, select a new brake flange.
HINT: There are 4 different flange thicknesses.

Flange thickness:

49. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the intermediate shaft.
50. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Install the transaxle rear cover with the 11 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(b) Using a dial indicator, measure the clearance of the intermediate shaft.
Standard clearance:
0.204 to 0.966 mm (0.008 to 0.038 in.)
(c) Remove the 11 bolts and the transaxle rear cover.

51. INSTALL TRANSAXLE CASE GASKET
(a) Install 4 new gaskets onto the transaxle case.
52. INSTALL REAR TRANSAXLE COVER ASSEMBLY

(a) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

(b) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

53. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Install the forward clutch hub sub-assembly onto the transaxle case.

54. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the forward clutch hub.

55. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the input shaft assembly.

56. INSTALL INPUT SHAFT ASSEMBLY
(a) Install the input shaft assembly onto the transaxle case.

57. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new gaskets onto the transaxle case.

58. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assembly onto the transaxle case.

59. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump with the 7 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)

60. INSPECT INPUT SHAFT ASSEMBLY
(a) Make sure that the input shaft turns smoothly.

61. INSPECT INPUT SHAFT END PLAY
(a) Measure the end play in the axial direction.
End play:
0.37 to 1.29 mm (0.0146 to 0.0508 in.)
If the end play is not as specified, replace the thrust needle roller bearing.
62. INSTALL TRANSAXLE HOUSING

(a) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent

(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
Bolt B - Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)
63. INSTALL C-2 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF and install them onto the C-2 accumulator piston.
NOTE: Do not damage the O-rings.

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

64. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF and install them onto the C-3 accumulator piston.
NOTE: Do not damage the O-rings.

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

65. INSTALL B-2 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF and install them onto the B-2 accumulator piston.
NOTE: Do not damage the O-rings.

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

66. INSTALL CHECK BALL BODY
(a) Install the spring and check ball body.

67. INSTALL BRAKE DRUM GASKET
(a) Install a new brake drum gasket.

68. INSTALL TRANSAXLE CASE GASKET
(a) Coat a new transaxle case gasket with ATF, and install it onto the transaxle case.

69. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it onto the transaxle case.
70. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF, and install it onto the transmission wire.

(b) Insert the transmission wire into the transaxle.

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

(b) Provisionally 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) Provisionally 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.)
72. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF, and install it into the oil strainer.

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

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

74. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose onto the transaxle case.
75. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 5 new O-rings with ATF, and install them onto the screw plugs.
(b) Install the 4 screw plugs onto the transaxle housing and transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)

76. INSTALL OIL COOLER TUBE UNION
(a) Coat 2 new O-rings with ATF, and install them into the 2 oil cooler tube unions.
(b) Install the 2 oil cooler tube unions onto the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)

77. INSTALL TRANSMISSION REVOLUTION SENSOR
(a) Coat a new O-ring with ATF, and install it into the transmission revolution sensor.
(b) Install the transmission revolution sensor onto the transaxle case with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
78. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch assembly onto the manual transaxle.
(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 (130 kgf-cm, 9 ft-lbf)

79. INSTALL SPEEDOMETER DRIVEN GEAR
(a) Coat a new O-ring with ATF and install it into the speedometer sensor.
(b) Install the driven gear into the speedometer sensor with the clip.

80. INSTALL SPEEDOMETER SENSOR
(a) Install the speedometer sensor onto the transaxle housing.