Part 3

U250E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

60. INSPECT INPUT SHAFT END PLAY Transaxle Unit
61. FIX AUTOMATIC TRANSAXLE ASSEMBLY

(a) Fix the transaxle assembly.
62. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with MP grease.
(b) Using SST, install the oil seal to the transaxle case.
SST: 09950-60010
09951-00230
SST: 09950-70010
09951-07100
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in. )
63. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod to the manual valve lever.
HINT: Align the dial with the notches on the manual valve lever and turn the dial 90° to install the parking lock rod.

64. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and the manual valve lever shaft to the transaxle case.
NOTICE: Do not damage the oil seal while installing the shaft to the transaxle case.

(b) Using a pin punch and hammer, drive in a new pin.

(c) Turn the spacer and the lever shaft to align the smaller hole of 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.
65. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
NOTICE: Hang the spring on the shaft securely.

66. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15ft-lbf)
Bolt length:
25 mm (0.98 in.)
NOTICE: Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket after the parking bracket is installed.

67. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring sub-assembly with the 2 bolts.
NOTICE: Make sure to install the manual detent spring and cover in this order.
HINT: Tighten the bolts in the order of A and B.

Bolt A - Torque: 20 Nm (205 kgf-cm, 15ft-lbf)
Bolt B - Torque: 12 Nm (120 kgf-cm, 9ft-lbf)
Bolt length:
Bolt A
27 mm (1.06 in.)
Bolt B
16 mm (0.63 in.)
68. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
NOTICE: Install the O-ring to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation. Be sure about the installation position.

(b) Coat the piston and springs with ATF, and install them to the transaxle case.
NOTICE: Install the correct springs to the B-3 accumulator piston by checking the color or dimension of the springs.

Accumulator spring:

69. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the reverse clutch accumulator piston.
NOTICE: Install the O-rings to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-rings prior to installation. Be sure about the installation positions.

(b) Coat the piston and spring with ATF, and install them to the transaxle case.
NOTICE: Install the correct spring to the reverse clutch accumulator piston by checking the color or dimension of the spring.

Accumulator spring:

70. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
NOTICE: Install the O-ring to the accumulator piston not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation. Be sure about the installation position.

(b) Coat the piston with ATF, and install it to the transaxle case.

(c) Install the spring to the C-3 accumulator piston.
NOTICE: Install the correct spring to the C-3 accumulator piston by checking the color or dimension of the spring.

Accumulator spring:

71. INSTALL CHECK BALL BODY

(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE: Regarding the installation of the spring for the check ball body, be sure to place the spring in the hole in the ball body. Be careful about the orientation of the parts.

72. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, and install it to the transaxle case.
NOTICE: Do not damage the lip portion of the brake drum gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts.

73. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
NOTICE: Do not damage the lip portion of the transaxle case 2nd brake gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts.

74. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
NOTICE: Do not damage the lip portion of the No. 1 governor apply gasket when inserting the gasket to the case. Apply enough ATF to the gasket prior to installation. Be careful about the orientation of the parts.

75. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Check the manual valve lever position. Install the valve body to the transaxle case with the 17 bolts.
Torque: 11 Nm (110 kgf-cm, 8ft-lbf)
Bolt length:
Bolt A
25 mm (0.984 in.)
Bolt B
57 mm (2.244 in.)
Bolt C
41 mm (1.614 in.)
NOTICE:
- Push the valve body against the accumulator piston spring and the check ball body to install it.
- When installing the valve body to the transaxle case, do not hold the solenoids.
- Temporarily tighten the bolts marked by (1) in the illustration first because they are positioning bolts.

76. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF, and install it to the oil strainer.
NOTICE: Install the O-ring carefully not to have a twist or a pinching. Apply enough ATF to the O-ring prior to installation.

(b) Install the oil strainer to the valve body with the 3 bolts.
Torque: 11 Nm (110 kgf-cm, 8ft-lbf)
NOTICE: Apply ATF to the bolts prior to installation.

77. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF, and install it to the transmission wire.
NOTICE: Install the O-ring not to have a twist or pinching. Apply enough ATF to the O-ring prior to installation.

(b) Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
78. CONNECT TRANSMISSION WIRE

(a) Coat an O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58in-lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
- Connect the connectors to A, B, C, D, E, F and G, starting with the shorter ones.
- Apply ATF to the bolt prior to installation.

79. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to the 18 bolts.
Seal packing:
Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent

(c) Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69in-lbf)
NOTICE:
- Apply seal packing to new bolts and tighten them within 10 minutes of application.
- Remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket completely before installing the oil pan to the case.

(d) Install a new gasket to the drain plug.
(e) Install the drain plug.
Torque: 49 Nm (500 kgf-cm, 36ft-lbf)
80. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.
(b) Install the 4 No. 1 transaxle case plugs to the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65in-lbf)
81. INSTALL SPEED SENSOR

(a) Apply liquid sealer to the "A" bolt threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque: 8.8 Nm (90 kgf-cm, 78in-lbf)
82. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Coat a new O-ring with ATF, and install it to the union.
(b) Install the union to the transaxle case.
Torque: 27 Nm (276 kgf-cm, 20ft-lbf)
83. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION)

(a) Coat a new O-ring with ATF, and install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 Nm (255 kgf-cm, 18ft-lbf)
84. INSTALL NO. 2 BREATHER PLUG
(a) Coat a new O-ring with ATF.

(b) Install the hose and a new O-ring to the breather plug.
(c) Install the No. 2 breather plug hose to the transaxle case.
85. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 Nm (70 kgf-cm, 61in-lbf)

(d) Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches.
(e) Remove the control shaft lever.

(f) Align the groove with the neutral basic line.
(g) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)

(h) Using a screwdriver, stake the nut with the nut stopper.

(i) Install the control shaft lever, washer and nut.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)