Part 2

U341E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

53. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Coat the direct clutch piston with ATF and install it to the intermediate shaft.
NOTE: Do not damage the O-ring or the direct clutch piston.

54. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the direct clutch return spring onto the direct clutch piston.
(b) Place SST on the piston return spring and compress the springs with a press.
SST: 09387-00020
(c) Using snap ring pliers, install the snap ring to the direct clutch drum.
NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
- Do not expand the snap ring excessively.

55. INSTALL DIRECT CLUTCH DISC

(a) Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with ATF and install them to the intermediate shaft.
(b) Install the snap ring to the intermediate shaft.
56. INSTALL REVERSE CLUTCH DISC

(a) Coat the 3 plates, 3 discs and flange with ATF, and install them to the intermediate shaft.
(b) Install the snap ring to the intermediate shaft.
57. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the rear transaxle cover.
(b) Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:
0.62 to 1.16 mm (0.0244 to 0.0456 in.)
NOTE: If the clearance is not within the specified range, select a new clutch flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

58. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
(b) Using a dial indicator and measuring terminal (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST: 09350-36010
09350-06110
HINT: The direct and reverse clutch will come out as compressed air is applied.
Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

Pack clearance:
0.62 to 1.02 mm (0.0244 to 0.0402 in.)
NOTE: If the clearance is not within the specified range, select a new clutch flange.
HINT: There are 4 different flange thicknesses.

Flange Thickness:

59. INSTALL INTERMEDIATE SHAFT ASSEMBLY

(a) Install the intermediate shaft assembly to the transaxle case.
60. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE

(a) As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using a vernier caliper. (Dimension B)

(b) As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper. (Dimension C)
Calculate the piston stroke value using the following formula.
Formula:
(Dimension A + Dimension B) - Dimension C
Pack clearance:
2.10 to 2.49 mm (0.0826 to 0.0980 in.)
NOTE: If the clearance is not within the specified range, select a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

61. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the intermediate shaft.
62. INSPECT INTERMEDIATE SHAFT ASSEMBLY

(a) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)

(b) Using a dial indicator, measure the intermediate shaft end play.
End play:
0.21 to 0.96 mm (0.00826 to 0.0377 in.)
If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.
HINT: There are 2 different thicknesses of trust needle roller bearings available.

(a) Install 4 new gaskets to the transaxle case.
64. INSTALL REAR TRANSAXLE COVER NEEDLE ROLLER BEARING

(a) Coat a new needle roller bearing with ATF.
(b) Using SST and a press, install the needle roller bearing into the rear transaxle cover.
SST: 09950-60010
09951-00190
09952-06010
SST: 09950-70010
09951-07100
Standard clearance:
25.1 mm (0.988 in.)
65. INSTALL CLUTCH DRUM OIL SEAL RING

(a) Compress the 3 oil seal rings from both sides to reduce dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat 3 oil seal rings with ATF and install them to the rear transaxle cover.
66. INSTALL 2ND COAST AND OVERDRIVE O-RING

(a) Coat 2 new O-rings with ATF and install them to the 2nd coast and overdrive brake piston.
NOTE: Do not damage the O-rings.

67. INSTALL 2ND COAST AND OVERDRIVE BRAKE PISTON

(a) Coat the piston with ATF and install it to the rear transaxle cover.
NOTE: Do not damage the O-rings.

68. INSTALL OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using SST and a press, install the overdrive brake return spring and snap ring to the rear transaxle cover.
SST: 09387-00070

NOTICE:
- Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
- Do not expand the snap ring excessively.

69. INSTALL REAR TRANSAXLE COVER PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 rear transaxle cover plugs.
(b) Install the 4 rear transaxle cover plugs to the rear transaxle cover.
Torque: 7.4 Nm (76 kgf-cm, 66 in-lbf)
NOTE: Do not damage the O-rings.

70. INSTALL REAR TRANSAXLE COVER ASSEMBLY

(a) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
71. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

(a) Install the forward clutch hub sub-assembly onto the transaxle case.
72. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the forward clutch hub.
73. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat a new input shaft oil seal ring with ATF, and install it to the input shaft.
74. INSTALL FORWARD CLUTCH PISTON O-RING

(a) Coat a new clutch piston O-ring with ATF, and install it to the forward clutch piston.
75. INSTALL FORWARD CLUTCH PISTON

(a) Install the forward clutch piston to the input shaft.
NOTE: Do not damage the O-ring.

76. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Install the return spring and clutch balancer to the input shaft.

(b) Using SST, a press and snap ring pliers, install the snap ring to the input shaft.
SST: 09320-89010
77. INSTALL FRONT CLUTCH DISC

(a) Install the 4 plates, 4 discs and flange.
(b) Using a screwdriver, install the snap ring to the input shaft.
78. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

(a) Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance:
1.41 to 1.80 mm (0.0555 to 0.0708 in.)
NOTE: If the clearance is not within the specified range, install a new brake flange.
HINT: There are 4 different thicknesses of flanges available.

Flange Thickness:

79. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING

(a) Install the bearing to the input shaft assembly.
80. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the input shaft assembly to the transaxle case.
81. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new gaskets to the transaxle case.
82. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear assembly to the transaxle case.
83. INSTALL OIL PUMP ASSEMBLY

(a) Install the oil pump with the 7 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
84. INSPECT INPUT SHAFT ASSEMBLY

(a) Make sure that the input shaft turns smoothly.
85. INSPECT INPUT SHAFT END PLAY

(a) Measure the end play in the axial direction.
End play:
0.38 to 1.29 mm (0.0149 to 0.0507 in.)
If the end play is not as specified, replace the forward clutch hub thrust needle roller bearing and the stator shaft thrust needle bearing.
86. INSTALL TRANSAXLE HOUSING

(a) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt B - Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
87. INSTALL C-2 ACCUMULATOR PISTON

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

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

88. INSTALL C-3 ACCUMULATOR PISTON

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

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

89. INSTALL B-2 ACCUMULATOR PISTON

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

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

90. INSTALL CHECK BALL BODY

(a) Install the spring and check ball body.
91. INSTALL BRAKE DRUM GASKET

(a) Install a new brake drum gasket.
92. INSTALL TRANSAXLE CASE GASKET

(a) Coat a new transaxle case gasket with ATF, and install it to the transaxle case.
93. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
94. INSTALL TRANSMISSION WIRE

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

(b) Insert the transmission wire to the transaxle.