Part 2

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)


41. INSTALL NEEDLE ROLLER BEARING





(a) Using SST and a press, install the needle roller bearing to the transaxle rear cover.
SST: 09950-60010
09951-00230
09952-06010
09951-00360
Press fit depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)

NOTICE:
- Face the inscribed side of the bearing race up.
- Keep pressing until the specified value is obtained.

(b) Coat the needle roller bearing with ATF.
42. INSTALL REAR CLUTCH OIL SEAL RING





(a) Coat 3 new rear clutch oil seal rings with ATF, and install them to the transaxle rear cover.
NOTE: The rear clutch oil seal rings should be securely engaged in the grooves of the drum.


43. INSTALL NO. 1 TRANSAXLE CASE PLUG





(a) Install a new O-ring to each No. 1 transaxle case plug.
(b) Install the 4 No. 1 transaxle case plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
44. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY





(a) Remove any packing material and keep the contact surfaces of the transaxle rear cover and the transaxle case away from oil.
(b) Apply FIPG to the cover.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent
NOTE: Apply FIPG in a continuous bead (width 1.2 mm (0.0472 in.)) along the sealing surface.





(c) Apply adhesive to the threads of bolt A.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(d) Install the 11 bolts.
Bolt A - Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)
Other bolts - Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
45. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC





(a) Coat the 3 discs with ATF.
(b) Install the 3 discs, 3 plates and flange to the transaxle case.
NOTE: Be sure to install the disks, plates and flange in the correct order.





(c) Using a screwdriver, install the snap ring.
NOTE: The snap ring should be securely engaged in the groove of the drum.

46. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE Transaxle Unit
47. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY Transaxle Unit
48. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY





(a) Install the outer race retainer to the one-way clutch.
NOTE: Securely install the outer race retainer onto the tooth of the one-way clutch.





(b) Install the one-way clutch to the transaxle case.
NOTE: Ensure that the outer race retainer and the mark on the transaxle case are aligned.





(c) Using a screwdriver, install the snap ring to the transaxle case.
NOTE: The snap ring should be securely engaged in the groove of the transaxle case.



49. INSTALL UNDERDRIVE CLUTCH DRUM O-RING





(a) Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
NOTE: Install the O-ring carefully so that it is not twisted or pinched.

50. INSTALL UNDERDRIVE CLUTCH PISTON SET





(a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.

NOTICE:
- Be careful not to damage the O-ring.
- Be careful not to damage the lip seal of the piston.

51. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY





(a) Install the return spring to the underdrive clutch drum.
NOTE: After installing the spring sub-assembly, check all of the springs are fitted in the piston correctly.

(b) Coat the clutch balancer with ATF.





(c) Install the clutch balancer to the underdrive clutch drum.
NOTE: Be careful not to damage the lip seal of the clutch balancer.





(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST: 09350-32014
09351-32070
(e) Using a snap ring expander, install the snap ring to the underdrive 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. This prevents the spring seat from being deformed.
- Do not expand the snap ring excessively.





(f) Position the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
NOTE: The end gap of the snap ring should not be aligned with any of the stoppers.

REASSEMBLY (Continued)
. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC

(a) Coat the 3 discs with ATF.





(b) Install the 3 plates, 3 discs, and flange to the underdrive clutch drum.
NOTE: Be careful about the order of discs, plates, and flange.

53. INSTALL NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING





(a) Using a screwdriver, install the No. 2 underdrive clutch flange hole snap ring.
(b) Check that the end gap of the snap ring is not aligned with one of the cutouts.
NOTE: The snap ring should be securely engaged in the groove of the drum.

54. INSTALL UNDERDRIVE CLUTCH ASSEMBLY





(a) Coat the bearing and bearing race with ATF, and install them onto the underdrive clutch.






(b) Install the underdrive clutch assembly to the transaxle case.
NOTE: When installing the underdrive clutch drum sub-assembly, do not damage the oil seal ring.

55. INSTALL PARKING LOCK PAWL





(a) Install the pawl pin and spring to the parking lock pawl.





(b) Temporarily install the parking lock pawl, pin and spring to the transaxle case as shown in the illustration.
56. INSTALL UNDERDRIVE PLANETARY RING GEAR





(a) Install a new snap ring to the outer race of the tapered roller bearing.
HINT: If replacing the bearing, also replace the counter driven gear with a new one.





(b) Using a piston ring compressor, squeeze the snap ring.





(c) Using SST and a press, press in the outer race of the angular ball bearing.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07100
NOTE: Do not damage the snap ring during installation of the outer race.





(d) Install the underdrive planetary ring gear to the counter driven gear.





(e) Using snap ring pliers, install the snap ring.