Diesel Data: Automotive Repair

Part 3








U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY CONTINUED


57. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY





(a) Using a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.
SST: 09726-40010
SST: 09950-60010
09951-00260
SST: 09950-70010
09951-07100





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





(c) Using SST and a press, press in the angular ball bearing inner race (front side).
SST: 09726-40010
SST: 09950-60010
09951-00260
SST: 09950-70010
09951-07100
NOTE: Press the counter driven gear while rotating it.





(d) Using a press, press in the parking lock gear.
SST: 09316-20011
SST: 09950-60010
09951-00260
SST: 09950-70010
09951-07100
NOTE: Press the counter driven gear while rotating it.

58. INSTALL DIFFERENTIAL DRIVE PINION





(a) Using a press, press in the differential drive pinion.
SST: 09726-40010
SST: 09950-60010
09951-00260
SST: 09950-70010
09951-07100
NOTE: Press the counter driven gear while rotating it.

59. INSTALL CYLINDRICAL ROLLER BEARING RACE INNER





(a) Using a press, press in the cylindrical roller bearing race inner.
SST: 09515-21010
SST: 09950-60010
09951-00260
SST: 09950-70010
09951-07100
NOTE: Press the counter driven gear while rotating it.

60. INSTALL FRONT PLANETARY GEAR NUT





(a) Clamp the underdrive planetary gear in a soft jaw vise.
NOTE: Be careful not to damage the differential drive pinion.

(b) Using a socket wrench, install a new gear nut.
Torque: 280 Nm (2855 kgf-cm, 207 ft-lbf)
HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.).





(c) Using a chisel and hammer, stake the gear nut.
CAUTION: Be sure that there are no cracks on the nut.

61. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY





(a) Install the underdrive planetary gear assembly to the transaxle case.
NOTE: Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly and securely assemble them.





(b) Install the parking lock pawl shaft.





(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)





(d) Using a straightedge and a vernier caliper 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).
NOTE: Take a note of dimension E because it is necessary for the following process.





(e) As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the following formula.
NOTE: Take a note of dimension F because it is necessary for the following process.
HINT: Dimension F = Dimension (1) - Dimension (2)

62. INSTALL MULTIPLE DISC CLUTCH HUB





(a) Install the No. 1 thrust bearing race to the transaxle case while checking its direction.










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






(c) Coat the needle roller bearing with ATF.





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






(e) Install the multiple disc clutch hub to the transaxle case.
63. INSTALL INPUT SHAFT OIL SEAL RING





(a) Compress a new input shaft oil seal ring from both sides to adjust dimension A.
Dimension A:
5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input shaft.
NOTE: Do not expand the gap of the oil seal ring too much. Securely engage the hooks.

64. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY





(a) Coat the forward clutch piston with ATF, and install it to the input shaft.
NOTE: Be careful not to damage the lip seal of the forward clutch piston.

65. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY





(a) Install the return spring to the input shaft.
NOTE: After installing the spring sub-assembly, check that all of the springs are fitted to piston correctly.

(b) Coat the clutch balancer with ATF.





(c) Install the clutch balancer to the input shaft.

NOTICE:
- Be careful not to damage the lip seal of the forward clutch balancer.
- Install the clutch balancer carefully not to pinch or damage at the sealing lip.
- Apply sufficient ATF to the sealing lip prior to installation.





(d) Place SST on the clutch balancer, and compress the clutch balancer with a press.
SST: 09387-00020
(e) Install the snap ring with a snap ring expander.
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 piston as shown in the illustration.
NOTE: The end gap of the snap ring should not be aligned with any of the stoppers.

66. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Coat the 5 discs with ATF.





(b) Install the 5 plates, 5 discs, and flange to the input shaft.
NOTE: Be careful about the order of discs, plates, and flange.





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

67. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transaxle Unit
68. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Transaxle Unit
69. 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





NOTE: Install the thrust bearing properly so that the tempered side of the 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 the multiple clutch hub to assemble them securely.
- Be careful not to damage the bush inside the forward clutch hub during installation.

70. INSTALL OVERDRIVE BRAKE GASKET





(a) Install 2 new overdrive brake gaskets.
71. INSTALL DIFFERENTIAL GEAR ASSEMBLY





(a) Install the differential gear assembly to the transaxle case.
72. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE





(a) Install the No. 2 thrust bearing underdrive race to the underdrive planetary gear assembly.
73. 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 Dimensions E and F that ware measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate No. 2 underdrive planetary gear thrust bearing race which satisfies the specified end play value, and install it.
End play:
0.198 to 0.693 mm (0.00779 to 0.02728 in.)
HINT: End play = Dimension F - Dimension E - Thrust bearing thickness 2.5 mm (0.0984 in.) - No. 2 underdrive thrust bearing race thickness.

Race Thickness: mm (in.)





Bearing and Bearing Race Diameter





74. INSTALL OIL PUMP ASSEMBLY





(a) Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)





(b) Coat the O-ring of the oil pump with ATF.
NOTE: Confirm that the input shaft rotates smoothly by hand after installing the oil pump.

75. INSTALL TRANSAXLE HOUSING





(a) Remove any FIPG material and keep the contact surfaces of the transaxle case and transaxle housing away from oil.
(b) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent





(c) Install the transaxle housing to the transaxle case with the 18 bolts.
Bolt A - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt B - Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
Bolt C - Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)
Bolt D - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
Bolt E - Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
Bolt F - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
HINT: Apply seal packing or equivalent to bolts C and F.

Seal packing:
Toyota Genuine Seal Packing 1344, Three Bond 1344 or equivalent
Bolt length
Bolt B, C, D, F
50 mm (1.969 in.)
Bolt A, E
42 mm (1.654 in.)
NOTE: Apply seal packing to new bolts and tighten them within 10 minutes of application.

76. INSPECT INPUT SHAFT END PLAY Transaxle Unit
77. SECURE AUTOMATIC TRANSAXLE ASSEMBLY





(a) Secure the transaxle assembly onto wooden blocks.
78. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL





(a) Coat a new oil seal with MP grease.
(b) Using SST and hammer, 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. )
79. 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.

80. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY





(a) Install a new spacer and the manual valve lever shaft to the transaxle case.
NOTE: 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.
81. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING





(a) Using needle-nose pliers, install the retainer spring.
NOTE: Securely attach the spring onto the shaft.

82. INSTALL PARKING LOCK PAWL BRACKET





(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
Bolt length:
25 mm (0.984 in.)
NOTE: Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket after the parking bracket is installed.

83. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY





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

Bolt A - Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
Bolt B - Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
Bolt length:
Bolt A
27 mm (1.06 in.)
Bolt B
16 mm (0.630 in.)
84. INSTALL B-3 ACCUMULATOR PISTON





(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.
NOTE: Install the O-ring to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-ring prior to installation. Be sure to confirm the installation position.





(b) Coat the piston and springs with ATF, and install them to the transaxle case.
NOTE: Install the correct springs to the B-3 accumulator piston after confirming the color and dimension of the springs.





85. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON





(a) Coat 2 new O-rings with ATF, and install them to the reverse clutch accumulator piston.
NOTE: Install the O-rings to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-rings prior to installation. Be sure to confirm the installation positions.





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





86. INSTALL C-3 ACCUMULATOR PISTON





(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.
NOTE: Install the O-ring to the accumulator piston, being careful not to twist or pinch it. Apply enough ATF to the O-ring prior to installation. Be sure to confirm 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.
NOTE: Install the correct spring to the C-3 accumulator piston after confirming the color and dimension of the spring.





87. INSTALL CHECK BALL BODY





(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTE: Regarding the installation of the spring and the check ball body, be sure to place the spring into ball body. Be sure to install the parts in the correct direction.

88. INSTALL BRAKE DRUM GASKET





(a) Coat a new brake drum gasket with ATF, and install it to the transaxle case.
NOTE: Do not damage the lip portion of the brake drum gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

89. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET





(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
NOTE: Do not damage the lip portion of the transaxle case 2nd brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

90. INSTALL NO. 1 GOVERNOR APPLY GASKET





(a) Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
NOTE: Do not damage the lip portion of the No. 1 governor apply gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket prior to installation. Be sure to install the parts in the correct direction.

91. 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, 8 ft-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.

92. INSTALL VALVE BODY OIL STRAINER ASSEMBLY





(a) Coat a new O-ring with ATF, and install it to the oil strainer.
NOTE: Install the O-ring carefully to avoid twists or pinches. Apply sufficient 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, 8 ft-lbf)
NOTE: Apply ATF to the bolts prior to installation.

93. INSTALL TRANSMISSION WIRE





(a) Coat a new O-ring with ATF, and install it to the transmission wire.
NOTE: Install the O-ring carefully to avoid twists or pinches. Apply enough ATF to the O-ring prior to installation.





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





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