Part 2

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

24. INSTALL 2ND BRAKE CLUTCH DISC

(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Temporarily install the snap ring.

(c) Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the pack clearance will meet the specified value.
Standard pack clearance:
0.50 to 0.91 mm (0.0197 to 0.0358 in.)
HINT: Pack clearance = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Flange Thickness:

(e) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
NOTE: Position the snap ring so that its gap is visible through the groove of the transaxle case.

25. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

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

(b) Install the direct clutch return spring sub-assembly to the direct clutch drum.

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

(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST: 09387-00020
(e) Using a snap ring expander, install the snap ring to the direct clutch drum.
NOTICE:
- Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
- 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.

26. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC

(a) Install the 3 plates, 3 discs and flange to the direct clutch drum.
Install in order:
P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.
27. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transaxle Unit
28. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC Transaxle Unit
29. INSTALL DIRECT CLUTCH

(a) Install the bearing race to the direct clutch.
Standard Bearing Race Diameter:

(b) Install the direct clutch and thrust bearing to the rear planetary sun gear.
NOTE: The discs in the direct clutch should be completely mated with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

(c) Clean the connector part of the transaxle case and rear cover.
(d) As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).

(e) Measure the 2 places of the rear cover as shown in the illustration. Calculate dimension C using the following formula:
HINT: Dimension C = Dimension (1) - Dimension (2)

(f) Calculate the end play value using the following formula:
NOTE: Make sure that the colored race side is facing the direct clutch assembly.
HINT: End play = Dimension C - Dimension B

End play:
0.20 to 0.93 mm (0.00787 to 0.0366 in.)
Select a thrust bearing which satisfies the end play value and install it.
Standard Bearing Thickness and Diameter:

30. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 2 new governor apply gaskets.
31. INSTALL FRONT CLUTCH APPLY TUBE

(a) Install the clamp to the front clutch apply tube.
NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

32. INSTALL BRAKE APPLY TUBE

(a) Install the clamp to the brake apply tube.
NOTE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

(b) Install the 2 apply tubes and to the transaxle with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTE: Each pipe should be securely inserted until it reaches the stopper.

33. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
34. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Using SST and a press, press in the needle roller bearing.
SST: 09950-60010
09951-00230
09952-06010
Standard depth:
12.05 to 12.75 mm (0.474 to 0.501 in.)

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

(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Using a T30 ''TORX'' socket wrench, install the transaxle rear cover plate with the 2 screws.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.

(e) Remove any packing material and be careful not to get oil on the contact surfaces of the transaxle rear cover or the transaxle.
(f) Apply FIPG to the cover.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(g) Coat the needle roller bearing with ATF.

(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(i) Install the 11 bolts.
Bolt A. - Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
Other bolts - Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
35. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC

(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT: P = Plate
D = Disc

(b) Using a screwdriver, install the snap ring.

(c) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Standard pack clearance:
1.59 to 2.20 mm (0.0626 to 0.0866 in.)
HINT: Select an appropriate flange from the table below so that it will meet the specified value.

Standard Flange Thickness:

(d) Temporarily remove the snap ring and attach the flange. Reinstall the snap ring.
36. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY Transaxle Unit
37. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the one-way clutch.

(b) Install the one-way clutch to the transaxle.
NOTE: Make sure that the mark on the one-way clutch outer race is visible.

(a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
NOTE: Be careful not to damage the O-ring.

(b) Install the underdrive piston return spring sub-assembly to the underdrive clutch drum.

(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:
- Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
- 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) Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
NOTE: Do not align the end gap of the snap ring with any of the stoppers.

39. INSTALL UNDERDRIVE CLUTCH DRUM O-RING

(a) Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
40. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC

(a) Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
Install in order:
P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

(b) Using a screwdriver, install the underdrive clutch flange hole snap ring.
(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.
41. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH Transaxle Unit
42. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
Standard Bearing and Race Diameter:

(b) Install the underdrive clutch to the transaxle.
43. INSTALL UNDERDRIVE PLANETARY RING GEAR

(a) Install a new snap ring to the outer race of the angular ball 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.
44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Using SST and 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: Rotate the counter driven gear while pressing.

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

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

45. INSTALL CYLINDRICAL ROLLER BEARING INNER RACE

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