Part 4

U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

64. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle housing.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
65. INSPECT INPUT SHAFT END PLAY Transaxle Unit
66. SECURE AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the automatic transaxle assembly on wooden blocks.
67. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Coat a new oil seal with ATF.
(b) Install the oil seal to the transaxle.
68. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod to the manual valve lever.
69. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft to the transaxle.

(b) Using a pin punch and hammer, tap 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.
70. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.
71. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Bolt length:
25 mm (0.984 in.)
72. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring and cover with the 2 bolts.
NOTE: Make sure to install the manual detent spring and cover in this order.

Bolt A - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
Bolt B - Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
HINT: Each bolt length is indicated below.
Bolt A 27 mm (1.063 in.)
Bolt B 16 mm (0.630 in.)

73. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the B-3 accumulator piston.

(b) Install the 2 springs to the transaxle.
(c) Coat the piston with ATF, and install it to the transaxle.
Standard Accumulator Spring Length and Diameter:

74. INSTALL C-1 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the C-1 accumulator piston.

(b) Install the spring to the transaxle.
(c) Coat the piston with ATF, and install it to the transaxle.
Standard Accumulator Spring Length and Diameter:

75. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the C-3 accumulator piston.

(b) Coat the piston with ATF, install it to the transaxle case.
Standard Accumulator Spring Length and Diameter:

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

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

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case.
79. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new No. 1 governor apply gasket with ATF, and install it to the transaxle case.
80. INSTALL TRANSMISSION WIRE

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

(b) Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
81. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve with the pin of lever.
(b) Install the 17 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
NOTICE:
- Push the valve body against the accumulator piston spring and the check ball body to install it.
- Tighten the bolts marked by * in the illustration first temporarily because they are positioning bolts.
HINT: Each bolt length is indicated below.

Bolt length:
Bolt A 25 mm (0.984 in.)
Bolt B 41 mm (1.614 in.)
Bolt C 45 mm (1.771 in.)

(c) Connect the 5 solenoid connectors.
(d) Coat the O-ring of the temperature sensor with ATF.
(e) Install the ATF temperature sensor with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 in-lbf)
82. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.

(c) Install the oil strainer with the 3 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
83. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 3 magnets to the oil pan.
(b) Apply adhesive or equivalent to the 18 bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTE: Since the bolts are seal bolts, apply adhesive to the bolts and tighten them within 10 minutes of application.

(c) Using a new gasket, install the oil pan to the transaxle case with the 18 bolts.
Torque: 7.6 Nm (77 kgf-cm, 67 in-lbf)
84. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 plugs.
(b) Install the 4 plugs to the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
85. INSTALL SPEED SENSOR

(a) Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.
(b) Install the 2 speed sensors with the 2 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
86. INSTALL OIL COOLER INLET TUBE UNION

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

(a) Coat a new O-ring with ATF, and install it to the union.
(b) Install the union to the transaxle.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
88. INSTALL BREATHER PLUG HOSE
89. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch to the manual valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock plate and tighten the manual valve shaft nut.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)

(d) Temporarily install the control shaft lever.

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

(g) Align the groove with the neutral basic line.
(h) Hold the switch in this position and tighten the 2 bolts.
Torque: 6.9 Nm (70 kgf-cm, 61 in-lbf)

(i) Using a screwdriver, stake the nut with the lock plate.

(j) Install the control shaft lever with the washer and nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)