Part 4

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

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 a 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 a 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 that 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.

NOTICE:
- Install the O-ring to the accumulator piston, being careful not to twist or pinch it.
- Apply sufficient 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.

NOTICE:
- Install the O-rings to the accumulator piston, being careful not to twist or pinch them.
- Apply sufficient 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.

NOTICE:
- Install the O-ring to the accumulator piston, being careful not to twist or pinch it.
- Apply sufficient 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: Ensure the spring is inserted into the check ball body and the parts are installed 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.

NOTICE:
- 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 part 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.

NOTICE:
- 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 part 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.

NOTICE:
- 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 part 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 (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.

NOTICE:
- 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 sufficient 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.

95. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 magnets to the oil pan.
(b) Apply seal packing or equivalent to the 18 bolts.
Seal packing:
Toyota Genuine Seal Packing 1344, Three Bond 1344 or Equivalent
NOTICE:
- Apply seal packing to the bolts and tighten them within 10 minutes of application.
- Completely remove any oil or grease from the gasket contact surfaces of the transaxle case and the oil pan before installing the oil pan to the case.

(c) Install a new oil pan gasket and the oil pan to the transaxle case with the 18 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)

NOTICE:
- Apply seal packing to the bolts and tighten them within 10 minutes of application.
- Completely remove any oil or grease from the gasket contact surfaces of the transaxle case and the oil pan before installing the oil pan to the case.

(d) Install a new gasket to the drain plug.
(e) Install the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
96. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 4 new O-rings with ATF, and install them to the 4 No. 1 transaxle case plugs.
(b) Install the 4 No. 1 transaxle case plugs to the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65 in-lbf)
97. INSTALL TRANSMISSION REVOLUTION SENSOR
(a) Coat 2 new O-rings with ATF, and install them to the 2 speed sensors.
(b) Apply adhesive to the bolt threads.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

(c) Install the 2 speed sensors to the transaxle case with the 2 bolts.
Bolt A - Torque: 8.8 Nm (90 kgf-cm, 78 in-lbf)
Bolt B - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
98. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Coat a new O-ring with ATF, and install it to the union.
(b) Install the union to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
99. INSTALL OIL COOLER TUBE ELBOW (INLET OIL COOLER ELBOW)

(a) Coat a new O-ring with ATF, and install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
100. INSTALL NO. 2 BREATHER PLUG
(a) Coat a new O-ring with ATF.

(b) Install the hose and the O-ring to the breather plug.
(c) Install the No. 2 breather plug to the transaxle case.
101. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 Nm (70 kgf-cm, 61 in-lbf)

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

(f) Align the groove with the neutral basic line.
(g) Hold the switch in that position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)

(h) Using a screwdriver, stake the nut with the nut stopper.

(i) Install the control shaft lever, washer and nut.
Torque: 13 Nm (130 kgf-cm, 9 ft-lbf)