Part 2

U660F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

Part 2

REASSEMBLY (Continued)

31. INSTALL UNDERDRIVE PLANETARY SUN GEAR

(a) Coat the thrust needle roller bearing with ATF, and install it to the oil pump assembly.

Test in Illustration

Bearing Diameter: mm (in.)

NOTICE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(b) Install the underdrive planetary sun gear to the oil pump assembly.

Text in Illustration

32. INSTALL INPUT SHAFT SUB-ASSEMBLY

(a) Coat 3 new input shaft oil seal rings with ATF and install them to the input shaft.

Test in Illustration

NOTICE: Do not expand the gap of the oil seal ring too much.

(b) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them on the oil pump assembly.

Text in Illustration

Bearing Diameter: mm (in.)

NOTICE: Be sure to install the thrust needle roller bearing in the correct direction.

(a) Using a snap ring expander, install the snap ring to the underdrive planetary gear assembly.

Test in Illustration

(b) Using a snap ring expander, install the front planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.

Text in Illustration

34. INSTALL UNDERDRIVE PLANETARY RING GEAR

(a) Install the underdrive planetary ring gear to the underdrive planetary gear assembly.

Test in Illustration

(b) Using needle-nose pliers, install the snap ring to the underdrive planetary ring gear.

Text in Illustration

NOTICE: Confirm that the snap ring is correctly located in the groove of the underdrive planetary ring gear.

35. INSTALL NO. 3 BRAKE HUB

(a) Coat the thrust needle roller bearing with ATF and install it on the underdrive planetary gear assembly.

Test in Illustration

Bearing Diameter: mm (in.)

NOTICE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(b) Coat the thrust needle roller race with MP grease and install it to the No. 3 brake hub.

Test in Illustration

(c) Install the No. 3 brake hub to the underdrive planetary gear assembly.
36. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the underdrive planetary gear assembly to the oil pump assembly.
37. INSTALL NO. 3 BRAKE DISC

(a) Install the 2 brake flanges, 3 brake discs and 2 brake plates to the oil pump assembly.

Test in Illustration

NOTICE: Make sure that the discs, plates and flanges are installed in the correct order.

(b) Using a screwdriver, install the snap ring to the oil pump assembly.

NOTICE:
- Confirm the snap ring is correctly located in the groove of the oil pump.
- Make sure that the snap ring ends are positioned as shown in the illustration (A).

38. INSPECT CLEARANCE OF NO. 3 BRAKE Transaxle Unit
39. INSTALL FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the transaxle case.

Test in Illustration

(b) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them on the underdrive planetary gear assembly.

Text in Illustration

Bearing and Race Diameter: mm (in.)

NOTICE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(d) Install the oil pump assembly to the transaxle case with the 7 bolts.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
40. INSTALL FRONT OIL PUMP BODY O-RING
41. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Install the differential gear lube apply tube to the transaxle housing.
NOTICE: Insert the differential gear lube apply tube into the transaxle case until it makes contact with the stopper.

(b) Install the apply tube clamp to the differential gear lube apply tube with the bolt.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
NOTICE: There should be clearance between the differential lube apply tube and apply tube clamp.

42. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Install the shim to the transaxle housing.
(b) Using SST, install a new counter driven gear front tapered roller bearing outer race to the transaxle housing.
SST: 09950-60020
09951-00810
SST: 09950-70010
09951-07100
NOTICE: Be sure to install the counter driven gear front tapered roller bearing outer race so that there is no clearance between the shim and the transaxle housing.

43. INSTALL TRANSAXLE HOUSING
(a) Remove packing material from the contact surfaces between the transaxle housing and case.
NOTICE: Make sure that there is no ATF on the contact surfaces.

(b) Apply FIPG to the transaxle case.

Test in Illustration

FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
NOTICE: Apply FIPG in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

(c) Install the transaxle housing to the transaxle case with the 20 bolts.
Bolt A - Torque: 31 Nm (316 kgf-cm, 23ft-lbf)
Bolt B - Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
44. ADJUST COUNTER DRIVEN GEAR PRELOAD

(a) Using SST and a torque wrench, measure the turning torque of the counter driven gear while rotating SST at 10 rpm.
SST: 09564-33010
Turning torque:
Differential side bearing preload 3.3 to 6.0 N*m (34 to 61 kgf*cm, 29 to 53 in.*lbf)
If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

Shim Thickness: mm (in.)

45. INSTALL NO. 1 CLUTCH DISC

(a) Install the clutch flange, 4 clutch discs and 4 clutch plates to the direct multiple disc clutch assembly.

Test in Illustration

NOTICE: Make sure that the flange, discs and plates are installed in the correct order.

(b) Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.
NOTICE: Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC Transaxle Unit
47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the direct multiple disc clutch assembly.

Bearing and Race Diameter: mm (in.)

Test in Illustration

NOTICE: Install the thrust needle roller bearing properly so that the temper colored side of the race will be visible.

(b) Install the rear planetary sun gear assembly to the direct multiple disc clutch assembly.

(c) Using a snap ring expander, install the snap ring to the direct multiple disc clutch assembly.
48. INSTALL NO. 2 CLUTCH DISC

(a) Install the clutch flange, 3 clutch discs and 3 clutch plates to the direct multiple disc clutch assembly.

Test in Illustration

NOTICE: Make sure that the flange, discs and plates are installed in the correct order.

49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

(a) Coat a new O-ring with ATF and install it to the direct multiple disc clutch assembly.

Test in Illustration

(b) Coat a new intermediate shaft oil seal with ATF and install it to the intermediate shaft.

Text in Illustration

(c) Install the No. 2 direct clutch piston to the direct multiple disc clutch assembly.
NOTICE: Be sure to engage the claws on the direct multiple disc clutch assembly in the grooves on the No. 2 direct clutch piston.

(d) Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly.

NOTICE:
- Position the opening of the snap ring as shown in the illustration.
- Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.

Continued in Part 3 Part 3