Part 2

U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

Part 2

REASSEMBLY (Continued)

31. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





(a) Install the 3 2nd brake piston return springs to the oil pump assembly.
NOTICE: Make sure that the 3 2nd brake piston return springs are installed onto the protrusions on the oil pump assembly.

32. INSTALL NO. 1 BRAKE DISC





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

Test in Illustration





NOTICE:
- Make sure that the discs, plates, and flange are installed in the correct order.
- Be sure to install the flange in the correct direction.

(b) Place SST on the flange and compress the flange with a press.
SST: 09387-00070
SST: 09495-65040
NOTICE: Stop the press when the brake piston return spring is flush with the snap ring groove. This prevents the brake piston return spring from being deformed.





(c) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#1).

NOTICE:
- Confirm that the snap ring is correctly located in the groove of the oil pump.
- Make sure to align the protruding part of the snap ring with the indented part (#1) of the front oil pump and gear body assembly shown in the illustration to install the snap ring.





(d) Install the brake snap ring stopper to the oil pump assembly.
NOTICE: Be sure to install the brake snap ring stopper in the correct direction.





(e) Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration (#2).

NOTICE:
- Confirm that the snap ring is correctly located in the groove of the oil pump.
- Make sure to align the protruding part of the snap ring with the indented part (#2) of the front oil pump assembly shown in the illustration to install the snap ring.





(f) Check that the brake snap ring stopper can be turned by hand.
NOTICE: If the brake snap ring stopper cannot be turned by hand, the brake snap ring stopper may have been installed upside down, or the snap ring may not have been completely located in the groove on the oil pump. Remove and reinstall the snap ring and the brake snap ring stopper.

33. INSPECT CLEARANCE OF NO. 1 BRAKE Transaxle Unit
34. 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.
35. 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.

Bearing and Race Diameter: mm (in.)





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





(c) Install the input shaft to the oil pump assembly.
36. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY





(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 planetary sun gear sub-assembly to the underdrive planetary gear assembly with the snap ring expanded.
37. 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 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.

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





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





(a) Install the underdrive planetary gear assembly to the oil pump assembly.
39. 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 that 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).

40. INSPECT CLEARANCE OF NO. 3 BRAKE Transaxle Unit
41. INSTALL OIL PUMP 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.

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.





(c) Coat a new O-ring with ATF and install it to the oil pump.





(d) Install the oil pump assembly to the transaxle case with the 7 bolts.

Test in Illustration





Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
(e) Coat a new O-ring with ATF and install it to the oil pump.
42. INSTALL TRANSAXLE HOUSING OIL SEPARATOR





(a) Install the transaxle housing oil separator to the transaxle case with the 3 new bolts.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
43. 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 a new bolt.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
NOTICE: There should be clearance between the differential lube apply tube and apply tube clamp.

44. INSTALL FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE Reassembly
45. INSTALL FRONT TRANSAXLE CASE OIL SEAL Reassembly
46. 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
09951-00710
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.

47. 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.
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 17 bolts.
Torque: 31 Nm (316 kgf-cm, 23ft-lbf)





(d) Install the transaxle housing to the transaxle case with the 3 new bolts.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
48. 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 + 3.5 to 7.0 N*m (35 to 71 kgf*cm, 31 to 62 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.)





49. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC Transaxle Unit

Continued in Part 3 Part 3