Part 1

U340E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION





2. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD





(a) Coat the front differential case and bearing with Toyota Genuine ATF WS or equivalent and install them onto the transaxle case.
(b) Install the transaxle housing with the 14 bolts.
Bolt A - Torque: 29 Nm (300 kgf-cm, 22 ft-lbf)
Bolt B - Torque: 22 Nm (225 kgf-cm, 16 ft-lbf)





(c) Using SST and a small torque wrench, measure the preload of the differential gear.
Preload:





If the preload is not within the specifications, remove the differential from the transaxle case.
Select a new transaxle case side adjusting shim in accordance with the following table.
Adjusting shim thickness:










3. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, drive in a new oil seal.
SST: 09554-14010
SST: 09950-70010
09951-07100
Oil seal drive in depth:
1.5 to 2.5 mm (0.059 to 0.098 in.)





4. INSTALL FRONT TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, drive in a new oil seal.
SST: 09726-27012
09726-02041
SST: 09950-70010
09951-07150
Oil seal drive in depth:
5.4 to 6.4 mm (0.213 to 0.252 in.)
5. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING





(a) Install transaxle case plate No. 1 onto the transaxle case.





(b) Using SST and a hammer, install the front drive pinion rear tapered roller bearing onto the transaxle case.
SST: 09950-60010
09951-00610
SST: 09950-70010
09951-07150
6. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Install the thrust bearing onto the transaxle housing.





(b) Using SST and a press, install a new front drive pinion front tapered roller bearing onto the transaxle housing.
SST: 09950-60010
09951-00650
SST: 09950-70010
09951-07150





7. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube onto the transaxle housing.





8. INSTALL BEARING LOCK PLATE
(a) Install the bearing lock plate onto the transaxle housing with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)





9. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the counter drive gear hole snap ring onto the transaxle case.
10. INSTALL COUNTER DRIVE GEAR BEARING





(a) Using SST and a hammer, install the counter drive gear bearing LH outer race onto the transaxle case.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150





(b) Using SST and a hammer, install the counter drive gear bearing RH outer race onto the transaxle case.
SST: 09950-60020
09951-00890
SST: 09950-70010
09951-07150
(c) Install the counter drive gear bearing onto the transaxle case.





11. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, install a new manual valve lever shaft oil seal.
SST: 09950-60010
09951-00220
SST: 09950-70010
09951-07100
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)





12. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, install the differential drive pinion onto the counter driven gear.
SST: 09950-60010
09951-00350
SST: 09950-70010
09951-07150
NOTE: When replacing the counter driven gear, replace the counter drive gear in the transaxle case as well.

Press the differential drive pinion in until it comes into contact with the counter driven gear.





13. INSTALL DIFFERENTIAL DRIVE PINION PLUG
(a) Using SST and a plastic hammer, install a new differential drive pinion plug onto the differential drive pinion.
SST: 09221-25026
09221-00071
Standard clearance:
2.5 to 2.6 mm (0.0984 to 0.1023 in.)





14. INSTALL COUNTER DRIVEN GEAR
(a) Install the counter driven gear and drive pinion thrust bearing onto the transaxle case.





15. INSTALL PARKING LOCK PAWL
(a) Coat the parking lock pawl shaft with Toyota Genuine ATF WS or equivalent.
(b) Install the parking lock pawl, parking lock pawl shaft torsion spring and parking lock pawl shaft onto the transaxle case.
NOTE: Check that the parking lock pawl moves smoothly.





16. INSTALL MANUAL VALVE LEVER SHAFT
(a) Install the manual valve lever shaft onto the transaxle case.
NOTE: Do not damage the oil seal lip.





17. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod onto the manual valve lever.
18. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Coat the manual valve lever sub-assembly with Toyota Genuine ATF WS or equivalent.
(b) Install the manual valve lever and a new manual valve lever spacer onto the manual valve lever shaft.





(c) Using a pin punch and hammer, drive in the pin.





(d) Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
(e) Using a pin punch, stake the spacer through the small hole.
(f) Check that the spacer does not turn.





19. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
(a) Install the manual valve lever shaft retainer spring onto the manual valve lever shaft.





20. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket, parking lock rod and cam guide sleeve onto the transaxle case with the 3 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)





21. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, install the counter drive gear onto the transaxle case.
SST: 09223-15030
SST: 09527-17011
SST: 09950-60010
09951-00650
SST: 09950-70010
09951-07150





22. INSTALL PLANETARY GEAR ASSEMBLY
(a) Using SST and a press, install the planetary gear assembly onto the transaxle case.
SST: 09950-60010
09951-00480
SST: 09223-15030
SST: 09527-17011
SST: 09950-70010
09951-07150
23. INSTALL COUNTER DRIVE GEAR NUT





(a) Fix the counter driven gear with the parking lock pawl.





(b) Using SST, install a new lock washer and nut.
SST: 09387-00120
Torque: 280 Nm (2,855 kgf-cm, 207 ft-lbf)





(c) Using SST and a small torque wrench, measure the rotating torque while turning the counter drive gear at 60 turns per minute.
SST: 09387-00120
Rotating torque:
0.20 to 0.49 N*m (2 to 5 kgf*cm, 2 to 4 in.*lbf)





(d) Using SST and a hammer, stake the lock nut washer.
SST: 09930-00010





24. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON O-RING
(a) Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them onto No. 2 brake piston.





25. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON
(a) Coat No. 2 1st and reverse brake piston with Toyota Genuine ATF WS or equivalent, and install it into the transaxle case.
NOTE: Do not damage the oil seal lip.





26. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Install the 1st and reverse brake return spring sub-assembly onto the transaxle case.
(b) Using SST, a press and a screwdriver, install the snap ring.
SST: 09387-00070





27. INSTALL 1ST AND REVERSE BRAKE DISC
(a) Install the 4 plates, 4 discs and flange onto the transaxle case.
(b) Using a screwdriver, install the snap ring.





28. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
(a) Using SST and a dial indicator, measure the first and reverse brake clearance while pressing the disc and plate from the rear side.
SST: 09350-36010
09350-06110
Pack clearance:
0.806 to 1.206 mm (0.0317 to 0.0475 in.)
NOTE: If the clearance is outside the specifications, select a new brake flange.
HINT: There are 4 different flange thicknesses.

Flange thickness:






(b) Check that the 1st and reverse brake piston moves when compressed air is applied (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole.





29. INSTALL FRONT PLANETARY SUN GEAR
(a) Install the planetary sun gear and needle roller bearing onto the planetary gear assembly.





30. INSTALL OUTER RACE RETAINER
(a) Install the outer retainer onto No. 2 1-way clutch.





31. INSTALL NO. 2 1-WAY CLUTCH
(a) Install the 1-way clutch and 2nd brake piston assembly onto the rear planetary gear assembly.