Part 2

U340E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY





32. INSTALL REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING
(a) Install No. 2 thrust bearing race, the planetary gear thrust needle roller bearing and thrust bearing race onto the rear planetary gear assembly.





33. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the rear planetary gear assembly onto the transaxle case.
(b) Using a screwdriver, install the snap ring.





34. INSPECT NO. 2 1-WAY CLUTCH
(a) Check that the rear planetary gear turns freely counterclockwise and locks when turned clockwise.





35. INSTALL 2ND BRAKE PISTON SLEEVE
(a) Install the 2nd brake piston sleeve onto the transaxle case.





36. INSTALL 2ND BRAKE BRAKE DISC
(a) Install the 3 discs, 3 plates and flange onto the transaxle case.
(b) Using a screwdriver, install a snap ring onto the transaxle case.





37. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
Pack clearance:
0.847 to 1.247 mm (0.0333 to 0.0491 in.)
NOTE: If the clearance is outside the specifications, select a new brake flange.
HINT: There are 4 different flange thicknesses.

Flange thickness:










38. INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING
(a) Using a screwdriver, install a snap ring onto the transaxle case.





39. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install No. 2 thrust washer onto the rear planetary gear assembly.
(b) Install 1-way clutch assembly onto the rear planetary sun gear assembly.





40. INSPECT 1-WAY CLUTCH ASSEMBLY
(a) Hold the rear planetary sun gear and turn the 1-way clutch and check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.





41. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
(a) Install the thrust bearing and a washer onto the rear planetary sun gear.





42. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Install the rear planetary sun gear assembly.





43. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
(a) Install the thrust bearing onto the rear planetary sun gear.





44. INSTALL DIRECT CLUTCH HUB
(a) Install the direct clutch hub.





45. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Install No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race onto the direct clutch hub.





46. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC
(a) Install the 2 discs, 2 plates and flange onto the transaxle case.





47. INSTALL INTERMEDIATE SHAFT ASSEMBLY
(a) Install the intermediate shaft assembly onto the transaxle case.
48. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE





(a) As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers. (Dimension A)





(b) As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and straight edge using vernier calipers. (Dimension B)
Calculate the piston stroke value using the following formula. Select a flange which meets the piston stroke value and install it.
Pack clearance:
2.091 to 2.491 mm (0.0823 to 0.0981 in.)
NOTE: If the clearance is outside the specifications, select a new brake flange.
HINT: There are 4 different flange thicknesses.

Flange thickness:










49. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the intermediate shaft.
50. INSPECT INTERMEDIATE SHAFT ASSEMBLY





(a) Install the transaxle rear cover with the 11 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)





(b) Using a dial indicator, measure the clearance of the intermediate shaft.
Standard clearance:
0.204 to 0.966 mm (0.008 to 0.038 in.)
(c) Remove the 11 bolts and the transaxle rear cover.





51. INSTALL TRANSAXLE CASE GASKET
(a) Install 4 new gaskets onto the transaxle case.
52. INSTALL REAR TRANSAXLE COVER ASSEMBLY





(a) Apply FIPG to the transaxle case.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent





(b) Install the rear transaxle cover with the 11 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)





53. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
(a) Install the forward clutch hub sub-assembly onto the transaxle case.





54. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the forward clutch hub.





55. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING
(a) Install the bearing onto the input shaft assembly.





56. INSTALL INPUT SHAFT ASSEMBLY
(a) Install the input shaft assembly onto the transaxle case.





57. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new gaskets onto the transaxle case.





58. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assembly onto the transaxle case.