Part 2
U140F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY - (Continued)
31. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
32. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.
(b) Install the 2 apply tubes and to the transaxle with the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
NOTICE:
Each pipe should be securely inserted until it reaches the stopper.
33. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)
34. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
(a) Using SST and a press, press in the needle roller bearing.
SST : 09950-60010
09951-00230
09952-06010
Standard depth:
12.05 to 12.75 mm (0.474 to 0.501 in.)
NOTICE:
* Face the inscribed side of the bearing race up.
* Keep pressing until the specified value is obtained.
(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(c) Using a T30 ''TORX'' socket wrench, install the transaxle rear cover plate with the 2 screws.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(d) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover.
(e) Remove any packing material and be careful not to get oil on the contact surfaces of the transaxle rear cover or the transaxle.
(f) Apply FIPG to the cover.
FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
(g) Coat the needle roller bearing with ATF.
(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(i) Install the 11 bolts.
Bolt A. - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
Other bolts - Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
35. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT
P = Plate
D = Disc
(b) Using a screwdriver, install the snap ring.
(c) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Standard pack clearance:
1.59 to 2.20 mm (0.0626 to 0.0866 in.)
HINT
Select an appropriate flange from the table below so that it will meet the specified value.
Standard Flange Thickness:
(d) Temporarily remove the snap ring and attach the flange. Reinstall the snap ring.
36. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY Transaxle Unit
37. INSTALL UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the one-way clutch.
(b) Install the one-way clutch to the transaxle.
NOTICE:
Make sure that the mark on the one-way clutch outer race is visible.
(c) Using a screwdriver, install the snap ring to the transaxle.
38. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum.
NOTICE:
Be careful not to damage the O-ring.
(b) Install the underdrive piston return spring sub-assembly to the underdrive clutch drum.
(c) Install the clutch balancer to the underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(d) Place SST on the clutch balancer and compress the piston return spring with a press.
SST : 09350-32014
09351-32070
(e) Using a snap ring expander, install the snap ring to the underdrive clutch drum.
NOTICE:
* Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
* Do not expand the snap ring excessively.
(f) Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration.
NOTICE:
Do not align the end gap of the snap ring with any of the stoppers.
39. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Coat a new O-ring with ATF, and install it to the underdrive clutch drum.
40. INSTALL NO. 1 UNDERDRIVE CLUTCH DISC
(a) Install the 3 plates, 3 discs and flange to the underdrive clutch drum.
Install in order:
P - D - P - D - P - D - F
HINT
P = Plate
D = Disc
F = Flange
(b) Using a screwdriver, install the underdrive clutch flange hole snap ring.
(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.
41. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH Transaxle Unit
42. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum jelly, and install them onto the underdrive clutch.
Standard Bearing and Race Diameter:
(b) Install the underdrive clutch to the transaxle.
43. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the angular ball bearing.
HINT
If replacing the bearing, also replace the counter driven gear with a new one.
(b) Using a piston ring compressor, squeeze the snap ring.
(c) Using SST and a press, press in the outer race of the angular ball bearing.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07100
NOTICE:
Do not damage the snap ring during installation of the outer race.
(d) Install the underdrive planetary ring gear to the counter driven gear.
(e) Using snap ring pliers, install the snap ring.
44. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Using SST and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear.
SST : 09726-40010
SST : 09950-60010
09951-00260
SST : 09950-70010
09951-07100
(b) Install the counter driven gear with planetary ring gear to the underdrive planetary gear.
(c) Using SST and a press, press in the angular ball bearing inner race (front side).
SST : 09726-40010
SST : 09950-60010
09951-00260
SST : 09950-70010
09951-07100
NOTICE:
Rotate the counter driven gear while pressing.
(d) Using SST and a press, press in the parking lock gear.
SST : 09316-20011
SST : 09950-60010
09951-00260
SST : 09950-70010
09951-07100
NOTICE:
Rotate the counter driven gear while pressing.
(e) Using SST and a press, press in the differential drive pinion.
SST : 09726-40010
SST : 09950-60010
09951-00260
SST : 09950-70010
09951-07100
NOTICE:
Rotate the counter driven gear while pressing.
45. INSTALL CYLINDRICAL ROLLER BEARING INNER RACE
(a) Using SST and a press, press in the cylindrical roller bearing inner race.
SST : 09515-21010
SST : 09950-60010
09951-00260
SST : 09950-70010
09951-07100
NOTICE:
Rotate the counter driven gear while pressing.
46. INSTALL UNDERDRIVE INPUT SHAFT NUT
(a) Clamp the underdrive planetary gear in a soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque : 280 Nm (2855 kgf-cm, 207 ft-lbf)
HINT
Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
47. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Transaxle Unit
48. INSTALL UNDERDRIVE INPUT SHAFT NUT
(a) Using a pin punch and a hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.
49. INSTALL UNDERDRIVE PLANETARY GEAR
(a) Install the pawl pin and spring to the parking lock pawl.
(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.
(c) Install the underdrive planetary gear to the transaxle.
NOTICE:
Firmly engage all the discs of the underdrive clutch with the hub splines of the underdrive planetary gear assembly.
(d) Install the parking lock pawl shaft.
(e) Install the pawl shaft clamp with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(f) Using a straightedge and a vernier caliper as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension D).
NOTICE:
Make a note of dimension D as it is necessary for the following process.
(g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate dimension E using the following formula:
NOTICE:
Make a note of dimension E as it is necessary for the following process.
HINT
Dimension E = Dimension (1) - Dimension (2)
50. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the bearing race to the transaxle while checking its direction.
Standard Bearing Race Diameter:
(b) Coat the thrust bearing with petroleum jelly, and install them onto the multiple disc clutch hub.
Standard Thrust Bearing Diameter:
(c) Install the bearing to the multiple disc clutch hub.
Standard Bearing Diameter:
(d) Install the multiple disc clutch hub to the transaxle.
51. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the oil seal ring from both sides to reduce dimension A.
Standard dimension A:
5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input shaft.
52. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
(a) Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
(b) Install the forward clutch piston to the forward clutch drum.
53. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
(a) Place the return spring onto the piston.
(b) Place SST on the return spring, and compress the return spring with a press.
SST : 09350-32014
(c) Install the snap ring using a snap ring expander. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
NOTICE:
* Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
* Do not expand the snap ring excessively.
(d) Set the end gap of the snap ring in the piston shown in the illustration.
NOTICE:
Do not align the end gap of the snap ring with any of the stoppers.
54. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Install the 5 plates, 5 discs and flange.
Install in order:
P - D - P - D - P - D - P - D - P - D - F
HINT
P = Plate
D = Disc
F = Flange
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not aligned with one of the cutouts.
55. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transaxle Unit
56. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Transaxle Unit
57. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Install the thrust bearing to the forward clutch.
Standard Thrust Bearing Diameter:
NOTICE:
Install the thrust bearing properly so that the race "B" will be visible.
(b) Install the forward clutch to the multiple clutch hub.
NOTICE:
Align the splines of all discs in the forward clutch with those of the multiple clutch hub to assemble them securely.
58. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
59. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle.
60. INSTALL NO. 2 THRUST BEARING UNDERDRIVE RACE
(a) Install the thrust bearing underdrive race to the underdrive planetary gear.
