Part 3

U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

REASSEMBLY (Continued)

50. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING





(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.





(c) Coat the rear planetary sun gear thrust needle roller bearing and thrust needle roller race with ATF, and install them to the direct multiple disc clutch assembly.

Test in Illustration





Bearing and Race Diameter: mm (in.)





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





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

Test in Illustration









(e) Using a snap ring expander, install the snap ring to the direct multiple disc clutch assembly.
51. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC Transaxle Unit
52. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING





(a) Coat the rear No. 2 planetary sun gear thrust needle roller bearing with ATF and install it on the transaxle case.

Test in Illustration





Bearing Diameter: mm (in.)





(b) Install the direct multiple disc clutch assembly to the transaxle case.
(c) Clean the contact surfaces of the transaxle case and rear transaxle cover sub-assembly.





(d) As shown in the illustration, place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension A).





(e) Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).
(f) Calculate the end play value using the following formula:
End play = Dimension B - Dimension A - Bearing Thickness
End play:
0.022 to 1.099 mm (0.000866 to 0.0433 in.)
53. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY





(a) Using SST and a hammer, install the needle roller bearing into the rear transaxle cover sub-assembly.
SST: 09950-60010
09951-00220
SST: 09950-70010
09951-07100
Installation depth:
21.5 to 21.9 mm (0.846 to 0862 in.)





(b) Using a "TORX" wrench (T30), install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 new "TORX" screws.
Torque: 7.5 Nm (76 kgf-cm, 66in-lbf)





(c) Coat the thrust needle roller bearing and thrust needle roller race with ATF and install them on the transaxle case.

Test in Illustration





Bearing and Race Diameter: mm (in.)





(d) Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover sub-assembly.





(e) Coat 3 new O-rings with ATF and install them to the transaxle case.
NOTICE: Ensure that the O-rings are not twisted.





(f) Remove packing material from the contact surfaces between the rear transaxle cover sub-assembly and transaxle case.
NOTICE: Make sure that there is no ATF on the contact surfaces.

FIPG:
Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent.





(g) Install the rear transaxle cover sub-assembly to the transaxle case with the 12 bolts.
Torque: 23 Nm (234 kgf-cm, 17ft-lbf)





(h) Install the rear transaxle cover sub-assembly to the transaxle case with the 2 new bolts.
Torque: 17 Nm (173 kgf-cm, 12ft-lbf)





(i) Install a new gasket to the refill plug.
(j) Install the refill plug to the rear transaxle cover sub-assembly.
Torque: 49 Nm (500 kgf-cm, 36ft-lbf)





(k) Coat 3 new O-rings with ATF and install them to the 3 No. 1 automatic transaxle case plugs.
(l) Install the 3 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.
Torque: 7.4 Nm (75 kgf-cm, 65in-lbf)
54. INSPECT INPUT SHAFT END PLAY Transaxle Unit
55. INSTALL TRANSAXLE CASE GASKET





(a) Coat 2 new gaskets with ATF and install them to the transaxle case.
56. INSTALL TRANSMISSION VALVE BODY ASSEMBLY





(a) Install the valve body assembly to the transaxle case with the 11 bolts.
Bolt A, B, C - Torque: 11 Nm (112 kgf-cm, 8ft-lbf)
Bolt D - Torque: 9.6 Nm (98 kgf-cm, 85in-lbf)





NOTICE:
- When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case to interfere with each other.
- Be sure to insert the pin of the manual valve lever shaft into the groove on the end of the manual valve.
- First, temporarily tighten the bolts marked *1 in the illustration because they are positioning bolts.

57. INSTALL VALVE BODY OIL STRAINER ASSEMBLY





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

Test in Illustration





NOTICE: Ensure that the O-ring is not twisted or pinched.





(b) Install the oil strainer assembly to the valve body assembly with the 2 new bolts.
Torque: 9.6 Nm (98 kgf-cm, 85in-lbf)
58. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY





(a) Install the 2 magnets in the automatic transaxle oil pan sub-assembly.





(b) Install the automatic transaxle oil pan sub-assembly and a new gasket to the transaxle case with the 17 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66in-lbf)
NOTICE: Completely remove any oil or grease from the contact surfaces of the transaxle case and oil pan sub-assembly with the gasket before installation.

(c) Apply adhesive to the 2 new bolts.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent





(d) Install the automatic transaxle oil pan sub-assembly with the 2 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62in-lbf)
NOTICE: In order to ensure proper sealing of the transmission pan bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.





(e) Using a hexagon wrench (6 mm), install the No. 1 oil filler tube to the automatic transaxle assembly.
Torque: 0.8 Nm (8 kgf-cm, 7in-lbf)





(f) Using a hexagon wrench (6 mm), install the overflow plug and a new gasket to the oil pan sub-assembly.
Torque: 40 Nm (408 kgf-cm, 30ft-lbf)
59. INSTALL NO. 1 TRANSAXLE CASE PLUG





(a) Install the 3 new gaskets to the 3 hexagon bolts.
(b) Apply adhesive to the 3 hexagon bolts.
Sealant:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
NOTICE: In order to ensure proper sealing of the hexagon bolts, apply adhesive to the bolts and install them within 10 minutes of adhesive application.

(c) Using a hexagon wrench (6 mm), install the 3 hexagon bolts to the transaxle housing with the gaskets.
Torque: 17 Nm (173 kgf-cm, 12ft-lbf)





(d) Coat 3 new O-rings with ATF and install them to the 3 No. 1 transaxle case plugs.
(e) Install the 3 No. 1 transaxle case plugs to the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65in-lbf)
60. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION)





(a) Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet oil cooler union).
(b) Install the oil cooler tube union (inlet oil cooler union) to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20ft-lbf)
61. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)





(a) Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet oil cooler union).
(b) Install the oil cooler tube union (outlet oil cooler union) to the transaxle case as shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20ft-lbf)
62. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY





(a) Align the protrusions of the park/neutral position switch.

Test in Illustration









(b) Install the park/neutral position switch to the control shaft with the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)

NOTICE:
- Before installing the park/neutral position switch, remove any dirt or rust on the control shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch cannot be reinstalled correctly.
- After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned.





(c) Install the control shaft lever to the control shaft with the washer and nut.
Torque: 13 Nm (133 kgf-cm, 10ft-lbf)
63. INSTALL BREATHER PLUG HOSE





(a) Coat a new O-ring with ATF and install it to the No. 2 breather plug (ATM).

Test in Illustration





(b) Install the No. 2 breather plug (ATM) to the breather plug hose.
(c) Install the breather plug cap to the breather plug hose.





(d) Install the breather plug hose to the transaxle case.