Automatic Transaxle (Service Information): Overhaul Scion tC II

REASSEMBLY

1. INSTALL SHIFT SOLENOID VALVE SL4 Coat shift solenoid valve SL4 with ATF. Install shift solenoid valve SL4 and the lock plate to the transmission valve body with the bolt. TEXT IN ILLUSTRATION *1 Lock Plate *2 Solenoid Valve SL4 Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
2. INSTALL SHIFT SOLENOID VALVE SL3 Coat shift solenoid valve SL3 with ATF. Install shift solenoid valve SL3 and the lock plate to the transmission valve body with the bolt. TEXT IN ILLUSTRATION *1 Lock Plate *2 Solenoid Valve SL3 Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
3. INSTALL SHIFT SOLENOID VALVE SLU Coat shift solenoid valve SLU with ATF. Install shift solenoid valve SLU to the transmission valve body. TEXT IN ILLUSTRATION *1 Lock Plate *2 Solenoid Valve SLT *3 Solenoid Valve SLU
4. INSTALL SHIFT SOLENOID VALVE SLT Coat shift solenoid valve SLT with ATF. Install shift solenoid valve SLT and the lock plate to the transmission valve body with the bolt. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
5. INSTALL SHIFT SOLENOID VALVE SL1 Coat shift solenoid valve SL1 with ATF. Install shift solenoid valve SL1 to the transmission valve body. TEXT IN ILLUSTRATION *1 Clamp *2 Lock Plate *3 Solenoid Valve SL2 *4 Solenoid Valve SL1
6. INSTALL SHIFT SOLENOID VALVE SL2 Coat shift solenoid valve SL2 with ATF. Install shift solenoid valve SL2, the clamp and lock plate to the transmission valve body with the 2 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
7. INSTALL SHIFT SOLENOID VALVE SL Coat shift solenoid valve SL with ATF. TEXT IN ILLUSTRATION *1 Solenoid Valve SL Install shift solenoid valve SL to the transmission valve body with the bolt. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
8. INSTALL TRANSMISSION WIRE See step 1
9. INSTALL SPEED SENSOR See step 1

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1. INSTALL MANUAL VALVE Coat the manual valve with ATF and install it to the transmission valve body assembly.
2. INSTALL NO. 1 GOVERNOR APPLY GASKET Coat 2 new No. 1 governor apply gaskets with ATF. Install the 2 No. 1 governor apply gaskets onto the transaxle case.
3. INSTALL TRANSMISSION VALVE BODY ASSEMBLY Coat the O-ring of the transmission wire with ATF. Confirm that the manual valve lever is positioned as shown in the illustration and install the transmission valve body assembly to the transaxle case with the 11 bolts. TEXT IN ILLUSTRATION *a Positioning Bolt Bolt A, B, C Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) Bolt D Torque: 9.6 N*m (98 kgf*cm, 85 in.*lbf) Bolt length Bolt A 25 mm (0.984 in.) Bolt B 30 mm (1.18 in.) Bolt C, D 35 mm (1.38 in.) NOTE: When installing the transmission valve body assembly, be careful not to allow the speed sensor and transaxle case to interfere with each other. Be sure to insert the pin of the manual valve lever into the groove on the end of the manual valve. First, temporarily install the bolts marked *a in the illustration because they are positioning bolts.
4. INSTALL VALVE BODY OIL STRAINER ASSEMBLY See step 54
5. INSTALL TRANSMISSION OIL CLEANER MAGNET See step 55
6. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET See step 56
7. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY See step 57
8. ADJUST AUTOMATIC TRANSAXLE FLUID Refer to «ADJUSTMENT»(ref-451170-S04278577072012020700000)
9. INSTALL NO. 1 ENGINE UNDER COVER . Refer to «INSTALLATION - Step 83»(ref-451161-S14091459052012020700000)

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HINT

Check the position and installation direction of each bearing.

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1. INSTALL COUNTER DRIVE GEAR BEARING HINT: Perform this procedure only when the counter drive gear bearing or transaxle case is replaced. Using SST and a press, install a new counter drive gear bearing (outer race) and snap ring to the transaxle case. SST: 09950-60020 09951-01030 SST: 09950-70010 09951-07100
2. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL Coat the lip of a new manual valve lever shaft oil seal with a small amount of MP grease. Using SST and a hammer, tap in the manual valve lever shaft oil seal. SST: 09950-60010 09951-00230 SST: 09950-70010 09951-07100 Oil seal tap in depth -0.5 to 0.5 mm (-0.0197 to 0.0196 in.) NOTE: Check that the manual valve lever shaft oil seal is installed in the correct direction.
3. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY Install the manual valve lever shaft to the transaxle case. NOTE: Do not damage the manual valve lever shaft oil seal while installing the manual valve lever shaft to the transaxle case. Using needle-nose pliers, install the manual valve shaft retainer spring to the transaxle case.
4. INSTALL PARKING LOCK ROD SUB-ASSEMBLY Align the slot with the notches on the manual valve lever shaft and install the parking lock rod.
5. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY Install the manual detent spring and manual detent spring cover to the transaxle case with the bolt. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) NOTE: Make sure to install the manual detent spring first, and then install the manual detent spring cover.
6. INSTALL NO. 3 BRAKE PISTON Coat 2 new O-rings with ATF and install them to the No. 3 brake piston. NOTE: Make sure that the 2 O-rings are not twisted. Temporarily install the No. 3 brake piston to the transaxle case. NOTE: Be careful not to damage the O-ring. Temporarily install the pawl stopper plate to the transaxle case with the 2 bolts. TEXT IN ILLUSTRATION *1 No. 3 Brake Piston *2 Pawl Stopper Plate NOTE: After installing, make sure that the protrusions on the No. 3 brake piston and the grooves on the pawl stopper plate are aligned. Press the No. 3 brake piston into the transaxle case. HINT: Use the installation surface of the return spring to press the piston into the transaxle case. Remove the 2 bolts and pawl stopper plate from the transaxle case. Install the brake piston return spring to the transaxle case. TEXT IN ILLUSTRATION *1 No. 3 Brake Piston *2 Brake Piston Return Spring NOTE: Install the brake piston return spring as shown in the illustration. Place SST on the brake piston return spring and compress the brake piston return spring with a press. TEXT IN ILLUSTRATION *1 Protective Tape *2 Snap Ring SST: 09387-00070 NOTE: 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. Be careful not to damage the No. 3 brake piston. HINT: Wrap the tip of the screwdriver with protective tape before use. Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration. NOTE: Confirm that the snap ring is correctly seated in the groove of the transaxle case. Be sure to align the opening of the snap ring with one of the protrusions on the brake piston return spring as shown in the illustration.
7. INSTALL COUNTER DRIVE GEAR Using SST and a press, install a new counter drive gear bearing inner race (front side) to the counter drive gear. SST: 09387-00020 Using SST, install a new counter drive gear bearing inner race (rear side) and counter drive gear to the transaxle case. SST: 09223-15030 SST: 09527-17011 SST: 09950-60020 09951-00810 SST: 09950-70010 09951-07100 NOTE: There should not be any clearance between the counter drive gear bearing inner race (front side) and counter drive gear.
8. INSTALL FRONT PLANETARY GEAR ASSEMBLY Using SST and a press, install a new front planetary gear assembly to the transaxle case. SST: 09223-15030 SST: 09527-17011 SST: 09951-01100
9. INSTALL NO. 2 BRAKE PISTON Coat 2 new O-rings with ATF and install them to the No. 2 brake piston. NOTE: Make sure that the 2 O-rings are not twisted. Install the No. 2 brake piston to the transaxle case. NOTE: Be careful not to damage the O-rings.
10. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Install the 1st and reverse brake return spring to the transaxle case. Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring with a press. SST: 09387-00060 NOTE: Stop the press when the 1st and reverse brake return spring is flush with the snap ring groove. This prevents the 1st and reverse brake return spring from being deformed. Using a screwdriver, install the snap ring to the transaxle case as shown in the illustration. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Confirm that the snap ring is correctly seated in the groove of the transaxle case. Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration. Be careful not to damage the transaxle case. HINT: Wrap the tip of the screwdriver with protective tape before use.
11. INSTALL NO. 2 BRAKE DISC Install the 5 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange to the transaxle case. TEXT IN ILLUSTRATION *1 No. 2 Brake Flange *2 No. 2 Brake Plate *3 No. 2 Brake Disc NOTE: Make sure that the discs, plates and flange are installed in the correct order. Using a screwdriver, install the snap ring to the transaxle case. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Confirm that the snap ring is correctly seated in the groove of the transaxle case. Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration. Be careful not to damage the transaxle case. HINT: Wrap the tip of the screwdriver with protective tape before use.
12. INSPECT CLEARANCE OF NO. 2 BRAKE See step 15
13. INSTALL PLANETARY RING GEAR FLANGE Install the planetary ring gear flange to the planetary ring gear. Using a screwdriver, install the snap ring to the planetary ring gear. NOTE: Confirm that the snap ring is correctly seated in the groove of the planetary ring gear.
14. INSTALL ONE-WAY CLUTCH ASSEMBLY Install the outer race retainer to the one-way clutch assembly. Install the one-way clutch assembly to the planetary ring gear. NOTE: Make sure that the one-way clutch assembly is positioned in the correct direction as shown in the illustration. Coat the thrust needle roller bearing with ATF and install it to the front planetary gear assembly. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Bearing BEARING DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 56.1 (2.21) 81.1 (3.19) NOTE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. Install the one-way clutch assembly together with the planetary ring gear to the transaxle case. NOTE: Make sure that there is no clearance between the retainer and the claw on the one-way clutch assembly. If there is any clearance, the spring of the retainer will be deformed. Using a screwdriver, install the snap ring to the transaxle case. TEXT IN ILLUSTRATION *1 Protective Tape NOTE: Confirm that the snap ring is correctly seated in the groove of the transaxle case. Be sure to align the opening of the snap ring with one of the protrusions on the transaxle case as shown in the illustration. Be careful not to damage the transaxle case. HINT: Wrap the tip of the screwdriver with protective tape before use.
15. INSTALL PARKING LOCK PAWL Install the parking lock pawl to the transaxle case with the parking lock pawl shaft. Install the parking lock pawl pin to the transaxle case. Install the spring to the parking lock pawl. NOTE: Make sure that one end of the spring is secured in the hole of the transaxle case and the other end is positioned on the parking lock pawl as shown in the illustration.
16. INSTALL PARKING LOCK SLEEVE Install the parking lock sleeve to the transaxle case.
17. INSTALL PAWL STOPPER PLATE Install the pawl stopper plate to the transaxle case with the 2 bolts. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)
18. INSTALL NO. 1 TRANSMISSION CASE PLATE Clean and degrease the bolt and the installation hole in the transaxle case. Apply adhesive to 2 or 3 threads at the end of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the No. 1 transmission case plate to the transaxle case with the bolt. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) HINT: Tighten the bolt while part A of the No. 1 transmission case plate contacts the transaxle case as shown in the illustration.
19. INSTALL PAWL SHAFT CLAMP Install the pawl shaft clamp to the transaxle case with the bolt. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)
20. INSTALL COUNTER DRIVEN GEAR BEARING RH (INNER RACE) Using SST and a press, install a new counter driven gear bearing RH (inner race) to the counter driven gear. SST: 09950-60010 09951-00490 NOTE: Be sure to install the counter driven gear bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.
21. INSTALL COUNTER DRIVEN GEAR BEARING RH (OUTER RACE) Install the shim to the transaxle housing. Using SST, install a new counter driven gear bearing RH (outer race) to the transaxle housing. SST: 09950-60020 09951-00710 SST: 09950-70010 09951-07100 NOTE: Be sure to install the counter driven gear bearing RH (outer race) so that there is no clearance between the bearing outer race, shim and the transaxle housing. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.
22. INSTALL COUNTER DRIVEN GEAR BEARING LH (INNER RACE) Using SST and a press, install a new counter driven gear bearing LH (inner race) to the counter driven gear. SST: 09950-60010 09951-00400 NOTE: Be sure to install the counter driven gear bearing so that there is no clearance between the bearing and the counter driven gear. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.
23. INSTALL COUNTER DRIVEN GEAR BEARING LH (OUTER RACE) Using SST and a hammer, install a new counter driven gear bearing LH (outer race) to the transaxle case. SST: 09950-60010 09951-00630 SST: 09950-70010 09951-07100 NOTE: Be sure to install the counter driven gear bearing so that there is no clearance between the bearing outer race and the transaxle case. If there is any clearance, the turning torque of the counter drive gear cannot be measured correctly.
24. INSTALL COUNTER DRIVEN GEAR Install the counter driven gear to the transaxle case.
25. INSTALL COUNTER DRIVE GEAR NUT Turn the manual valve lever shaft counterclockwise to set it to the P position as shown in the illustration. Using SST, install a new counter drive gear nut. SST: 09387-00130 Torque: 150 N*m (1530 kgf*cm, 111 ft.*lbf) Turn the manual valve lever shaft 2 notches clockwise to set it to the N position as shown in the illustration. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. SST: 09387-00130 Turning torque 0.1 to 0.8 N*m (1 to 8 kgf*cm, 1 to 7 in.*lbf) If the measured value is not within the specified range, gradually tighten the nut until the turning torque falls within the specified range. Maximum torque 180 N*m (1835 kgf*cm, 133 ft.*lbf) Using SST and a hammer, stake the counter drive gear nut. SST: 09930-00010
26. INSTALL FRONT DIFFERENTIAL CASE Install the front differential case to the transaxle case.
27. INSTALL NO. 1 BRAKE PISTON Coat 2 new O-rings with ATF and install them to the No. 1 brake piston. NOTE: Make sure that the 2 O-rings are not twisted. Install the No. 1 brake piston to the oil pump assembly. NOTE: Be careful not to damage the O-rings.
28. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Install the 3 2nd brake piston return springs to the oil pump assembly. NOTE: Make sure that the 3 2nd brake piston return springs are installed to the protrusions on the oil pump assembly.
29. INSTALL NO. 1 BRAKE DISC Install the 3 No. 1 brake discs, 3 No. 1 brake plates and No. 1 brake flange to the oil pump assembly. TEXT IN ILLUSTRATION *1 Flange *2 Brake Plate *3 Brake Disc NOTE: Make sure that the discs, plates and flange are installed in the correct order. Be sure to install the flange in the correct direction. Place SST on the No. 1 brake flange and compress the No. 1 brake flange with a press. SST: 09387-00070 SST: 09495-65040 NOTE: Stop the press when the 2nd brake piston return spring is flush with the snap ring groove. This prevents the 2nd brake piston return spring from being deformed. Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration. NOTE: Confirm that the snap ring is correctly seated in the groove of the oil pump assembly. Make sure to align the protruding part of the snap ring with the indented part (#1) of the oil pump and gear body assembly shown in the illustration to install the snap ring. Install the brake snap ring stopper to the oil pump assembly. NOTE: Be sure to install the brake snap ring stopper in the correct direction. Using a screwdriver, install the snap ring to the oil pump assembly as shown in the illustration. NOTE: Confirm that the snap ring is correctly seated 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 oil pump assembly shown in the illustration to install the snap ring. Check that the brake snap ring stopper can be turned by hand. TEXT IN ILLUSTRATION *1 Brake Snap Ring Stopper *2 Snap Ring *a Correctly Installed NOTE: 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 be completely seated in the groove on the oil assembly pump. Remove and reinstall the snap ring and brake snap ring stopper.
30. INSPECT CLEARANCE OF NO. 1 BRAKE See step 14
31. INSTALL UNDERDRIVE PLANETARY SUN GEAR Coat the thrust needle roller bearing with ATF and install it to the oil pump assembly. TEXT IN ILLUSTRATION *1 Underdrive Planetary Sun Gear *2 Thrust Needle Roller Bearing BEARING DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 57.75 to 58.0 mm (2.27 to 2.28 in.) 74.9 to 75.15 mm (2.94 to 2.96 in.) NOTE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. Install the underdrive planetary sun gear to the oil pump assembly.
32. INSTALL INPUT SHAFT SUB-ASSEMBLY Coat 3 new oil seal rings with ATF and install them to the input shaft. TEXT IN ILLUSTRATION *1 Thrust Bearing Race *2 Thrust Needle Roller Bearing *3 Input Shaft *4 Oil Seal Ring NOTE: Do not expand the gap of the oil seal ring too much. Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the input shaft. BEARING AND RACE DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 29.15 to 29.4 mm (1.15 to 1.16 in.) 48.3 to 48.6 mm (1.90 to 1.91 in.) Race 30.7 to 31.0 mm (1.21 to 1.22 in.) 48.0 to 48.25 mm (1.89 to 1.90 in.) NOTE: Be sure to install the thrust needle roller bearing in the correct direction. Install the input shaft to the oil pump assembly.
33. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY Using snap ring pliers, install the snap ring to the underdrive planetary gear assembly. Using a snap ring expander, install the planetary sun gear to the underdrive planetary gear assembly with the snap ring expanded.
34. INSTALL NO. 3 BRAKE HUB Coat the thrust needle roller bearing with ATF and install it to the underdrive planetary gear assembly. TEXT IN ILLUSTRATION *1 Thrust Bearing Race *2 Thrust Needle Roller Bearing BEARING AND RACE DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 62.65 to 62.9 mm (2.47 to 2.48 in.) 81.9 to 82.4 mm (3.22 to 3.24 in.) Race 65.95 to 66.2 mm (2.58 to 2.61 in.) 81.9 to 82.25 mm (3.22 to 3.24 in.) NOTE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. Coat the thrust bearing race with ATF and install it to the No. 3 brake hub. Install the No. 3 brake hub to the underdrive planetary gear assembly.
35. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY Install the underdrive planetary gear assembly to the oil pump assembly.
36. INSTALL NO. 3 BRAKE DISC Install the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates to the oil pump assembly. TEXT IN ILLUSTRATION *1 Brake Flange *2 Brake Plate *3 Brake Disc NOTE: Make sure that the discs, plates and flanges are installed in the correct order. Using a screwdriver, install the snap ring to the oil pump assembly. NOTE: Confirm that the snap ring is correctly seated in the groove of the oil pump assembly. Make sure that the snap ring ends are positioned as shown in the illustration (A).
37. INSPECT CLEARANCE OF NO. 3 BRAKE See step 16
38. INSTALL OIL PUMP ASSEMBLY Coat a new O-ring with ATF and install it to the transaxle case. TEXT IN ILLUSTRATION *1 Thrust Bearing Race *2 Thrust Needle Roller Bearing *3 O-ring Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the counter drive gear nut. BEARING AND RACE DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 53.52 to 53.82 mm (2.11 to 2.12 in.) 78.64 to 78.94 mm (3.10 to 3.11 in.) Race 59.4 to 59.6 mm (2.34 to 2.35 in.) 75.64 to 75.94 mm (2.98 to 2.99 in.) NOTE: Be sure to install the thrust needle roller bearing properly so that the temper colored side of the race will be visible. Coat a new O-ring with ATF and install it to the oil pump assembly. Install the oil pump assembly to the transaxle case with the 7 bolts. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) Coat a new O-ring with ATF and install it to the oil pump assembly.
39. INSTALL TRANSAXLE HOUSING OIL SEPARATOR Clean and degrease the 3 bolts and the installation holes in the transaxle housing. Apply adhesive to 2 or 3 threads at the ends of the 3 bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the transaxle housing oil separator to the transaxle housing with the 3 bolts. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)
40. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE Install the differential gear lube apply tube to the transaxle housing. NOTE: Insert the differential gear lube apply tube into the transaxle housing until it makes contact with the stopper. Clean and degrease the bolt and the installation hole in the transaxle housing. Apply adhesive to 2 or 3 threads at the end of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the clamp to the differential gear lube apply tube with the bolt. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) NOTE: There should be clearance of the differential lube apply tube and apply tube clamp.
41. ADJUST COUNTER DRIVEN GEAR PRELOAD Remove the seal packing material from the contact surfaces of the transaxle housing and case. Install the transaxle housing to the transaxle case with the 20 bolts. Bolt A Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) except Bolt A Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) 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 + 3.14 to 6.19 N*m (32.02 to 63.12 kgf*cm, 27.80 to 54.78 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 Part No. Thickness 90564-61022 2.000 mm (0.0787 in.) 90564-61023 2.025 mm (0.0797 in.) 90564-61024 2.050 mm (0.0807 in.) 90564-61025 2.075 mm (0.0817 in.) 90564-61026 2.100 mm (0.0827 in.) 90564-61027 2.125 mm (0.0837 in.) 90564-61028 2.150 mm (0.0846 in.) 90564-61029 2.175 mm (0.0856 in.) 90564-61030 2.200 mm (0.0866 in.) 90564-61031 2.225 mm (0.0876 in.) 90564-61032 2.250 mm (0.0886 in.) 90564-61033 2.275 mm (0.0896 in.) 90564-61034 2.300 mm (0.0906 in.) 90564-61035 2.325 mm (0.0915 in.) 90564-61036 2.350 mm (0.0925 in.) 90564-61037 2.375 mm (0.0935 in.) 90564-61038 2.400 mm (0.0945 in.) 90564-61039 2.425 mm (0.0955 in.) 90564-61040 2.450 mm (0.0965 in.) 90564-61041 2.475 mm (0.0974 in.) 90564-61042 2.500 mm (0.0984 in.) 90564-61043 2.525 mm (0.0994 in.) 90564-61044 2.550 mm (0.100 in.) 90564-61045 2.575 mm (0.101 in.) 90564-61046 2.600 mm (0.102 in.) 90564-61047 2.625 mm (0.103 in.) 90564-61048 2.650 mm (0.104 in.) 90564-61049 2.675 mm (0.105 in.) 90564-61050 2.700 mm (0.106 in.) 90564-61051 2.725 mm (0.107 in.) 90564-61052 2.750 mm (0.108 in.) 90564-61053 2.775 mm (0.109 in.) 90564-61054 2.800 mm (0.110 in.) 90564-61055 2.825 mm (0.111 in.) 90564-61056 2.850 mm (0.112 in.) 90564-61057 2.875 mm (0.113 in.) 90564-61058 2.900 mm (0.114 in.) 90564-61059 2.925 mm (0.115 in.) 90564-61060 2.950 mm (0.116 in.) 90564-61061 2.975 mm (0.117 in.) 90564-61062 3.000 mm (0.118 in.) Remove the 20 bolts and transaxle housing.
42. INSTALL TRANSAXLE HOUSING Clean and degrease the contact surfaces of the transaxle housing and case. NOTE: Make sure that there is no ATF on the contact surfaces. Apply FIPG to the transaxle case. FIPG Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent NOTE: Apply FIPG in a continuous line (width: 1.2 mm (0.0472 in.)) along the sealing surface. After applying FIPG, install the transaxle housing to the transaxle case within 3 minutes and tighten the bolts within 20 minutes. Install the transaxle housing to the transaxle case with the 17 bolts. Torque: 31 N*m (312 kgf*cm, 23 ft.*lbf) Clean and degrease the 3 bolts and the installation holes in the automatic transaxle. Apply adhesive to 2 or 3 threads at the ends of the 3 bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 3 bolts. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf)
43. INSPECT CLEARANCE OF NO. 1 CLUTCH See step 17
44. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the rear multiple disc clutch assembly. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Bearing *2 Thrust Bearing Race BEARING AND RACE DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 28.04 to 28.17 mm (1.10 to 1.11 in.) 46.8 to 47.05 mm (1.84 to 1.85 in.) Race 26.15 to 26.4 mm (1.03 to 1.04 in.) 43.7 to 44 mm (1.72 to 1.73 in.) NOTE: Install the rear planetary sun gear thrust needle roller bearing properly so that the temper colored side of the race will be visible. Install the rear planetary sun gear assembly to the rear multiple disc clutch assembly. Using a snap ring expander, install the snap ring to the rear multiple disc clutch assembly. Coat a new O-ring with ATF and install it to the rear multiple disc clutch assembly. NOTE: Make sure that the O-ring is not twisted. Coat a new oil seal ring with ATF and install it to the rear multiple disc clutch assembly.
45. INSPECT CLEARANCE OF NO. 2 CLUTCH See step 18
46. INSTALL REAR MULTIPLE DISC CLUTCH ASSEMBLY Coat the thrust needle roller bearing with ATF and install it to the transaxle case. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Bearing *2 Rear Multiple Disc Clutch Assembly BEARING DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 61.25 to 61.5 mm (2.41 to 2.42 in.) 78.7 to 78.95 mm (3.10 to 3.11 in.) Install the rear multiple disc clutch assembly to the transaxle case.
47. INSPECT INTERMEDIATE SHAFT END PLAY See step 3
48. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY Using SST and a hammer, install a new needle roller bearing to the rear transaxle cover. SST: 09950-60010 09951-00220 SST: 09950-70010 09951-07100 Installation depth 21.5 to 21.9 mm (0.847 to 0862 in.) Clean and degrease the 2 screws and the installation holes in the rear transaxle cover. Apply adhesive to 2 or 3 threads at the ends of the 2 screws. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Using a T30 "TORX" socket wrench, install the rear transaxle cover plate to the rear transaxle cover with the 2 screws. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the rear transaxle cover. TEXT IN ILLUSTRATION *1 Oil Seal Ring *2 Thrust Needle Roller Bearing *3 Thrust Bearing Race BEARING AND RACE DIAMETER - Inside [mm (in.)] Outside [mm (in.)] Bearing 48.95 to 49.2 mm (1.93 to 1.94 in.) 71.5 to 72.0 (2.81 to 2.83 in.) Race 52.25 to 52.5 mm (2.06 to 2.07 in.) 70.1 to 70.4 mm (2.76 to 2.77 in.) Coat 2 new oil seal rings with ATF and install them to the rear transaxle cover. Coat 3 new O-rings with ATF and install them to the transaxle case. Remove the seal packing material from the contact surfaces of the rear transaxle cover and transaxle case. NOTE: Make sure that there is no ATF on the contact surfaces. Apply FIPG to the transaxle case. FIPG Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent. NOTE: Apply FIPG in a continuous line (width: 1.2 mm (0.0472 in.)) along the sealing surface. After applying FIPG, install the rear transaxle cover to the transaxle case within 3 minutes and tighten the bolts within 20 minutes. Install the rear transaxle cover to the transaxle case with the 12 bolts. Torque: 23 N*m (231 kgf*cm, 17 ft.*lbf) Clean and degrease the 2 bolts and the installation holes in the transaxle case. Apply adhesive to 2 or 3 threads at the ends of the 2 bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 2 bolts. Torque: 17 N*m (172 kgf*cm, 12 ft.*lbf)
49. INSTALL REAR TRANSAXLE COVER PLUG Coat 3 new O-rings with ATF and install them to the 3 rear transaxle cover plugs. NOTE: Make sure that the 3 O-rings are not twisted. Install the 3 rear transaxle cover plugs to the rear transaxle cover. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
50. INSTALL REFILL PLUG Install a new gasket to the refill plug. Install the refill plug to the rear transaxle cover sub-assembly. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
51. INSPECT INPUT SHAFT END PLAY See step 2
52. INSTALL NO. 1 GOVERNOR APPLY GASKET Coat 2 new No. 1 governor apply gaskets with ATF. Install the 2 No. 1 governor apply gaskets to the transaxle case.
53. INSTALL TRANSMISSION VALVE BODY ASSEMBLY Coat the O-ring of the transmission valve body assembly wire with ATF. Insert the pin of the manual valve lever into the groove on the end of the manual valve and install the transmission valve body assembly to the automatic transaxle with the 11 bolts. TEXT IN ILLUSTRATION *a Positioning Bolt BOLT LENGTH Bolt Length A 25 mm (0.984 in.) B 30 mm (1.18 in.) C and D 35 mm (1.38 in.) for Bolt A, B, C Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) for Bolt D Torque: 9.6 N*m (98 kgf*cm, 85 in.*lbf) NOTE: When installing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and automatic transaxle to interfere with each other. First, temporarily install the bolts marked *a in the illustration because they are positioning bolts.
54. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Coat a new O-ring with ATF. Install the O-ring to the valve body oil strainer assembly. NOTE: Make sure that the O-ring is not twisted. Install the valve body oil strainer to the transmission valve body assembly with the 2 bolts. Torque: 9.6 N*m (98 kgf*cm, 85 in.*lbf)
55. INSTALL TRANSMISSION OIL CLEANER MAGNET Install the 2 transmission oil cleaner magnets to the automatic transaxle oil pan as shown in the illustration. TEXT IN ILLUSTRATION *1 Transmission Oil Cleaner Magnet
56. INSTALL AUTOMATIC TRANSAXLE OIL PAN GASKET Install a new automatic transaxle oil pan gasket to the automatic transaxle oil pan.
57. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Install the automatic transaxle oil pan together with the automatic transaxle oil pan gasket to the automatic transaxle with the 17 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE: Completely remove any oil or grease from the contact surfaces of the transaxle case and the oil pan with the gasket before installation. Clean and degrease the 2 bolts and the installation holes in the transaxle case. Apply adhesive to 2 or 3 threads at the end of the bolt. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
58. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the automatic transaxle oil pan. Torque: 0.8 N*m (8 kgf*cm, 7 in.*lbf)
59. INSTALL OVERFLOW PLUG Using a 6 mm hexagon socket wrench, install the overflow plug and a new gasket to the automatic transaxle oil pan. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
60. INSTALL NO. 2 TRANSAXLE CASE PLUG Clean and degrease the 3 No. 2 transaxle case plugs and the installation holes in the transaxle housing. Apply adhesive to 2 or 3 threads at the ends of the 3 No. 2 transaxle case plugs. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install 3 new gaskets to the 3 No. 2 transaxle case plugs. Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs together with the gaskets to the transaxle housing. Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
61. INSTALL NO. 1 TRANSAXLE CASE PLUG Coat 3 new O-rings with ATF and install them to the 3 No. 1 transaxle case plugs. NOTE: Make sure that the 2 O-rings are not twisted. Install the 3 No. 1 transaxle case plugs to the transaxle case. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
62. INSTALL OIL COOLER TUBE UNION (INLET) Coat a new O-ring with ATF and install it to the oil cooler tube union (inlet). NOTE: Make sure that the O-ring is not twisted. Install the oil cooler tube union (inlet) to the transaxle case. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
63. INSTALL OIL COOLER TUBE UNION (OUTLET) Coat a new O-ring with ATF and install it to the oil cooler tube union (outlet). NOTE: Make sure that the O-ring is not twisted. Install the oil cooler tube union (outlet) to the transaxle case. Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
64. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY Temporarily install the park/neutral position switch assembly to the transaxle case with the 2 bolts. NOTE: Before installing the park/neutral position switch assembly, 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 assembly cannot be reinstalled correctly. Align the protrusions of the park/neutral position switch assembly as shown in the illustration. TEXT IN ILLUSTRATION *1 Protrusion Tighten the 2 bolts Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTE: After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned.
65. INSTALL TRANSMISSION CONTROL SHAFT LEVER Install the transmission control shaft lever to the manual valve lever shaft with the washer and nut. Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf)
66. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY Coat a new O-ring with ATF and install it to the No. 2 breather plug. NOTE: Make sure that the O-ring is not twisted. Install the No. 2 breather plug to the breather plug hose. Install the No. 1 breather plug to the breather plug hose. Install the transmission breather plug hose to the transaxle case.

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Scheme 390

1. INSPECT TORQUE CONVERTER ASSEMBLY Inspect the one-way clutch. Press on the spline of the stator with a finger and rotate the stator. Check that it rotates smoothly when turned clockwise and locks when turned counterclockwise. TEXT IN ILLUSTRATION Lock Free *1 Spline If necessary, clean the torque converter and recheck the one-way clutch. Replace the torque converter if the one-way clutch still fails the inspection. Determine the condition of the torque converter. TEXT IN ILLUSTRATION *1 Sample showing maximum allowable amount of powder in ATF If the inspection result of the torque converter satisfies the following conditions, replace the torque converter. Malfunction A metallic sound is emitted from the torque converter during the stall test or when the shift lever is moved to N. The one-way clutch rotates freely or locks in both directions. The amount of powder in the ATF is more than the sample shown in the illustration (see the sample). HINT: The sample shows approximately 0.025 liters (0.026 US qts, 0.022 Imp. qts) of ATF that was taken out from a removed torque converter. Replace the ATF in the torque converter. If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter thoroughly and drain the ATF with the torque converter facing upward. Clean and check the oil cooler and oil pipe line. If the torque converter is inspected or the ATF is replaced, clean the oil cooler and oil pipe line. HINT: Apply compressed air at 196 kPa (2.0 kgf/ cm 2 , 28 psi) into the inlet hose. If a large amount of powder is found in the ATF, add new ATF using a bucket pump and clean the oil cooler and oil pipe line again. If the ATF is cloudy, inspect the oil cooler (radiator). Prevent deformation of the torque converter and damage to the oil pump gear. When there is any damage to the end of a bolt for the torque converter and to the bottom of the bolt hole, replace the bolt and the torque converter. TEXT IN ILLUSTRATION *a Correct *b Incorrect *c The bottom is damaged. All of the bolts should be the same length. Bolts with washers must be used.
2. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Check the drive plate and ring gear for damage. Set up a dial indicator and measure the runout of the 6 portions around the torque converter contact surfaces. TEXT IN ILLUSTRATION *a Measurement Point Maximum runout 0.30 mm (0.0118 in.) If the runout is not within the specification or the drive plate and ring gear is damaged, replace the drive plate and ring gear. Removal: Refer to «REMOVAL - Step 71»(ref-451161-S28460905572012020700000) Installation: Refer to «INSTALLATION - Step 11»(ref-451161-S14091459052012020700000)

Scheme 391