Automatic Transaxle (Service Information): Removal & Installation Scion xD I

INSTALLATION

1. INSTALL SPEED SENSOR NT Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it onto the speed sensor NT. Install the speed sensor NT with the bolt. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf) Connect the speed sensor NT connector.
2. INSTALL BATTERY CARRIER . Refer to «INSTALLATION - Step 73»(ref-388728-S32238584442011031100000)
3. INSTALL BATTERY TRAY
4. INSTALL BATTERY . Refer to «INSTALLATION - Step 86»(ref-388728-S32238584442011031100000)
5. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK

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1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Install the transmission control cable assembly onto the control shaft lever with the nut. Torque: 12 N*m ( 122 kgf*cm, 9 in.*lbf) Fix the transmission control cable assembly onto the control cable bracket with a new clip. NOTE: Make sure that the marking on the cable is aligned with the slit in the transmission control cable bracket before installing the cable. Connect the transmission control cable assembly to the transmission control cable support. Run the transmission control cable between the transmission control cable support and vehicle body. Install the transmission control cable assembly with the 3 nuts. Torque: 5.0 N*m ( 51 kgf*cm, 44 ft.*lbf) Turn the nut on the transmission control cable assembly and push in the lock. Install the transmission control cable assembly onto the shift lever retainer. NOTE: Install the cable with the protruding portion of the cable outer facing upward. After installing, check that the lock of the cable outer is protruding beyond portion A-A, as shown in the illustration. Connect the transmission control cable assembly to the transmission floor shift assembly. NOTE: Connect the control cable so that the adjusting mechanism lock of the control cable is installed on the left side of the vehicle.
2. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR Install the front No. 1 floor heat insulator with the 2 bolts and the nut. Torque: 5.5 N*m ( 56 kgf*cm, 49 ft.*lbf)
3. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION - Step 38»(ref-388728-S32238584442011031100000)
4. INSTALL AIR CLEANER BRACKET . Refer to «INSTALLATION - Step 74»(ref-388728-S32238584442011031100000)
5. INSTALL AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 75»(ref-388728-S32238584442011031100000)
6. REMOVE BATTERY TRAY
7. INSTALL BATTERY . Refer to «INSTALLATION - Step 86»(ref-388728-S32238584442011031100000)
8. INSPECT SHIFT LEVER POSITION . See step 1
9. ADJUST SHIFT LEVER POSITION . See step 4
10. INSTALL FRONT CONSOLE BOX . Refer to «INSTALLATION - Step 16»(ref-388757-S06079887162011031100000)
11. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-388756-S01871674392011031100000)
12. INSTALL CONSOLE BOX CARPET . Refer to «INSTALLATION - Step 2»(ref-388756-S01871674392011031100000)
13. INSTALL REAR CONSOLE BOX COVER . Refer to «INSTALLATION - Step 3»(ref-388756-S01871674392011031100000)
14. INSTALL UPPER CONSOLE PANEL . Refer to «INSTALLATION - Step 4»(ref-388756-S01871674392011031100000)
15. INSPECT FOR EXHAUST GAS LEAK

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1. REMOVE ENGINE UNDER COVER
2. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain the ATF. Install a new gasket and the drain plug. Torque: 49 N*m ( 500 kgf*cm, 36 in.*lbf)
3. REMOVE FRONT WHEEL
4. REMOVE FRONT AXLE HUB NUT . Refer to «REMOVAL - Step 5»(ref-388761-S40081284942011031100000)
5. SEPARATE FRONT SPEED SENSOR . Refer to «REMOVAL - Step 6»(ref-388761-S40081284942011031100000)
6. SEPARATE FRONT STABILIZER LINK ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-388761-S40081284942011031100000)
7. SEPARATE TIE ROD END SUB-ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-388761-S40081284942011031100000)
8. SEPARATE FRONT LOWER SUSPENSION ARM . Refer to «REMOVAL - Step 9»(ref-388761-S40081284942011031100000)
9. SEPARATE FRONT AXLE ASSEMBLY . Refer to «REMOVAL - Step 10»(ref-388761-S40081284942011031100000)
10. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «REMOVAL - Step 11»(ref-388761-S40081284942011031100000)
11. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «REMOVAL - Step 12»(ref-388761-S40081284942011031100000)
12. REMOVE FRONT TRANSAXLE CASE OIL SEAL Using SST, remove the front transaxle case oil seal. SST: 09308-00010
13. REMOVE TRANSAXLE CASE OIL SEAL Using SST, remove the transaxle case oil seal. SST: 09308-00010
14. INSTALL TRANSAXLE CASE OIL SEAL Coat the lip of a new transaxle case oil seal with MP grease. Using SST and a hammer, install the transaxle case oil seal. SST: 09710-20011 09710-06071 SST: 09950-70010 09951-07200 Drive in depth 2.2 to 3.2 mm (0.087 to 0.126 in.) NOTE: Do not damage the oil seal lip.
15. INSTALL FRONT TRANSAXLE CASE OIL SEAL Coat the lip of a new front transaxle case oil seal with MP grease. Using SST and a hammer, install the front transaxle case oil seal. SST: 09554-14010 SST: 09950-70010 09951-07200 Drive in depth -0.5 to 0.5 mm (-0.020 to 0.020 in.) NOTE: Do not damage the oil seal lip.
16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to «INSTALLATION - Step 1»(ref-388761-S00662923462011031100000)
17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to «INSTALLATION - Step 2»(ref-388761-S00662923462011031100000)
18. INSTALL FRONT AXLE ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-388761-S00662923462011031100000)
19. INSTALL FRONT LOWER SUSPENSION ARM . Refer to «INSTALLATION - Step 4»(ref-388761-S00662923462011031100000)
20. INSTALL TIE ROD END SUB-ASSEMBLY . Refer to «INSTALLATION - Step 5»(ref-388761-S00662923462011031100000)
21. INSTALL FRONT STABILIZER LINK ASSEMBLY . Refer to «INSTALLATION - Step 6»(ref-388761-S00662923462011031100000)
22. INSTALL FRONT SPEED SENSOR . Refer to «INSTALLATION - Step 7»(ref-388761-S00662923462011031100000)
23. INSTALL FRONT AXLE HUB NUT . Refer to «INSTALLATION - Step 8»(ref-388761-S00662923462011031100000)
24. INSTALL FRONT WHEEL Torque: 103 N*m ( 1050 kgf*cm, 76 in.*lbf)
25. ADD AUTOMATIC TRANSAXLE FLUID
26. INSPECT AUTOMATIC TRANSAXLE FLUID . See step 1
27. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK
28. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT HINT: Refer to «ADJUSTMENT»(ref-388760-S42826249022011031100000)
29. CHECK VSC SENSOR SIGNAL HINT: Refer to «TEST MODE PROCEDURE»(ref-388763-S29332552962011031100000)
30. INSTALL ENGINE UNDER COVER Torque: 5.0 N*m ( 51 kgf*cm, 44 ft.*lbf)

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1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Remove the engine assembly with transaxle. Refer to «REMOVAL»(ref-388728-S01034749312011031100000) .
2. REMOVE ENGINE LATERAL CONTROL ROD Remove the 3 bolts and remove the engine lateral control rod from the automatic transaxle.
3. REMOVE FLYWHEEL HOUSING UNDER COVER Remove the flywheel housing under cover.
4. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Remove the 6 torque converter set bolts while holding the crankshaft pulley bolt with a wrench.
5. SEPARATE INLET NO. 1 OIL COOLER TUBE Using union nut wrench, separate the inlet No. 1 oil cooler tube while holding the oil cooler tube union with a wrench.
6. SEPARATE OUTLET NO. 1 OIL COOLER TUBE Using union nut wrench, separate the outlet No. 1 oil cooler tube while holding the oil cooler tube union with a spanner.
7. REMOVE NO. 2 OIL COOLER TUBE CLAMP Remove the bolt and remove No. 2 oil cooler tube clamp from the oil filler tube. Remove the inlet No. 1 oil cooler tube and the No. 1 outlet oil cooler tube from the automatic transaxle.
8. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY Remove the bolt and remove the oil filler tube subassembly. Remove the O-ring from the oil filler tube subassembly.
9. REMOVE TRANSMISSION CONTROL CABLE SUPPORT Remove the bolt and remove the transmission control cable bracket from the automatic transaxle.
10. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET Remove the 2 bolts and remove the No. 1 transmission control cable bracket from the automatic transaxle.
11. REMOVE ENGINE MOUNTING BRACKET LH Remove the 4 bolts and remove the engine mounting bracket LH from the automatic transaxle.
12. REMOVE FLYWHEEL HOUSING SIDE COVER . Refer to «REMOVAL - Step 4»(ref-388740-S02254333642011031100000)
13. REMOVE STARTER ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-388740-S02254333642011031100000)
14. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Remove the 7 bolts and remove the automatic transaxle from the engine.
15. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY Remove the torque converter clutch from the automatic transaxle.

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1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY . See step 1
2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY Using vernier calipers, measure dimension A between the transaxle fitting part of the engine and the converter fitting part of the drive plate. Set the key at the top of the front oil pump drive gear and put a mark on the housing. Put a mark on the torque converter so that its groove is clearly indicated. Align the mark on the case with the one on the converter and fit the spline of the input shaft to the spline of the turbine runner. Rotating the converter, fit the spline of the stator shaft with that of the stator. HINT: Rotate it approximately 180 degrees. Rotating the converter, align the mark on the case with the one on the converter again and fit the key of the oil pump drive gear into the keyway of the converter. NOTE: Do not push the converter excessively when rotating it. Using vernier calipers and a straight edge, measure dimension B shown in the illustration and check that dimension B is greater than dimension A, which was measured in step (a). Standard A + 1 mm (0.04 in.) or more NOTE: Subtract the thickness of the straight edge from the measured value to gain dimension B.
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Install the automatic transaxle to the engine with the 7 bolts. Torque: 29 N*m ( 296 kgf*cm, 21 in.*lbf)
4. INSTALL STARTER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-388740-S31031435182011031100000)
5. INSTALL FLYWHEEL HOUSING SIDE COVER . Refer to «INSTALLATION - Step 2»(ref-388740-S31031435182011031100000)
6. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET Install the No. 1 transmission control cable bracket to the automatic transaxle with the 2 bolts. Torque: 12 N*m ( 122 kgf*cm, 9 in.*lbf)
7. INSTALL TRANSMISSION CONTROL CABLE SUPPORT Install the transmission control cable support to the automatic transaxle with the bolt. Torque: 5.0 N*m ( 51 kgf*cm, 44 ft.*lbf)
8. INSTALL ENGINE MOUNTING BRACKET LH Install the engine mounting bracket LH to the automatic transaxle with the 4 bolts. Torque: 64 N*m ( 653 kgf*cm, 47 in.*lbf)
9. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it onto the oil filler tube sub-assembly. Install the oil filler tube sub-assembly onto the automatic transaxle with the bolt. Torque: 12 N*m ( 122 kgf*cm, 9 in.*lbf)
10. INSTALL TRANSMISSION OIL LEVEL GAUGE SUBASSEMBLY Install the oil level gauge sub-assembly into the transmission oil filler tube sub-assembly.
11. INSTALL NO. 2 OIL COOLER TUBE CLAMP Provisionally install the outlet No. 1 oil cooler tube into the oil cooler tube union. Provisionally install the inlet No. 1 oil cooler tube into the oil cooler tube union. Install the No. 2 oil cooler tube clamp onto the transmission oil filler tube sub-assembly with the bolt. Torque: 5.5 N*m ( 56 kgf*cm, 49 ft.*lbf)
12. INSTALL OUTLET NO. 1 OIL COOLER TUBE Using a union nut wrench, install the outlet No. 1 oil cooler tube while holding the oil cooler tube union with a wrench. without union nut wrench Torque: 34 N*m ( 347 kgf*cm, 25 in.*lbf) with union nut wrench Torque: 32 N*m ( 327 kgf*cm, 24 in.*lbf) HINT: This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.). This torque value is effective when the union nut wrench is parallel to the torque wrench.
13. INSTALL INLET NO. 1 OIL COOLER TUBE Using a union nut wrench, install the inlet No. 1 oil cooler tube while holding the oil cooler tube union with a wrench. without union nut wrench Torque: 34 N*m ( 347 kgf*cm, 25 in.*lbf) with union nut wrench Torque: 32 N*m ( 327 kgf*cm, 24 in.*lbf) HINT: This torque value can be obtained by using a torque wrench with a fulcrum length of 345 mm (13.58 in.) and a union nut wrench with a fulcrum length of 30 mm (1.18 in.). This torque value is effective when the union nut wrench is parallel to the torque wrench.
14. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the 6 torque converter set bolts while holding the crankshaft pulley bolt with a wrench. Torque: 28 N*m ( 286 kgf*cm, 21 in.*lbf) NOTE: First install the black colored bolt, and then install the remaining 5 bolts.
15. INSTALL FLYWHEEL HOUSING UNDER COVER Install the flywheel housing under cover to the automatic transaxle.
16. INSTALL ENGINE LATERAL CONTROL ROD Install the lateral control rod onto the automatic transaxle with the 3 bolts. Torque: 64 N*m ( 653 kgf*cm, 47 in.*lbf)
17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Install the engine assembly with transaxle. Refer to «INSTALLATION»(ref-388728-S39274038492011031100000) .

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1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY Inspect the one-way clutch. Install SST so that it fits into the notch on the converter hub and the notch on the outer race of the one-way clutch. SST: 09350-32014 09351-32010 09351-32020 Press on the serrations of the starter with a finger and rotate it. Check that it rotates smoothly when turned clockwise and locks up when turned counterclockwise. SST: 09350-32014 09351-32010 09351-32020 If necessary, clean the converter and check the one-way clutch. Replace the converter if the one-way clutch still does not operate as specified. Check the condition of the torque converter clutch assembly. If the inspection result of the torque converter clutch assembly meets any of the cases mentioned below, replace the torque converter clutch. Malfunction Item Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in the N position. The one-way clutch is released or locked in both directions. Fine powder exceeding the sample limit is identified in ATF. (See the sample in (Scheme 165).) HINT: The sample shows approximately 0.25 liters (0.26 US qts, 0.22 lmp. qts) of ATF that is taken out from the removed torque converter clutch. Replace the ATF in the torque converter clutch. If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the installation surface facing up. Clean and check the oil cooler and oil pipe line. If the torque converter clutch is inspected or the ATF is changed, clean the oil cooler and oil pipe line. HINT: Spray compressed air of 196 kpa (2 kgf/cm 2, 28 psi) from the inlet hose. If excessive fine powder is found in the ATF, add new ATF using a bucket pump and clean it again. If the ATF is cloudy, inspect the oil cooler (radiator). Prevent deformation of the torque converter clutch and damage to the oil pump gear. When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and torque converter clutch. All of the bolts should be the same length. Make sure no spring washers are missing.
2. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Set up a dial indicator with a roller instrument and measure the drive plate runout. Maximum runout 0.20 mm (0.0079 in.) Check the ring gear for damage. If the runout is not within the specification or the ring gear is damaged, replace the drive plate and ring gear sub-assembly.

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1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle housing. Remove the O-ring from the speedometer driven hole cover sub-assembly.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY Remove the nut, washer and control shaft lever. Pry out the lock plate and remove the manual valve shaft nut. Remove the 2 bolts and pull out the park/neutral position switch assembly.
3. REMOVE SPEED SENSOR Remove the bolt and remove the speed sensor from the transaxle case.
4. REMOVE OIL COOLER TUBE UNION Remove the 2 oil cooler tube unions from the transaxle case. Remove the 2 O-rings from the 2 oil cooler tube unions.
5. REMOVE NO. 1 TRANSAXLE CASE PLUG Remove the 4 No. 1 transaxle case plugs from the transaxle housing and transaxle case. Remove the No. 1 transaxle case plug from the transaxle case. Remove the O-rings from the No. 1 transaxle case plugs.
6. REMOVE BREATHER PLUG HOSE Remove the breather plug hose from the breather plug.
7. REMOVE BREATHER PLUG Remove the breather plug from the transaxle case.
8. FIX AUTOMATIC TRANSAXLE ASSEMBLY Place the transaxle onto wooden blocks.
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Remove the 19 bolts and remove the oil pan and oil pan gasket. Remove the 2 oil cleaner magnets from the oil pan. Examine the particles in the pan. Collect any steel chips with the removed magnets. Carefully look at the foreign matter and particles in the pan and on the magnets to predict the type of wear which might be found in the transaxle. Steel (magnetic): bearing, gear and clutch plate wear Brass (non-magnetic): bearing wear
10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 3 bolts and remove the oil strainer assembly. Remove the oil strainer gasket from the oil strainer.
11. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Disconnect the 5 solenoid connectors. Remove the bolt and lock plate and remove the ATF temperature sensor. Remove the 2 bolts and remove the detent spring cover and detent spring. Remove the 13 bolts and the valve body assembly from the transaxle case.
12. REMOVE TRANSMISSION WIRE Remove the bolt and the transmission wire from the transaxle case. Remove the O-ring from the transmission wire.
13. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET Remove the transaxle case 2nd brake gasket from the transaxle case.
14. REMOVE TRANSAXLE CASE GASKET Remove the transaxle case gasket from the transaxle case.
15. REMOVE BRAKE DRUM GASKET Remove the brake drum gasket from the transaxle case.
16. REMOVE CHECK BALL BODY Remove the check ball body and spring from the transaxle case.
17. REMOVE B-2 ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole and remove the B-2 accumulator piston and spring. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth. Do not splash ATF with the compressed air. Remove the 2 O-rings from the B-2 accumulator piston.
18. REMOVE C-3 ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole and remove the C-3 accumulator piston and spring. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth. Do not splash ATF with the compressed air. Remove the 2 O-rings from the C-3 accumulator piston.
19. REMOVE C-2 ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole and remove the C-2 accumulator piston and the spring. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth. Do not splash ATF with the compressed air. Remove the 2 O-rings from the C-2 accumulator piston.
20. REMOVE TRANSAXLE HOUSING Remove the 14 bolts. Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. NOTE: The differential gear assembly may be accidentally removed when the transaxle housing is removed.
21. INSPECT INPUT SHAFT END PLAY Measure the end play in the axial direction. End play 0.374 to 1.292 mm (0.0147 to 0.0509 in.) If the end play is not as specified, replace the stator shaft thrust needle roller bearing and the forward clutch hub thrust needle roller bearing.
22. REMOVE OIL PUMP ASSEMBLY Remove the 7 bolts and the oil pump assembly from the transaxle case.
23. REMOVE DIFFERENTIAL GEAR ASSEMBLY Remove the differential gear assembly from the transaxle case.
24. REMOVE OVERDRIVE BRAKE GASKET Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.
25. REMOVE INPUT SHAFT ASSEMBLY Remove the input shaft assembly from the transaxle case.
26. REMOVE STATOR SHAFT THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing from the input shaft.
27. REMOVE FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing from the forward clutch hub.
28. INSPECT INTERMEDIATE SHAFT ASSEMBLY Using a dial indicator, measure the intermediate shaft end play. Standard clearance 0.204 to 0.966 mm (0.008 to 0.038 in.) If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.
29. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY Remove the forward clutch hub from the transaxle case.
30. REMOVE REAR TRANSAXLE COVER ASSEMBLY Remove the 11 bolts. Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.
31. REMOVE TRANSAXLE CASE GASKET Remove the 4 transaxle case gaskets.
32. REMOVE REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING Using a magnetic finger, remove the thrust needle roller bearing.
33. REMOVE INTERMEDIATE SHAFT ASSEMBLY Remove the intermediate shaft assembly from the transaxle case.
34. REMOVE 2ND COAST AND OVERDRIVE BRAKE DISC Remove the flange, 2 discs and 2 No. 2 flanges from the transaxle.
35. REMOVE THRUST NEEDLE ROLLER BEARING Using a magnetic finger, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the No. 3 thrust bearing race from the direct clutch hub.
36. REMOVE DIRECT CLUTCH HUB Remove the direct clutch hub from the transaxle case.
37. REMOVE REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING Using a magnetic finger, remove the thrust bearing from the rear thrust needle bearing.
38. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY Remove the rear planetary sun gear from the transaxle case.
39. REMOVE REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING Remove the rear planetary sun gear thrust needle roller bearing and No. 1 planetary carrier thrust washer from the rear planetary sun gear.
40. INSPECT ONE-WAY CLUTCH ASSEMBLY Hold the rear planetary sun gear and turn the one-way clutch. Make sure that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
41. REMOVE ONE-WAY CLUTCH ASSEMBLY Remove the one-way clutch assembly and No. 2 planetary carrier thrust washer from the rear planetary sun gear.
42. REMOVE 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING Using a screwdriver, remove the snap ring from the transaxle case.
43. REMOVE 2ND BRAKE DISC Using a screwdriver, remove the snap ring. Remove the 2 flanges, 4 discs and 3 No. 1 flanges from the transaxle.
44. REMOVE 2ND BRAKE PISTON SLEEVE Remove the 2nd brake piston sleeve from the transaxle case.
45. INSPECT NO. 2 ONE-WAY CLUTCH Turn the rear planetary gear assembly. Make sure that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.
46. REMOVE REAR PLANETARY GEAR ASSEMBLY Using a screwdriver, remove the snap ring. Remove the rear planetary gear assembly from the transaxle case.
47. REMOVE REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing and 2 bearing races from the rear planetary gear assembly.
48. REMOVE NO. 2 ONE-WAY CLUTCH Separate the 2nd brake cylinder, No. 2 one-way clutch and the rear planetary gear.
49. REMOVE OUTER RACE RETAINER Remove the retainer from the No. 2 one-way clutch.
50. REMOVE FRONT PLANETARY SUN GEAR Remove the front planetary sun gear and thrust needle roller bearing from the transaxle case.
51. REMOVE 1ST AND REVERSE BRAKE DISC Using a screwdriver, remove the snap ring. Remove the flange, 4 discs and 4 plates from the transaxle case.
52. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Using SST, a press and a screwdriver, remove the snap ring. SST: 09387-00070 Remove the 1st and reverse brake return spring sub-assembly.
53. REMOVE NO. 2 1ST AND REVERSE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle case to remove the No. 2 1st and reverse brake piston. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth. Do not splash ATF with the compressed air.
54. REMOVE NO. 2 1ST AND REVERSE BRAKE PISTON O-RING Remove the 2 O-rings from No. 2 1st and reverse brake piston.
55. REMOVE COUNTER DRIVE GEAR NUT Fix the counter driven gear with the parking lock pawl. Using SST and a hammer, release the lock washer. SST: 09930-00010 Using SST, remove the nut and lock washer. SST: 09387-00120
56. REMOVE PLANETARY GEAR ASSEMBLY Using SST and a press, remove the planetary gear assembly from the transaxle case. SST: 09950-60010 09951-00400 09951-00320 09952-06010 SST: 09950-70010 09951-07100
57. REMOVE COUNTER DRIVE GEAR Install the 2 bolts to the counter drive gear. Bolt (M6) Length = 40 to 80 mm (1.57 to 3.15 in.) Pitch = 1.0 mm (0.04 in.) Rotate the 2 bolts and remove the counter drive gear and front planetary sun gear. Remove the 2 radial ball bearings from the counter drive gear and front planetary sun gear.
58. REMOVE PARKING LOCK PAWL BRACKET Remove the 3 bolts, cam guide and bracket from the transaxle case.
59. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING Remove the manual valve lever shaft retainer spring from the manual valve lever shaft.
60. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY Using a screwdriver, release and remove the spacer. Using a pin punch and hammer, drive out the manual valve lever shaft spring pin. Remove the manual valve lever shaft and manual valve lever.
61. REMOVE PARKING LOCK ROD SUB-ASSEMBLY Remove the parking lock rod from the manual valve lever.
62. REMOVE MANUAL VALVE LEVER SHAFT Remove the manual valve lever shaft from the transaxle case.
63. REMOVE PARKING LOCK PAWL Using a screwdriver, remove the parking lock pawl shaft from the transaxle case. Remove the parking lock pawl torsion spring and parking lock pawl from the transaxle case.
64. REMOVE COUNTER DRIVEN GEAR Remove the counter driven gear, drive pinion and thrust needle roller bearing from the transaxle case.
65. REMOVE DIFFERENTIAL DRIVE PINION PLUG Using a brass bar and a hammer, remove the differential drive pinion plug.
66. REMOVE DIFFERENTIAL DRIVE PINION Using SST and a press, remove the differential drive pinion from the counter driven gear. SST: 09950-60010 09951-00350 SST: 09950-70010 09951-07150
67. REMOVE BEARING LOCK PLATE Remove the bolt and the bearing lock plate.
68. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE Remove the differential gear lube apply tube from the transaxle housing.
69. REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST, remove the front drive pinion front tapered roller bearing from the transaxle housing. SST: 09308-10010
70. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Using SST, remove the front drive pinion rear tapered roller bearing from the transaxle case. SST: 09612-65014 09612-01040 Remove the No. 1 transaxle case plate from the transaxle case.
71. REMOVE COUNTER DRIVE GEAR BEARING LH Remove the counter drive gear bearing LH from the transaxle case. Using SST, remove the counter drive gear bearing outer race LH from the transaxle case. SST: 09308-00010
72. REMOVE COUNTER DRIVE GEAR BEARING RH Remove the counter drive gear bearing RH from the transaxle case. Using SST, remove the counter drive gear bearing outer race RH from the transaxle case. SST: 09308-00010
73. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.
74. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL Using a screwdriver, remove the oil seal from the transaxle case.
75. REMOVE FRONT TRANSAXLE CASE OIL SEAL Using SST and a hammer, remove the oil seal from the transaxle case. SST: 09950-60010 09951-00550 SST: 09950-70010 09951-07100
76. REMOVE TRANSAXLE CASE OIL SEAL Using SST and a hammer, remove the transaxle case oil seal from the transaxle housing. SST: 09950-60010 09951-00530 SST: 09950-70010 09951-07100

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1. INSPECT 2ND COAST AND OVERDRIVE BRAKE DISC Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all the discs. Before assembling new discs, soak them in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
2. INSPECT 2ND BRAKE DISC Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored or even if a part of the printed mark is defaced, replace all the discs. Before assembling new discs, soak them in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
3. INSPECT 1ST AND REVERSE BRAKE DISC Check to see if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all the discs. Before assembling new discs, soak in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
4. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 13.96 mm (0.5496 in.)

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1. BEARING POSITION Check bearing position and installation direction.
2. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD Coat the front differential case and bearing with Toyota Genuine ATF WS or equivalent and install them onto the transaxle case. Install the transaxle housing with the 14 bolts. Bolt A Torque: 29 N*m ( 300 kgf*cm, 22 in.*lbf) Bolt B Torque: 22 N*m ( 225 kgf*cm, 16 in.*lbf) Using SST and a small torque wrench, measure the preload of the differential gear. SST: 09564-32011 Preload Bearing Standard New 0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm 8.7 to 13.9 in.*lbf) Used 0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm 4.3 to 6.9 in.*lbf) 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 Mark Thickness mm (in.) Mark Thickness mm (in.) 01 1.90 (0.0748) 11 2.40 (0.0945) 02 1.95 (0.0768) 12 2.45 (0.0965) 03 2.00 (0.0787) 13 2.50 (0.0984) 04 2.05 (0.0807) 14 2.55 (0.1004) 05 2.10 (0.0827) 15 2.60 (0.1024) 06 2.15 (0.0846) 16 2.65 (0.1043) 07 2.20 (0.0866) 17 2.70 (0.1063) 08 2.25 (0.0885) 18 2.75 (0.1082) 09 2.30 (0.0906) 19 2.80 (0.1102) 10 2.35 (0.0925)
3. INSTALL FRONT TRANSAXLE CASE OIL SEAL Coat the lip of a new oil seal with MP grease. Using SST and a hammer, drive in a new oil seal. SST: 09387-00010 SST: 09950-70010 09951-07100 Oil seal drive in depth -0.5 to 0.5 mm (-0.020 to 0.020 in.)
4. INSTALL TRANSAXLE CASE OIL SEAL Coat the lip of a new oil seal with MP grease. 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 2.2 to 3.2 mm (0.087 to 0.126 in.)
5. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING Install the No. 1 transaxle case plate onto the transaxle case. Using SST and a hammer, install the front drive pinion rear tapered roller bearing to the transaxle case. SST: 09950-60010 09951-00610 SST: 09950-70010 09951-07150
6. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING Install the thrust bearing to the transaxle housing. Using SST and a press, install a new front drive pinion front tapered roller bearing to the transaxle housing. SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07150
7. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE Install the differential gear lube apply tube to the transaxle housing.
8. INSTALL BEARING LOCK PLATE Install the bearing lock plate to the transaxle housing with the bolt. Torque: 11 N*m ( 110 kgf*cm, 8 in.*lbf)
9. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING Using a screwdriver, install the counter drive gear hole snap ring to the transaxle case.
10. INSTALL COUNTER DRIVE GEAR BEARING LH Using SST and a hammer, install the counter drive gear bearing outer race LH to the transaxle case. SST: 09950-60020 09951-00890 SST: 09950-70010 09951-07150 Install the counter drive gear bearing LH to the transaxle case.
11. REMOVE COUNTER DRIVE GEAR BEARING RH Using SST and a hammer, install the counter drive gear bearing outer race RH to the transaxle case. SST: 09950-60020 09951-00890 SST: 09950-70010 09951-07150 Install the counter drive gear bearing RH to the transaxle case.
12. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL Coat the lip of a new oil seal with MP grease. 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.)
13. INSTALL DIFFERENTIAL DRIVE PINION Using SST and a press, install the differential drive pinion to 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 in the differential drive pinion until it comes into contact with the counter driven gear.
14. INSTALL DIFFERENTIAL DRIVE PINION PLUG Using SST and a plastic hammer, install a new differential drive pinion plug to the differential drive pinion. SST: 09221-25026 09221-00071 Standard clearance 2.5 to 3.5 mm (0.0984 to 0.1378 in.)
15. INSTALL COUNTER DRIVEN GEAR Install the counter driven gear and drive pinion thrust bearing to the transaxle case.
16. INSTALL PARKING LOCK PAWL Coat the parking lock pawl shaft with Toyota Genuine ATF WS or equivalent. Install the parking lock pawl, parking lock pawl shaft torsion spring and parking lock pawl shaft to the transaxle case. NOTE: Check that the parking lock pawl moves smoothly.
17. INSTALL MANUAL VALVE LEVER SHAFT Install the manual valve lever shaft to the transaxle case. NOTE: Do not damage the oil seal lip.
18. INSTALL PARKING LOCK ROD SUB-ASSEMBLY Install the parking lock rod to the manual valve lever.
19. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY Coat the manual valve lever sub-assembly with Toyota Genuine ATF WS or equivalent. Install the manual valve lever and a new manual valve lever spacer to the manual valve lever shaft. Using a pin punch and hammer, drive in the pin. Turn the spacer and lever shaft to align the small hole for locating the staking position mark on the lever shaft. Using a pin punch, stake the spacer through the small hole. Check that the spacer does not turn.
20. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING Install the manual valve lever shaft retainer spring to the manual valve lever shaft.
21. INSTALL PARKING LOCK PAWL BRACKET Install the parking lock pawl bracket, parking lock rod and cam guide sleeve to the transaxle case with the 3 bolts. Torque: 20 N*m ( 204 kgf*cm, 15 in.*lbf)
22. INSTALL COUNTER DRIVE GEAR Using SST and a press, install the counter drive gear to the transaxle case. SST: 09223-15030 SST: 09527-17011 SST: 09950-60010 09951-00650 SST: 09950-70010 09951-07150
23. INSTALL PLANETARY GEAR ASSEMBLY Using SST and a press, install the planetary gear assembly to the transaxle case. SST: 09950-60010 09951-00480 SST: 09223-15030 SST: 09527-17011 SST: 09950-70010 09951-07150
24. INSTALL COUNTER DRIVE GEAR NUT Fix the counter driven gear with the parking lock pawl. Using SST, install a new lock washer and nut. SST: 09387-00120 Torque: 280 N*m ( 2855 kgf*cm, 207 in.*lbf) 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 (2.0 to 5.0 kgf*cm, 1.8 to 4.3 in.*lbf) Using SST and a hammer, stake the lock nut washer. SST: 09930-00010
25. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON O-RING Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them to the No. 2 brake piston.
26. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON Coat the No. 2 1st and reverse brake piston with Toyota Genuine ATF WS or equivalent, and install it to the transaxle case. NOTE: Do not damage the oil seal lip.
27. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Install the 1st and reverse brake return spring sub-assembly to the transaxle case. Using SST, a press and a screwdriver, install the snap ring. SST: 09387-00070
28. INSTALL 1ST AND REVERSE BRAKE DISC Install the 4 plates, 4 discs and flange to the transaxle case. Using a screwdriver, install the snap ring.
29. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 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 not within the specified range, select a new brake flange. HINT: There are 4 different flange thicknesses. Flange thickness Mark Thickness mm (in.) Mark Thickness mm (in.) - 3.4 (0.134) 2 3.8 (0.150) 1 3.6 (0.142) 3 4.0 (0.157) Check that the 1st and reverse brake piston moves when compressed air is applied (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole.
30. INSTALL FRONT PLANETARY SUN GEAR Install the planetary sun gear and needle roller bearing to the planetary gear assembly.
31. INSTALL OUTER RACE RETAINER Install the outer retainer to the No. 2 one-way clutch.
32. INSTALL NO. 2 ONE-WAY CLUTCH Install the one-way clutch and 2nd brake piston assembly to the rear planetary gear assembly.
33. INSTALL REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING Install the No. 2 thrust bearing race, the planetary gear thrust needle roller bearing and thrust bearing race to the rear planetary gear assembly.
34. INSTALL REAR PLANETARY GEAR ASSEMBLY Install the rear planetary gear assembly to the transaxle case. Using a screwdriver, install the snap ring.
35. INSPECT NO. 2 ONE-WAY CLUTCH Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.
36. INSTALL 2ND BRAKE PISTON SLEEVE Install the 2nd brake piston sleeve to the transaxle case.
37. INSTALL 2ND BRAKE DISC Install the 4 discs, 2 flanges and 3 No. 1 flanges to the transaxle case. Using a screwdriver, install a snap ring to the transaxle case.
38. INSPECT PACK CLEARANCE OF 2ND BRAKE Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm 2 , 57 to 114 psi). Pack clearance 0.847 to 1.247 mm (0.0333 to 0.0491 in.) NOTE: If the clearance is not within the specified range, select a new brake flange. HINT: There are 4 different flange thicknesses. Flange thickness Mark Thickness mm (in.) Mark Thickness mm (in.) - 3.0 (0.118) 2 3.4 (0.134) 1 3.2 (0.126) 3 3.6 (0.142)
39. INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING Using a screwdriver, install a snap ring to the transaxle case.
40. INSTALL ONE-WAY CLUTCH ASSEMBLY Install the No. 2 thrust washer to the rear planetary gear assembly. Install the one-way clutch assembly to the rear planetary sun gear assembly.
41. INSPECT ONE-WAY CLUTCH ASSEMBLY Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.
42. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING Install the thrust bearing and a washer to the rear planetary sun gear.
43. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY Install the rear planetary sun gear assembly.
44. INSTALL REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING Install the thrust bearing to the rear planetary sun gear.
45. INSTALL DIRECT CLUTCH HUB Install the direct clutch hub.
46. INSTALL THRUST NEEDLE ROLLER BEARING Install the No. 3 thrust bearing race, the thrust needle roller bearing and the C-2 hub thrust bearing race to the direct clutch hub.
47. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC Install the 2 discs, No. 2 flanges and flange to the transaxle case.
48. INSTALL INTERMEDIATE SHAFT ASSEMBLY Install the intermediate shaft assembly to the transaxle case.
49. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE 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) 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 not within the specified range, select a new brake flange. HINT: There are 4 different flange thicknesses. Flange thickness Mark Thickness mm (in.) Mark Thickness mm (in.) 4 4.0 (0.1575) 6 4.4 (0.1732) 5 4.2 (0.1654) 7 4.6 (0.1811)
50. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING Install the bearing to the intermediate shaft.
51. INSPECT INTERMEDIATE SHAFT ASSEMBLY Install the transaxle rear cover with the 11 bolts. Torque: 25 N*m ( 255 kgf*cm, 18 in.*lbf) Using a dial indicator, measure the intermediate shaft end play. Standard clearance 0.204 to 0.966 mm (0.008 to 0.038 in.) If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing. HINT: There are 2 different trust needle roller bearing thicknesses. Color Thickness mm (in.) Brown 0.785 (0.0309) Black 1.1 (0.0433) Remove the 11 bolts and the transaxle rear cover.
52. INSTALL TRANSAXLE CASE GASKET Install 4 new gaskets to the transaxle case.
53. INSTALL REAR TRANSAXLE COVER ASSEMBLY Apply seal packing to the transaxle case. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Install the rear transaxle cover with the 11 bolts. Torque: 25 N*m ( 255 kgf*cm, 18 in.*lbf)
54. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY Install the forward clutch hub sub-assembly onto the transaxle case.
55. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING Install the bearing to the forward clutch hub.
56. INSTALL STATOR SHAFT THRUST NEEDLE ROLLER BEARING Install the bearing to the input shaft assembly.
57. INSTALL INPUT SHAFT ASSEMBLY Install the input shaft assembly to the transaxle case.
58. INSTALL OVERDRIVE BRAKE GASKET Install 2 new gaskets to the transaxle case.
59. INSTALL DIFFERENTIAL GEAR ASSEMBLY Install the differential gear assembly to the transaxle case.
60. INSTALL OIL PUMP ASSEMBLY Install the oil pump with the 7 bolts. Torque: 22 N*m ( 224 kgf*cm, 16 in.*lbf)
61. INSPECT INPUT SHAFT ASSEMBLY Make sure that the input shaft turns smoothly.
62. INSPECT INPUT SHAFT END PLAY Measure the end play in the axial direction. End play 0.374 to 1.292 mm (0.0147 to 0.0509 in.) If the end play is not as specified, replace the forward clutch hub thrust needle roller bearing and the stator shaft thrust needle bearing.
63. INSTALL TRANSAXLE HOUSING Apply seal packing to the transaxle case. Seal packing Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent Install the transaxle housing with the 14 bolts. Bolt A Torque: 29 N*m ( 296 kgf*cm, 21 in.*lbf) Bolt B Torque: 22 N*m ( 224 kgf*cm, 16 in.*lbf)
64. INSTALL C-2 ACCUMULATOR PISTON Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the C-2 accumulator piston. NOTE: Do not damage the O-rings. Install the spring and C-2 accumulator piston. Accumulator spring Spring Free length/ Outer diameter mm (in.) Color C-2 66.2 to 67.6 (2.606 to 2.661) 17.20 (0.6772)
65. INSTALL C-3 ACCUMULATOR PISTON Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the C-3 accumulator piston. NOTE: Do not damage the O-rings. Install the spring and C-3 accumulator piston. Accumulator spring Spring Free length/ Outer diameter mm (in.) Color C-3 87.30 (3.4370) 18.70 (0.7362) Orange
66. INSTALL B-2 ACCUMULATOR PISTON Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the B-2 accumulator piston. NOTE: Do not damage the O-rings. Install the spring and B-2 accumulator piston. Accumulator spring Spring Free length/ Outer diameter mm (in.) Color B-2 66.90 (2.6339) 15.50 (0.6102) White
67. INSTALL CHECK BALL BODY Install the spring and check ball body.
68. INSTALL BRAKE DRUM GASKET Install a new brake drum gasket.
69. INSTALL TRANSAXLE CASE GASKET Coat a new transaxle case gasket with Toyota Genuine ATF WS or equivalent, and install it to the transaxle case.
70. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET Coat a new transaxle case 2nd brake gasket with Toyota Genuine ATF WS or equivalent, and install it to the transaxle case.
71. INSTALL TRANSMISSION WIRE Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the transmission wire. Insert the transmission wire to the transaxle. Install the transmission wire with the bolt. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf)
72. INSTALL TRANSMISSION VALVE BODY ASSEMBLY Align the groove of the manual valve with the pin of the manual valve lever. Temporarily install the valve body with the 13 bolts. Bolt length Bolt A: 32 mm (1.26 in.) Bolt B: 22 mm (0.87 in.) Bolt C: 55 mm (2.17 in.) Bolt D: 45 mm (1.77 in.) Temporarily install the detent spring and detent spring cover with the 2 bolts. Bolt length Bolt A: 14 mm (0.55 in.) Bolt B: 45 mm (1.77 in.) Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring. Tighten the 15 bolts. Torque: 11 N*m ( 110 kgf*cm, 8 in.*lbf) Connect the 5 solenoid connectors. Install the ATF temperature sensor with the lock plate and bolt. Torque: 11 N*m ( 110 kgf*cm, 8 in.*lbf) Bolt length 55 mm (2.17 in.)
73. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the oil strainer. Install the valve body oil strainer assembly to the automatic transaxle with the 3 bolts. Torque: 11 N*m ( 110 kgf*cm, 8 in.*lbf)
74. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Install the 2 magnets to the oil pan. Install a new oil pan gasket to the oil pan. Install the oil pan with the 19 bolts. Torque: 7.8 N*m ( 80 kgf*cm, 69 ft.*lbf)
75. INSTALL BREATHER PLUG Install the breather plug to the transaxle case.
76. INSTALL BREATHER PLUG HOSE Install the breather plug hose to the breather plug.
77. INSTALL NO. 1 TRANSAXLE CASE PLUG Coat 5 new O-rings with Toyota Genuine ATF WS or equivalent, and install them to the No. 1 transaxle case plugs. Install the 4 No. 1 transaxle case plugs to the transaxle housing and transaxle case. Torque: 7.4 N*m ( 76 kgf*cm, 66 ft.*lbf) Install the No. 1 transaxle case plug to the transaxle case. Torque: 7.4 N*m ( 76 kgf*cm, 66 ft.*lbf)
78. INSTALL OIL COOLER TUBE UNION Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 2 oil cooler tube unions. Install the 2 oil cooler tube unions to the transaxle case. Torque: 27 N*m ( 275 kgf*cm, 20 in.*lbf)
79. INSTALL SPEED SENSOR Coat a new O-ring with Toyota Genuine ATF WS or equivalent, and install it to the speed sensor. Install the speed sensor to the transaxle case with the bolt. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf)
80. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY Install the park/neutral position switch assembly onto the manual valve lever shaft. Provisionally install the 2 bolts. Replace the lock plate with a new one and tighten the manual valve shaft nut. Torque: 6.9 N*m ( 70 kgf*cm, 61 ft.*lbf) Provisionally install the control shaft lever. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. Align the groove with the neutral basic line. Hold the switch in this position and tighten the 2 bolts. Torque: 5.4 N*m ( 55 kgf*cm, 48 ft.*lbf) Using a screwdriver, stake the nut with the lock plate. Install the control shaft lever with the nut and washer. Torque: 13 N*m ( 129 kgf*cm, 9 in.*lbf)
81. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it to the speedometer driven hole cover sub-assembly. Install the speedometer driven hole cover sub-assembly to the transaxle housing. Torque: 7.0 N*m ( 71 kgf*cm, 62 ft.*lbf)

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1. REMOVE FRONT OIL PUMP BODY O-RING Remove the front oil pump body O-ring from the oil pump.
2. REMOVE STATOR SHAFT ASSEMBLY Using a "TORX" socket wrench T30, remove the 10 "TORX" screws.
3. REMOVE FRONT OIL PUMP DRIVE GEAR Remove the front oil pump drive gear from the oil pump body.
4. REMOVE FRONT OIL PUMP DRIVEN GEAR Remove the front oil pump driven gear from the oil pump body.
5. REMOVE FRONT OIL PUMP OIL SEAL Using SST, remove the front oil pump oil seal from the oil pump body. SST: 09308-00010
6. REMOVE CLUTCH DRUM OIL SEAL RING Using a screwdriver, remove the 2 clutch drum oil seal rings from the stator shaft assembly.

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1. INSPECT STATOR SHAFT ASSEMBLY Using a dial indicator, measure the inside diameter of the stator shaft bushings. Standard inside diameter 21.500 to 21.526 mm (0.84646 to 0.84748 in.) Maximum inside diameter 21.526 mm (0.84748 in.) If the inside diameter is greater than the maximum, replace the stator shaft. Install the input shaft assembly onto the stator shaft assembly and check that the input shaft assembly turns smoothly. NOTE: Replace the stator assembly with a new one if it moves roughly or makes unusual noise. Inspect the input shaft's contact surface with the bearing when replacing, and replace the input shaft with a new one if any damage or discoloration is found.
2. INSPECT OIL PUMP GEAR CLEARANCE Measure the clearance between the tips of the driven gear teeth and the drive gear teeth. Standard tip clearance 0.07 to 0.15 mm (0.0028 to 0.0059 in.) Maximum tip clearance 0.15 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the oil pump body sub-assembly. Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance 0.10 to 0.15 mm (0.0039 to 0.0059 in.) Maximum body clearance 0.15 mm (0.0059 in.) If the body clearance is greater than the maximum, replace the oil pump body sub-assembly. Using a steel straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance 0.02 to 0.05 mm (0.0008 to 0.0020 in.) Maximum side clearance 0.05 mm (0.0020 in.) If the side clearance is greater than the maximum, replace the drive gear, driven gear or pump body. Drive gear thickness No. Thickness mm (in.) 1 9.44 to 9.45 (0.3717 to 0.3720) 2 9.45 to 9.46 (0.3720 to 0.3724) 3 9.46 to 9.47 (0.3724 to 0.3728) 4 9.47 to 9.48 (0.3728 to 0.3732) 5 9.48 to 9.49 (0.3732 to 0.3736) Driven gear thickness No. Thickness mm (in.) 1 9.44 to 9.45 (0.3717 to 0.3720) 2 9.45 to 9.46 (0.3720 to 0.3724) 3 9.46 to 9.47 (0.3724 to 0.3728) 4 9.47 to 9.48 (0.3728 to 0.3732) 5 9.48 to 9.49 (0.3732 to 0.3736)
3. INSPECT FRONT OIL PUMP BODY SUB-ASSEMBLY Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter 38.113 to 38.138 mm (1.50050 to 1.50149 in.) Maximum inside diameter 38.138 mm (1.50149 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assembly.

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1. INSTALL CLUTCH DRUM OIL SEAL RING Coat 2 new clutch drum oil seal rings with Toyota Genuine ATF WS or equivalent, and install them to the stator shaft.
2. INSTALL FRONT OIL PUMP OIL SEAL Using SST, install a new front oil pump oil seal to the oil pump body. SST: 09950-60010 09951-00550 SST: 09950-70010 09951-07100 Oil seal drive in depth -0.15 to 0.15 mm (-0.006 to 0.006 in.)
3. INSTALL FRONT OIL PUMP DRIVEN GEAR Coat the front oil pump driven gear with Toyota Genuine ATF WS or equivalent, and install it to the oil pump body with the marked side facing upward.
4. INSTALL FRONT OIL PUMP DRIVE GEAR Coat the front oil pump drive gear with Toyota Genuine ATF WS or equivalent, and install it to the oil pump body with the marked side facing upward.
5. INSTALL STATOR SHAFT ASSEMBLY Using a "TORX" socket wrench T30, install the stator shaft assembly with 10 "TORX" screws. Torque: 9.8 N*m ( 100 kgf*cm, 87 ft.*lbf)
6. INSPECT OIL PUMP ASSEMBLY Turn the drive gear with 2 screwdrivers and make sure that it rotates smoothly. NOTE: Do not damage the oil seal lip.
7. INSTALL FRONT OIL PUMP BODY O-RING Coat a new front oil pump body O-ring with Toyota Genuine ATF WS or equivalent, and install it to the oil pump.

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1. REMOVE FRONT CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 4 discs and 4 plates from the input shaft.
2. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Using SST on the clutch balancer, compress the return spring with a press. SST: 09320-89010 NOTE: Do not compress the return spring excessively. Using a snap ring expander, remove the snap ring. Remove the clutch balancer and piston return spring.
3. REMOVE FORWARD CLUTCH PISTON Place the input shaft onto the oil pump. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil pump to remove the forward clutch piston. HINT: When the piston cannot be removed due to being slanted, either apply compressed air again with the raised side pushed level or remove the piston using needle-nose pliers with their tips wrapped in protective tape.
4. REMOVE FORWARD CLUTCH PISTON O-RING Using a screwdriver, remove the clutch piston O-ring from the forward clutch piston.
5. REMOVE INPUT SHAFT OIL SEAL RING Using a screwdriver, remove the input shaft oil seal ring from the input shaft.

Scheme 337

1. INSPECT FRONT CLUTCH DISC Check whether the sliding surface of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all the discs. Before assembling new discs, soak them in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
2. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 21.69 mm (0.8540 in.)

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1. INSTALL INPUT SHAFT OIL SEAL RING Coat a new input shaft oil seal ring with Toyota Genuine ATF WS or equivalent, and install it to the input shaft.
2. INSTALL FORWARD CLUTCH PISTON O-RING Coat a new clutch piston O-ring with Toyota Genuine ATF WS or equivalent, and install it to the forward clutch piston.
3. INSTALL FORWARD CLUTCH PISTON Install the forward clutch piston to the input shaft. NOTE: Do not damage the O-ring.
4. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Install the return spring and clutch balancer to the input shaft. Using SST, a press and snap ring pliers, install the snap ring to the input shaft. SST: 09320-89010
5. INSTALL FRONT CLUTCH DISC Install the 4 plates, 4 discs and flange. Using a screwdriver, install the snap ring to the input shaft.
6. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance 1.406 to 1.806 mm (0.05535 to 0.07110 in.) NOTE: If the clearance is not within the specified range, install a new brake flange. HINT: There are 4 different flange thicknesses. Flange thickness No. Thickness mm (in.) No. Thickness mm (in.) - 3.0 (0.118) 2 3.4 (0.134) 1 3.2 (0.126) 3 3.6 (0.142)

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1. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Using SST and a press, remove the snap ring from the 2nd brake piston. SST: 09387-00060 Remove the 2nd brake return spring from the 2nd brake cylinder. Remove the 2nd brake piston return spring sub-assembly from the 2nd brake cylinder.
2. REMOVE 2ND BRAKE PISTON Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
3. REMOVE 2ND BRAKE CYLINDER O-RING Using a screwdriver, remove the 2 O-rings from the 2nd brake cylinder.

Scheme 347

1. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 14.65 mm (0.5768 in.)

Scheme 348

1. INSTALL 2ND BRAKE CYLINDER O-RING Coat 2 new 2nd brake cylinder O-rings with Toyota Genuine ATF WS or equivalent, and install them into the 2nd brake cylinder. NOTE: Do not damage the O-rings.
2. INSTALL 2ND BRAKE PISTON Coat the 2nd brake piston with Toyota Genuine ATF WS or equivalent, and install it into the 2nd brake cylinder. WARNING: Do not damage the O-rings when pressing the 2nd brake piston into the 2nd brake cylinder by hand.
3. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Install the piston return spring. Place SST on the piston return spring, and compress the piston return spring with a press. SST: 09387-00060 Using a screwdriver, install the snap ring. NOTE: Make sure that the end gap of the snap ring is not aligned with the piston return spring claw.

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1. REMOVE REVERSE CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 3 discs and 3 plates.
2. REMOVE DIRECT CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the direct clutch flange, 3 direct clutch discs and 3 rear clutch flanges.
3. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY Using SST and a press, remove the snap ring. SST: 09387-00020 Remove the direct clutch return spring sub-assembly from the intermediate shaft.
4. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY Install the intermediate shaft onto the transaxle rear cover. Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole shown in the illustration and remove the direct clutch piston from the intermediate shaft. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a or piece of cloth. Do not splash ATF with the compressed air.
5. REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY Install the intermediate shaft onto the transaxle rear cover. Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly. Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil hole shown in the illustration and remove the direct clutch drum from the intermediate shaft. NOTE: Blowing the air may cause the drum to jump out. When removing the drum, hold it by hand using a shop rag or piece of cloth. Do not splash ATF with the compressed air.
6. REMOVE DIRECT CLUTCH PISTON O-RING Using a screwdriver, remove the 2 piston O-rings from the direct clutch piston.
7. REMOVE DIRECT CLUTCH DRUM O-RING Using a screwdriver, remove the direct clutch drum O-ring from the direct clutch drum.

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1. INSPECT REVERSE CLUTCH DISC Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all the discs. Before assembling new discs, soak them in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
2. INSPECT DIRECT CLUTCH DISC Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. NOTE: If the lining of any disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all the discs. Before assembling new discs, soak them in Toyota Genuine ATF WS or equivalent for at least 15 minutes.
3. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length 31.7 mm (1.2480 in.)
4. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY Shake the direct clutch pin and confirm that the check ball is not stuck. Apply low pressure compressed air to the check ball and confirm that there is no air leakage.
5. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY Shake the direct clutch pin and confirm that the check ball is not stuck. Apply low pressure compressed air to the check ball and confirm that there is air leakage.

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1. INSTALL DIRECT CLUTCH DRUM O-RING Coat a new O-ring with Toyota Genuine ATF WS or equivalent and install it to the direct clutch drum. NOTE: Do not damage the O-ring.
2. INSTALL DIRECT CLUTCH PISTON O-RING Coat 2 new O-rings with Toyota Genuine ATF WS or equivalent and install them to the direct clutch piston. NOTE: Do not damage the O-rings.
3. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY Coat the direct clutch drum with Toyota Genuine ATF WS or equivalent. Align a cutout on the intermediate shaft assembly with the matchmark on the direct clutch drum and install the direct clutch drum to the intermediate shaft assembly. NOTE: Do not damage the O-ring or the lip of the clutch drum.
4. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY Coat the direct clutch piston with Toyota Genuine ATF WS or equivalent and install it to the intermediate shaft. NOTE: Do not damage the O-ring or the direct clutch piston.
5. INSTALL DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY Install the direct clutch return spring onto the direct clutch piston. Place SST on the piston return spring and compress the springs with a press. SST: 09387-00020 Using snap ring pliers, install the snap ring to the direct clutch drum. NOTE: Stop pressing the press when the spring seat is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from deforming. Do not expand the snap ring excessively.
6. INSTALL DIRECT CLUTCH DISC Coat the 3 rear clutch flanges, 3 discs and direct clutch flange with Toyota Genuine ATF WS or equivalent and install them to the intermediate shaft. Install the snap ring to the intermediate shaft.
7. INSTALL REVERSE CLUTCH DISC Coat the 3 plates, 3 discs and flange with Toyota Genuine ATF WS or equivalent, and install them to the intermediate shaft. Install the snap ring to the intermediate shaft.
8. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance 0.862 to 1.262 mm (0.339 to 0.0497 in.) NOTE: If the clearance is not within the specified range, select a new clutch flange. HINT: There are 4 different flange thicknesses. Flange thickness No. Thickness mm (in.) No. Thickness mm (in.) - 3.0 (0.118) 2 3.4 (0.134) 1 3.2 (0.126) 3 3.6 (0.142)
9. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover. Using a dial indicator and measuring terminal (SST), measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). SST: 09350-36010 09350-06110 HINT: The direct and reverse clutch will come out as the compressed air is applied. Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch. Pack clearance 0.62 to 1.02 mm (0.0244 to 0.0402 in.) NOTE: If the clearance is not within the specified range, select a new clutch flange. HINT: There are 4 different flange thicknesses. Flange thickness No. Thickness mm (in.) No. Thickness mm (in.) - 3.0 (0.118) 2 3.4 (0.134) 1 3.2 (0.126) 3 3.6 (0.142)

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1. REMOVE REAR TRANSAXLE COVER PLUG Remove the 4 rear transaxle cover plugs from the rear transaxle cover. Using a screwdriver, remove the 4 O-rings from the 4 rear transaxle cover plugs.
2. REMOVE OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY Using SST, a press and a screwdriver, remove the snap ring. SST: 09387-00070 NOTE: Stop the press when the overdrive brake piston is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the overdrive brake piston from being deformed. Remove the overdrive brake return spring from the transaxle rear cover.
3. REMOVE 2ND COAST AND OVERDRIVE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle rear cover to remove the overdrive brake piston. NOTE: Blowing the air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth. Do not splash ATF with the compressed air.
4. REMOVE 2ND COAST AND OVERDRIVE O-RING Using a screwdriver, remove the 2 O-rings from the 2nd coast and overdrive brake piston.
5. REMOVE CLUTCH DRUM OIL SEAL RING Remove the 3 oil seal rings from the transaxle rear cover.
6. REMOVE REAR TRANSAXLE COVER NEEDLE ROLLER BEARING Using SST, remove the bearing from the rear transaxle cover. SST: 09387-00041 09387-01021