Toyota Avalon (XX50): Automatic Transaxle Unit

*1

NO. 1 OIL COOLER OUTLET TUBE SUB-ASSEMBLY

*2

NO. 1 TRANSMISSION OIL FILLER TUBE

*3

OIL COOLER UNION SUB-ASSEMBLY

*4

OVERFLOW PLUG

*5

PARK/NEUTRAL POSITION SWITCH ASSEMBLY

*6

REFILL PLUG

*7

TRANSMISSION CONTROL SHAFT LEVER

*8

GASKET

*9

OIL COOLER UNION BOLT

*10

O-RING

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

*

For use with a union nut wrench

●

Non-reusable part

Toyota Genuine ATF WS

*A

for TMC Made

*B

for TMMWV Made

*1

TRANSMISSION CASE SIDE COVER

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

★

Precoated part

*1

TRANSMISSION REVOLUTION SENSOR (NC)

*2

TRANSMISSION REVOLUTION SENSOR (NT)

*3

TRANSMISSION WIRE

*4

TRANSMISSION VALVE BODY ASSEMBLY

*5

NO. 1 FRONT OIL PUMP COVER GASKET

*6

TRANSAXLE CASE GASKET

*7

NO. 2 FRONT OIL PUMP COVER GASKET

*8

TEMPERATURE SENSOR CLAMP

*9

SPACER

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

-

-

*A

for TMC Made

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

-

-

*A

for TMMWV Made

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

★

Precoated part

-

-

*1

DIFFERENTIAL GEAR LUBE APPLY TUBE

*2

TRANSAXLE HOUSING

*3

TRANSAXLE HOUSING OIL SEPARATOR

*4

TRANSMISSION LUBE APPLY TUBE

*5

TRANSMISSION OIL CLEANER MAGNET

*6

O-RING

*7

TRANSAXLE CASE GASKET

*8

CLAMP

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

-

-

*1

CLUTCH DRUM OIL SEAL RING

*2

DIFFERENTIAL CASE ASSEMBLY

*3

FRONT OIL PUMP ASSEMBLY

*4

MANUAL DETENT SPRING SUB-ASSEMBLY

*5

OIL PUMP SPROCKET FRONT THRUST WASHER

*6

OIL PUMP SPROCKET REAR THRUST WASHER

*7

TRANSMISSION DRIVE CHAIN

*8

TRANSMISSION OIL PUMP DRIVE SPROCKET

*9

OIL PUMP DRIVE SHAFT SUB-ASSEMBLY

*10

NO. 1 BREATHER PLUG (ATM)

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

MP grease

*1

PLANETARY CARRIER THRUST WASHER

*2

C-3 AND C-4 CLUTCH ASSEMBLY

*1

FRONT PLANETARY GEAR ASSEMBLY

*2

FRONT PLANETARY RING GEAR

*3

INPUT SHAFT OIL SEAL RING

*4

NO. 2 PLANETARY CARRIER THRUST WASHER

*5

NO. 6 THRUST BEARING RACE

*6

NO. 7 THRUST BEARING RACE

*7

NO. 8 THRUST BEARING RACE

*8

NO. 9 THRUST BEARING RACE

*9

PLANETARY SUN GEAR

*10

REAR INPUT SHAFT OIL SEAL RING

*11

THRUST NEEDLE ROLLER BEARING

*12

FRONT PLANETARY RING GEAR FLANGE

*13

SNAP RING

-

-

●

Non-reusable part

Toyota Genuine ATF WS

MP grease

-

-

*1

FORWARD CLUTCH PISTON

*2

FRONT CLUTCH CLUTCH DISC

*3

NO. 1 CLUTCH BALANCER

*4

NO. 5 THRUST BEARING RACE

*5

REAR CLUTCH PISTON RETURN COMPRESSION SPRING

*6

SUN GEAR INPUT HUB SUB-ASSEMBLY

*7

THRUST NEEDLE ROLLER BEARING

*8

SNAP RING

*9

O-RING

*10

FORWARD CLUTCH FLANGE

*11

CLUTCH DRUM SUB-ASSEMBLY

*12

FORWARD MULTIPLE DISC CLUTCH CLUTCH PLATE

*13

D-RING

-

-

●

Non-reusable part

Toyota Genuine ATF WS

*1

MANUAL VALVE LEVER SHAFT RETAINER SPRING

*2

MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

*3

MANUAL VALVE LEVER SUB-ASSEMBLY

*4

PARKING LOCK PAWL

*5

PARKING LOCK PAWL SHAFT

*6

PARKING LOCK PAWL TORSION SPRING

*7

PARKING LOCK ROD SUB-ASSEMBLY

*8

PARKING LOCK SLEEVE

*9

PAWL STOPPER PLATE

*10

O-RING

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

-

-

*1

COUNTER DRIVE GEAR SUB-ASSEMBLY

*2

NO. 1 BRAKE DISC

*3

PINION AND COUNTER DRIVEN GEAR SUB-ASSEMBLY

*4

NO. 1 BRAKE PLATE

*5

NO. 1 BRAKE FLANGE

*6

SNAP RING

*7

O-RING

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

Do not apply lubricants to the threaded parts

*1

NO. 2 THRUST BEARING RACE

*2

NO. 3 PLANETARY CARRIER THRUST WASHER

*3

NO. 3 THRUST BEARING RACE

*4

NO. 4 PLANETARY CARRIER THRUST WASHER

*5

NO. 4 THRUST BEARING RACE

*6

PLANETARY SUN GEAR SUB-ASSEMBLY

*7

REAR PLANETARY GEAR ASSEMBLY

*8

REAR PLANETARY SUN GEAR SUB-ASSEMBLY

*9

THRUST BEARING RACE

*10

THRUST NEEDLE ROLLER BEARING

Toyota Genuine ATF WS

-

-

*1

C-2 CLUTCH BALANCER

*2

C-2 CLUTCH PISTON

*3

CLUTCH RETURN SPRING SUB-ASSEMBLY

*4

DIRECT CLUTCH DRUM OIL SEAL RING

*5

NO. 1 THRUST BEARING RACE

*6

NO. 2 CLUTCH DISC

*7

THRUST NEEDLE ROLLER BEARING

*8

NO. 2 CLUTCH PLATE

*9

DIRECT CLUTCH FLANGE

*10

INTERMEDIATE SHAFT SUB-ASSEMBLY

*11

SNAP RING

*12

O-RING

●

Non-reusable part

Toyota Genuine ATF WS

MP grease

-

-

*1

1ST AND REVERSE BRAKE PISTON

*2

1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

*3

2ND BRAKE BRAKE DISC

*4

NO. 2 1ST AND REVERSE BRAKE PISTON

*5

2ND BRAKE BRAKE FLANGE

*6

2ND BRAKE BRAKE PLATE

*7

SNAP RING

*8

O-RING

●

Non-reusable part

Toyota Genuine ATF WS

*1

AUTOMATIC TRANSMISSION CASE STRAIGHT PIN

*2

COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE)

*3

COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (OUTER RACE)

*4

COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE)

*5

COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE)

*6

FRONT DRIVE SHAFT OIL SEAL LH

*7

FRONT DRIVE SHAFT OIL SEAL RH

*8

MANUAL VALVE LEVER SHAFT OIL SEAL

*9

NEEDLE ROLLER BEARING

*10

NO. 1 TRANSAXLE CASE PLUG

*11

NO. 2 TRANSAXLE CASE PLUG

*12

TRANSAXLE CASE OIL SEAL

*13

PINION AND COUNTER DRIVEN GEAR SHIM

*14

PINION AND COUNTER DRIVEN GEAR SUB-ASSEMBLY

*15

GASKET

*16

O-RING

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

●

Non-reusable part

Toyota Genuine ATF WS

MP grease

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

★

Precoated part

(a) Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.

(a) Remove the 2 bolts and park/neutral position switch assembly from the automatic transaxle case sub-assembly.

(a) Remove the refill plug and gasket from the automatic transaxle case sub-assembly.

(a) Using a 10 mm socket hexagon wrench, remove the overflow plug and gasket from the transaxle housing.

(a) Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube from the transaxle housing.

(a) Remove the bolt to separate the oil cooler union sub-assembly bracket portion from the automatic transaxle case sub-assembly.

(a) Using a 19 mm union nut wrench, remove the No. 1 oil cooler outlet tube sub-assembly from the automatic transaxle case sub-assembly.

(b) Remove the O-ring from the No. 1 oil cooler outlet tube sub-assembly.

(a) Remove the 10 bolts and transmission case side cover from the automatic transaxle case sub-assembly.

(a) Disengage the clamp to disconnect the transmission wire from the solenoid lock plate.

(c) Remove the bolt and temperature sensor clamp and disconnect the temperature sensor from the transmission valve body assembly.

(d) Disconnect the transmission revolution sensor (NT) connector and transmission revolution sensor (NC) connector.

(e) Remove the bolt and transmission wire from the automatic transmission case sub-assembly.

(a) Disengage the clamp to disconnect the transmission revolution sensor (NC) wire connector.

(b) Remove the 9 bolts and transmission valve body assembly from the automatic transaxle case sub-assembly.

(c) Remove the 2 transaxle case gaskets from the automatic transaxle case sub-assembly.

(a) Remove the bolt and transmission revolution sensor (NT) from the automatic transaxle case sub-assembly.

(a) Remove the bolt, spacer and transmission revolution sensor (NC) from the counter drive gear sub-assembly.

(a) Remove the 21 bolts.

(b) Using a plastic hammer, tap on the circumference of the transaxle housing to remove it from the automatic transaxle case sub-assembly.

(c) Remove the 5 transaxle case gaskets from the front oil pump assembly.

(a) Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.

(a) Remove the 3 transmission oil cleaner magnets from the transaxle housing oil separator.

(a) Remove the differential gear lube apply tube from the transaxle housing.

(a) Remove the bolt and clamp from the transaxle housing.

(b) Remove the transmission lube apply tube from the transaxle housing.

(a) Remove the differential case assembly from the automatic transaxle case sub-assembly.

(a) Remove the clutch drum oil seal ring from the front oil pump assembly.

(a) Remove the oil pump sprocket front thrust washer from the transmission oil pump drive sprocket.

(a) Remove the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly from the front oil pump assembly.

NOTICE:

To avoid damaging the bush of the front oil pump assembly, remove the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.

(a) Remove the oil pump sprocket rear thrust washer from the front oil pump assembly.

(a) Remove the bolt and manual detent spring sub-assembly from the front oil pump assembly.

(a) Remove the 7 bolts and front oil pump assembly from the automatic transaxle case sub-assembly.

(a) Remove the planetary carrier thrust washer from the C-3 and C-4 clutch assembly.

(a) Remove the C-3 and C-4 clutch assembly from the front planetary gear assembly.

(a) Remove the No. 2 planetary carrier thrust washer from the front planetary gear assembly.

(a) Remove the planetary sun gear from the front planetary gear assembly.

(a) Remove the No. 9 thrust bearing race from the front planetary gear assembly.

(a) Remove the thrust needle roller bearing from the front planetary gear assembly.

(a) Remove the No. 8 thrust bearing race from the front planetary gear assembly.

(a) Remove the front planetary gear assembly from the front planetary ring gear.

(a) Remove the thrust needle roller bearing from the front planetary ring gear.

(a) Remove the No. 7 thrust bearing race from the front planetary gear assembly.

(a) Remove the 5 input shaft oil seal rings from the front planetary gear assembly.

(a) Remove the 2 rear input shaft oil seal rings from the front planetary gear assembly.

(a) Remove the front planetary ring gear with front planetary ring gear flange from the C-1 clutch assembly.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front planetary ring gear.

NOTICE:

Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

(c) Remove the front planetary ring gear flange from the front planetary ring gear.

(a) Remove the thrust needle roller bearing from the C-1 clutch assembly.

(a) Remove the No. 6 thrust bearing race from the C-1 clutch assembly.

(a) Remove the C-1 clutch assembly from the sun gear input hub sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the clutch drum sub-assembly.

NOTICE:

Be careful not to damage the clutch drum sub-assembly.

(b) Remove the forward clutch flange, 5 front clutch clutch discs and 5 forward multiple disc clutch clutch plates from the clutch drum sub-assembly.

(a) Place SST on the No. 1 clutch balancer and compress the rear clutch piston return compression spring with a press.

SST: 09387-00020

NOTICE:

Do not compress the rear clutch piston return compression spring excessively.

(c) Remove the No. 1 clutch balancer from the forward clutch piston.

(a) Remove the rear clutch piston return compression spring from the forward clutch piston.

(a) Apply compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole of the clutch drum sub-assembly to remove the forward clutch piston from the clutch drum sub-assembly.

NOTICE:

• Applying compressed air may cause the forward clutch piston to jump out. When removing the forward clutch piston, hold it by hand using a piece of cloth.
• Be careful as ATF may spray when applying compressed air.

(b) Remove the O-ring from the clutch drum sub-assembly.

(c) Remove the D-ring from the clutch drum sub-assembly.

(a) Remove the sun gear input hub sub-assembly from the counter drive gear sub-assembly.

(a) Remove the thrust needle roller bearing from the sun gear input hub sub-assembly.

(a) Remove the No. 5 thrust bearing race from the sun gear input hub sub-assembly.

(a) Remove the bolt.

(b) Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and remove the manual valve lever shaft sub-assembly.

HINT:

Rotating the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

(c) Remove the O-ring from the manual valve lever shaft sub-assembly.

(a) Remove the manual valve lever sub-assembly from the automatic transaxle case sub-assembly.

(a) Remove the 2 bolts and pawl stopper plate from the automatic transaxle case sub-assembly.

(a) Remove the manual valve lever shaft retainer spring from the automatic transaxle case sub-assembly.

(a) Move the manual valve lever shaft sub-assembly and parking lock rod sub-assembly as shown in the illustration, and remove the parking lock rod sub-assembly.

HINT:

Align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly and remove the parking lock rod sub-assembly.

(a) Remove the manual valve lever shaft sub-assembly from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl torsion spring from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl shaft from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl from the automatic transaxle case sub-assembly.

(a) Remove the parking lock sleeve from the automatic transaxle case sub-assembly.

(a) Using a T50 "TORX" socket wrench, remove the 2 bolts (A) from the counter drive gear sub-assembly.

(c) Remove the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly from the automatic transaxle case sub-assembly.

(d) Remove the O-ring from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the counter drive gear sub-assembly.

NOTICE:

Be careful not to damage the counter drive gear sub-assembly.

(b) Remove the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates from the counter drive gear sub-assembly.

(a) Remove the No. 3 planetary carrier thrust washer from the rear planetary gear assembly.

(a) Remove the planetary sun gear sub-assembly from the rear planetary gear assembly.

(a) Remove the rear planetary sun gear sub-assembly from the C-2 clutch assembly.

(a) Remove the rear planetary gear assembly from the C-2 clutch assembly.

(a) Remove the No. 4 planetary carrier thrust washer from the rear planetary gear assembly.

(a) Remove the No. 4 thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the thrust needle roller bearing from the rear planetary sun gear sub-assembly.

(a) Remove the thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the No. 3 thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the thrust needle roller bearing from the C-2 clutch assembly.

(a) Remove the No. 2 thrust bearing race from the C-2 clutch assembly.

(a) Remove the C-2 clutch assembly from the automatic transaxle case sub-assembly.

(a) Remove the thrust needle roller bearing from the C-2 clutch assembly.

(a) Remove the No. 1 thrust bearing race from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the intermediate shaft sub-assembly.

NOTICE:

Be careful not to damage the intermediate shaft sub-assembly.

(b) Remove the direct clutch flange, 4 No. 2 clutch discs and 4 No. 2 clutch plates from the intermediate shaft sub-assembly.

(a) Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.

SST: 09387-00020

NOTICE:

Do not compress the clutch return spring sub-assembly excessively.

(c) Remove the C-2 clutch balancer from the intermediate shaft sub-assembly.

(a) Remove the clutch return spring sub-assembly from the intermediate shaft sub-assembly.

(a) Apply compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole of the intermediate shaft sub-assembly.

NOTICE:

• Applying compressed air may cause the C-2 clutch piston to jump out. When removing the C-2 clutch piston, hold it by hand using a piece of cloth.
• Be careful as ATF may spray when applying compressed air.

(b) Remove the C-2 clutch piston from the intermediate shaft sub-assembly.

(c) Remove the 2 O-rings from the intermediate shaft sub-assembly.

(a) Remove the 2 direct clutch drum oil seal rings from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(b) Remove the 2nd brake brake flange, 5 2nd brake brake discs and 5 2nd brake brake plates from the automatic transaxle case sub-assembly.

(a) Remove the No. 2 1st and reverse brake piston from the automatic transaxle case sub-assembly.

(a) Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.

SST: 09380-60011

09381-06020

09381-06050

09381-06060

09381-06100

09381-06110

SST: 09950-70010

09951-07200

NOTICE:

Do not compress the 1st and reverse brake return spring sub-assembly excessively.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(c) Remove the 1st and reverse brake return spring sub-assembly from the automatic transaxle case sub-assembly.

(a) Apply compressed air (approximately 392 kPa (4.0 kgf/cm2, 57 psi)) to the ATF hole to remove the 1st and reverse brake piston from the automatic transaxle case sub-assembly.

(b) Remove the 2 O-rings from the 1st and reverse brake piston.

(a) Using SST, remove the needle roller bearing from the automatic transaxle case sub-assembly.

SST: 09303-55010

SST: 09502-12010

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped with protective tape, remove the manual valve lever shaft oil seal from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using SST, remove the transaxle case oil seal from the transaxle housing.

SST: 09308-36010

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the front drive shaft oil seal RH from the transaxle housing.

SST: 09308-36010

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the front drive shaft oil seal LH from the automatic transaxle case sub-assembly.

SST: 09308-36010

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using SST and a press, remove the needle roller bearing from the transaxle housing.

SST: 09950-60011

09951-00550

SST: 09950-70010

09951-07200

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the counter driven gear rear tapered roller bearing (inner race) from the pinion and counter driven gear sub-assembly.

SST: 09950-40011

09951-04010

09952-04010

09953-04030

09954-04010

09955-04011

09957-04010

09958-04011

SST: 09950-60011

09951-00310

NOTICE:

Because SST is attached to the roller portion, there is a possibility that the roller portion could break and SST could come off before the counter driven gear tapered roller bearing (rear side inner race) comes off.

(b) If the roller portion breaks and SST comes off, reattach SST to the inner race in the position shown in the illustration, and continue removing the parts.

SST: 09950-40011

09951-04010

09952-04010

09953-04030

09954-04010

09955-04011

09957-04010

09958-04011

SST: 09950-60011

09951-00310

(a) Using SST, remove the counter driven gear front tapered roller bearing (inner race) from the pinion and counter driven gear sub-assembly.

SST: 09950-00020

SST: 09950-00030

SST: 09950-60011

09951-00380

(a) Remove the 4 No. 1 transaxle case plugs from the automatic transaxle case sub-assembly.

(b) Remove the 4 No. 1 transaxle case plugs from the transaxle housing.

(c) Remove the 8 O-rings from the 8 No. 1 transaxle case plugs.

(a) Using a 6 mm socket hexagon wrench, remove the 3 No. 2 transaxle case plugs and 3 gaskets from the automatic transaxle case sub-assembly.

(b) Using a 6 mm socket hexagon wrench, remove the 3 No. 2 transaxle case plugs and 3 gaskets from the transaxle housing.

(a) Remove the 2 automatic transmission case straight pins from the automatic transaxle case sub-assembly.

(a) Disengage each claw and remove the No. 1 breather plug (ATM) from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the transaxle housing and on the transmission oil cleaner magnets to determine what type of wear might be found in the automatic transaxle assembly.

Result:

Steel (magnetic)

Bearing, gear and plate wear

Brass (non-magnetic)

Bushing wear

(a) Check if the contact surfaces of the front clutch clutch disc, forward multiple disc clutch clutch plate and forward clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

• If the lining of any front clutch clutch disc is peeled off or discolored, or even if part of the groove is damaged, replace all the front clutch clutch disc.
• Before assembling new front clutch clutch disc, soak them in Toyota Genuine ATF WS for at least 15 minutes.

(a) Check if the contact surfaces of the No. 2 clutch disc, No. 2 clutch plate and direct clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

• If the lining of any No. 2 clutch disc is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 2 clutch disc.
• Before assembling new No. 2 clutch disc soak them in Toyota Genuine ATF WS for at least 15 minutes.

(a) Check if the contact surfaces of the No. 1 brake disc, No. 1 brake plate and No. 1 brake flange are worn or burnt.

If necessary, replace them.

NOTICE:

• If the lining of any No. 1 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 1 brake disc.
• Before assembling new No. 1 brake disc, soak them in Toyota Genuine ATF WS for at least 15 minutes.

(a) Check if the contact surfaces of the 2nd brake brake disc, 2nd brake brake plate and 2nd brake brake flange are worn or burnt.

If necessary, replace them.

NOTICE:

• If the lining of any 2nd brake brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all the 2nd brake brake disc.
• Before assembling new 2nd brake brake disc, soak them in Toyota Genuine ATF WS for at least 15 minutes.

(a) Using a vernier caliper, measure the free length of the clutch return spring sub-assembly together with the spring seat.

Standard Free Length:

14.61 mm (0.575 in.)

If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.

(a) Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly together with the spring seat.

Standard Free Length:

18.29 mm (0.720 in.)

If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

(a) Using a caliper gauge, measure the inside diameter of the bushing of the planetary sun gear sub-assembly.

Standard Inside Diameter:

33.286 to 33.312 mm (1.310 to 1.311 in.)

Maximum Inside Diameter:

33.312 mm (1.311 in.)

If the inside diameter is more than the maximum, replace the planetary sun gear sub-assembly.

(a) Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.

Standard Inside Diameter:

24.287 to 24.313 mm (0.956 to 0.957 in.)

Maximum Inside Diameter:

24.313 mm (0.957 in.)

If the inside diameter is more than the maximum, replace the rear planetary sun gear sub-assembly.

(a) for Outer Pinion:

(1) Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 5 points.

Standard Clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

If the clearance is more than the standard clearance, replace the front planetary gear assembly.

(b) for Inner Pinion:

(1) Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 5 points.

Standard Clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

If the clearance is more than the standard clearance, replace the front planetary gear assembly.

(a) for Long Pinion:

(1) Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 4 points.

Standard Clearance:

0.15 to 1.05 mm (0.00591 to 0.0413 in.)

If the clearance is more than the standard clearance, replace the rear planetary gear assembly.

(b) for Short Pinion:

(1) Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 4 points.

Standard Clearance:

0.15 to 0.85 mm (0.00591 to 0.0335 in.)

If the clearance is more than the standard clearance, replace the rear planetary gear assembly.

(a) Using a dial indicator, measure the input shaft end play.

Standard Input Shaft End Play:

0.332 to 1.103 mm (0.0131 to 0.0434 in.)

Cover Oil Hole

Cover Oil Hole

*a

TMC Made

*b

TMMWV Made

(a) Using a dial indicator, measure the clearance of the C-1 clutch while applying compressed air (approximately 200 kPa (2.0 kgf/cm2, 29 psi)).

Pack Clearance (Reference):

1.0 to 1.2 mm (0.0394 to 0.0472 in.)

HINT:

• Make sure to cover the ATF holes shown in the illustration.
• To find the clearance, measure in at least 3 locations and average the results.

If the clearance is not as specified, select an appropriate forward clutch flange so that the clearance will be within the specified range.

Forward Clutch Flange Thickness:

*a

TMC Made

*b

TMMWV Made

(a) Using a dial indicator, measure the clearance of the B-1 brake while applying compressed air (approximately 200 kPa (2.0 kgf/cm2, 29 psi)).

Pack Clearance:

0.8 to 1.0 mm (0.0315 to 0.0394 in.)

HINT:

To find the clearance, measure in at least 3 locations and average the results.

If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.

No. 1 Brake Flange Thickness:

*a

TMC Made

*b

TMMWV Made

(a) Using a dial indicator, measure the clearance of the C-2 clutch while applying compressed air (approximately 400 kPa (4.1 kgf/cm2, 58 psi)).

Piston Stroke:

0.8 to 1.0 mm (0.0315 to 0.0394 in.)

HINT:

To find the clearance, measure in at least 3 locations and average the results.

If the clearance is not as specified, select an appropriate direct clutch flange so that the clearance will be within the specified range.

Direct Clutch Flange Thickness:

*a

TMC Made

*b

TMMWV Made

(a) Using a dial indicator, measure the clearance of the B-2 brake while applying compressed air (approximately 200 kPa (2.0 kgf/cm2, 29 psi)).

Piston Stroke:

1.0 to 1.2 mm (0.0394 to 0.0472 in.)

HINT:

To find the clearance, measure in at least 3 locations and average the results.

If the clearance is not as specified, select an appropriate 2nd brake brake flange so that the clearance will be within the specified range.

HINT:

There are 7 2nd brake brake flanges of different thicknesses available.

2nd Brake Brake Flange Thickness:

A

32.6 (1.28) / 54.2 (2.13)

31.7 (1.25) / 52.3 (2.06)

31.7 (1.25) / 52.3 (2.06)

B

59.8 (2.35) / 77.0 (3.03)

58.3 (2.30) / 75.0 (2.95)

-

C

-

39.2 (1.54) / 52.6 (2.07)

38.1 (1.50) / 50.2 (1.98)

D

-

33.3 (1.31) / 46.3 (1.82)

34.2 (1.35) / 47.3 (1.86)

E

34.4 (1.35) / 48.7 (1.92)

33.2 (1.31) / 47.7 (1.88)

33.2 (1.31) / 47.7 (1.88)

F

25.58 (1.01) / 43.7 (1.72)

24.2 (0.953) / 43.7 (1.72)

24.2 (0.953) / 43.7 (1.72)

G

-

50.5 (1.99) / 74.5 (2.93)

52.8 (2.08) / 76.4 (3.01)

*a

TMC Made

*b

TMMWV Made

(a) Using a plastic hammer, tap in 2 new automatic transmission case straight pins to the specified protrusion height.

Protrusion Height:

for TMC Made

10.7 to 11.3 mm (0.421 to 0.445 in.)

for TMMWV Made

7.0 to 8.0 mm (0.276 to 0.315 in.)

(a) Using SST and a press, install a new counter driven gear front tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.

SST: 09950-60011

09951-00550

SST: 09950-70010

09951-07150

NOTICE:

Be sure to install the counter driven gear front tapered roller bearing (inner race) so that there is no clearance between the counter driven gear front tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

(a) Using SST and a hammer, install a new counter driven gear front tapered roller bearing (outer race) and pinion and counter driven gear shim to the transaxle housing.

SST: 09950-60021

09951-00780

SST: 09950-70010

09951-07150

NOTICE:

Be sure to install the counter driven gear front tapered roller bearing (outer race) so that there is no clearance between the counter driven gear front tapered roller bearing (outer race), pinion and counter driven gear shim and the transaxle housing. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

(a) Using SST and a press, install a new counter driven gear rear tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.

SST: 09506-30012

SST: 09950-60011

09951-00420

09951-00550

SST: 09950-70010

09951-07150

NOTICE:

Be sure to install the counter driven gear rear tapered roller bearing (inner race) so that there is no clearance between the counter driven gear rear tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

(a) Using SST and a hammer, install a new counter driven gear rear tapered roller bearing (outer race) to the automatic transaxle case sub-assembly.

SST: 09950-60021

09951-00680

SST: 09950-70010

09951-07150

NOTICE:

Be sure to install the counter driven gear rear tapered roller bearing (outer race) so that there is no clearance between the counter driven gear rear tapered roller bearing (outer race) and the automatic transaxle case sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

(c) Install the differential case assembly to the automatic transaxle case sub-assembly.

(d) Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

Torque:

29.4 N·m {300 kgf·cm, 22 ft·lbf}

Bolt Length:

(e) Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.

SST: 09564-33010

(f) Using SST and a torque wrench, measure the turning torque of the front differential case tapered roller bearing while rotating SST at 10 rpm.

SST: 09564-33010

Standard Turning Torque:

for TMC Made

0.69 to 1.02 N*m (8 to 10 kgf*cm, 7 to 9 in.*lbf)

for TMMWV Made

0.99 to 1.28 N*m (11 to 13 kgf*cm, 9 to 11 in.*lbf)

If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

Differential Drive Pinion Shim Thickness:

(b) Install the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.

(c) Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

Torque:

29.4 N·m {300 kgf·cm, 22 ft·lbf}

Bolt Length:

(d) Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.

SST: 09564-33010

(e) Using SST and a torque wrench, measure the turning torque of the pinion and counter driven gear tapered roller bearing while rotating SST at 10 rpm.

SST: 09564-33010

Standard Turning Torque:

for TMC Made

Front differential case tapered roller bearing preload + 0.99 to 2.26 N*m (11 to 23 kgf*cm, 9 to 20 in.*lbf)

for TMMWV Made

Front differential case tapered roller bearing preload + 1.75 to 2.61 N*m (18 to 26 kgf*cm, 16 to 23 in.*lbf)

If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

Pinion and Counter Driven Gear Shim Thickness:

(b) Apply adhesive to 2 or 3 threads on the end of the No. 2 transaxle case plug.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Make sure to install the No. 2 transaxle case plug immediately after applying adhesive to prevent foreign matter from attaching to them.

(c) Using a 6 mm socket hexagon wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the automatic transaxle case sub-assembly.

Torque:

17 N·m {173 kgf·cm, 13 ft·lbf}

(d) Using a 6 mm socket hexagon wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the transaxle housing.

Torque:

17 N·m {173 kgf·cm, 13 ft·lbf}

(a) Coat 8 new O-rings with Toyota Genuine ATF WS and install them to the 8 No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs to the automatic transaxle case sub-assembly.

Torque:

7.4 N·m {75 kgf·cm, 65 in·lbf}

(c) Install the 4 No. 1 transaxle case plugs to the transaxle housing.

Torque:

7.4 N·m {75 kgf·cm, 65 in·lbf}

(a) Using SST and a press, install a new needle roller bearing to the transaxle housing.

SST: 09950-60011

09951-00560

SST: 09950-70010

09951-07200

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST and a hammer, install a new front drive shaft oil seal LH to the automatic transaxle case sub-assembly.

SST: 09649-17010

SST: 09950-70010

09951-07200

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

(a) Using SST and a hammer, install a new front drive shaft oil seal RH to the transaxle housing.

SST: 09316-10010

SST: 09950-70010

09951-07200

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

(b) Using SST and a hammer, install a new transaxle case oil seal to the transaxle housing.

SST: 09950-60011

09951-00640

SST: 09950-70010

09951-07200

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

(a) Using SST and a hammer, install a new manual valve lever shaft oil seal to the automatic transaxle case sub-assembly.

SST: 09950-60011

09951-00210

SST: 09950-70010

09951-07200

Standard Depth:

-0.3 to 0.4 mm (-0.0118 to 0.0157 in.)

(a) Using SST and a press, install a new needle roller bearing to the automatic transaxle case sub-assembly.

SST: 09950-60011

09951-00210

SST: 09950-70010

09951-07150

Standard Depth:

2.1 to 2.5 mm (0.0827 to 0.0984 in.)

NOTICE:

Install the needle roller bearing with its supplier name mark facing the front of the automatic transaxle assembly.

(a) Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the 1st and reverse brake piston.

NOTICE:

• Make sure to correctly distinguish between the inner side and outer side O-rings.
• Be careful not to damage or twist the O-rings.

(b) Set the 1st and reverse brake return spring sub-assembly on the 1st and reverse brake piston.

(c) Install the 1st and reverse brake piston with 1st and reverse brake return spring sub-assembly to the automatic transaxle case sub-assembly.

NOTICE:

Make sure that the O-rings are not damaged or do not jump out of position during installation.

(a) Set the snap ring on the automatic transaxle case sub-assembly as shown in the illustration.

NOTICE:

The opening of the snap ring should be within the area shown in the illustration (spline portion).

(b) Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.

SST: 09380-60011

09381-06020

09381-06050

09381-06060

09381-06100

09381-06110

SST: 09950-70010

09951-07200

NOTICE:

Stop the press when the 1st and reverse brake return spring sub-assembly is flush with the snap ring groove.

(c) Using a screwdriver with its tip wrapped with protective tape, install the snap ring into the snap ring groove of the automatic transaxle case sub-assembly.

NOTICE:

• Be careful not to damage the automatic transaxle case sub-assembly.
• Make sure that the snap ring is installed in the groove of the automatic transaxle case sub-assembly correctly.

(a) Install the No. 2 1st and reverse brake piston to the automatic transaxle case sub-assembly.

(a) Install the 5 2nd brake brake plates, 5 2nd brake brake discs and 2nd brake brake flange to the automatic transaxle case sub-assembly.

NOTICE:

Assemble the 2nd brake brake flange with its tapered surface facing toward the 2nd brake brake disc.

(b) Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.

NOTICE:

The opening of the snap ring should be within the area shown in the illustration (spline portion).

(b) Coat 2 new direct clutch drum oil seal rings with Toyota Genuine ATF WS and install them to the automatic transaxle case sub-assembly.

NOTICE:

While making the spread of the opening of the direct clutch drum oil seal ring as small as possible, install it to the automatic transaxle case sub-assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

(a) Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install it to the intermediate shaft sub-assembly.

NOTICE:

Be careful not to damage or twist the O-ring.

(c) Install the C-2 clutch piston to the intermediate shaft sub-assembly.

NOTICE:

• Make sure the lip is not cut or folded.
• Be careful not to damage the lip seal of the C-2 clutch piston.

(a) Install the clutch return spring sub-assembly to the intermediate shaft sub-assembly.

(b) Install the C-2 clutch balancer to the intermediate shaft sub-assembly.

NOTICE:

Be careful not to damage the lip seal of the C-2 clutch balancer.

NOTICE:

• Make sure the lip is not cut or folded.
• Be careful not to damage the lip seal of the C-2 clutch balancer.

(c) Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.

SST: 09387-00020

NOTICE:

Stop the press when the clutch return spring sub-assembly is flush with the snap ring groove.

(a) Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the intermediate shaft sub-assembly.

NOTICE:

• Be careful during assembly because there are 2 types of No. 2 clutch plate with different thicknesses.
• Assemble the direct clutch flange with its tapered surface facing toward the No. 2 clutch disc.

(b) Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the intermediate shaft sub-assembly.

NOTICE:

• Be careful not to damage the intermediate shaft sub-assembly.
• Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.

(a) Coat the No. 1 thrust bearing race with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

No. 1 Thrust Bearing Race Diameter:

NOTICE:

Securely insert the claw of the No. 1 thrust bearing race into the hole of the automatic transaxle case sub-assembly.

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

Thrust Needle Roller Bearing Diameter:

NOTICE:

Make sure to assemble the thrust needle roller bearing in the correct direction.

HINT:

When installing the C-2 clutch assembly, if the thrust needle roller bearing falls off, coat the C-2 clutch assembly installation surface with MP grease and install the parts.

(a) Install the C-2 clutch assembly to the automatic transaxle case sub-assembly.

(a) Install the No. 4 planetary carrier thrust washer to the rear planetary gear assembly.

HINT:

• Securely insert each protrusion of the No. 4 planetary carrier thrust washer into each indentation of the rear planetary gear assembly.
• When installing the rear planetary gear assembly, if the No. 4 planetary carrier thrust washer falls off, coat the rear planetary gear assembly installation surface with MP grease and install the parts.

(a) Install the rear planetary gear assembly to the C-2 clutch assembly.

(a) Coat the No. 2 thrust bearing race with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

No. 2 Thrust Bearing Race Diameter:

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

Thrust Needle Roller Bearing Diameter:

(a) Coat the No. 3 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

No. 3 Thrust Bearing Race Diameter:

HINT:

When installing the rear planetary sun gear sub-assembly, if the No. 3 thrust bearing race falls off, coat the rear planetary sun gear sub-assembly installation surface with MP grease and install the parts.

(a) Install the rear planetary sun gear sub-assembly to the C-2 clutch assembly.

(a) Coat the thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

Thrust Bearing Race Diameter:

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

Thrust Needle Roller Bearing Diameter:

(a) Coat the No. 4 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

No. 4 Thrust Bearing Race Diameter:

(a) Install the planetary sun gear sub-assembly to the rear planetary gear assembly.

(a) Coat the No. 3 planetary carrier thrust washer with Toyota Genuine ATF WS and install it to the rear planetary gear assembly.

NOTICE:

Securely insert the claw of the No. 3 planetary carrier thrust washer into the hole of the rear planetary gear assembly.

(a) Install the 4 No. 1 brake plates, 4 No. 1 brake discs and No. 1 brake flange to the counter drive gear sub-assembly.

NOTICE:

• Be careful during assembly because there are 2 types of No. 1 brake plate with different thicknesses.
• Assemble the No. 1 brake flange with its tapered surface facing toward the No. 1 brake disc.

(b) Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the counter drive gear sub-assembly.

NOTICE:

• Be careful not to damage the counter drive gear sub-assembly.
• Make sure that the snap ring is installed in the groove of the counter drive gear sub-assembly correctly.
• The opening of the snap ring should be within the area shown in the illustration (spline portion).

(b) Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

(c) Install the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.

(d) Temporarily install the 8 bolts (A and B).

HINT:

Bolt (A) is a hexagon socket head cap bolt.

(a) Coat the parking lock sleeve with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

(a) Coat the parking lock pawl with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

(a) Coat the parking lock pawl shaft with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

(a) Install the parking lock pawl torsion spring to the automatic transaxle case sub-assembly as shown in the illustration.

NOTICE:

Securely insert the parking lock pawl torsion spring all the way into the parking lock pawl shaft.

(a) Install the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly.

NOTICE:

When installing the manual valve lever shaft sub-assembly, be careful not to damage the manual valve lever shaft oil seal.

(a) Parking lock rod sub-assembly as shown in the illustration, and install the parking lock rod sub-assembly.

NOTICE:

Securely align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly.

(a) Install the manual valve lever shaft retainer spring to the automatic transaxle case sub-assembly.

(a) Install the pawl stopper plate to the automatic transaxle case sub-assembly with the 2 bolts.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(a) Install the manual valve lever sub-assembly to the automatic transaxle case sub-assembly.

NOTICE:

The pin portion of the manual valve lever shaft sub-assembly must be inserted into the slot of the manual valve lever sub-assembly.

(a) Coat a new O-ring with Toyota Genuine ATF WS and install it to the manual valve lever shaft sub-assembly.

NOTICE:

Ensure that the O-ring it not twisted.

(b) Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and install the manual valve lever shaft sub-assembly.

HINT:

Installing the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

(c) Secure the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

(a) Coat the No. 5 thrust bearing race with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

No. 5 Thrust Bearing Race Diameter:

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

Thrust Needle Roller Bearing Diameter:

(a) Install the sun gear input hub sub-assembly to the counter drive gear sub-assembly.

(a) Apply a light coat of Toyota Genuine ATF WS to a new D-ring and install it to the clutch drum sub-assembly.

HINT:

• Be careful not to damage or twist the D-ring.
• The rounded surface of the D-ring will be on the outer side of the ring groove.

(b) Apply a light coat of Toyota Genuine ATF WS to a new O-ring and install it to the clutch drum sub-assembly.

NOTICE:

Be careful not to damage or twist the O-ring.

(c) Apply a light coat of Toyota Genuine ATF WS to the forward clutch piston and install it to the clutch drum sub-assembly.

NOTICE:

• Make sure that the O-ring and the D-ring is not damaged or does not jump out of position during installation.
• Make sure the lip is not cut or folded.

(a) Install the rear clutch piston return compression spring to the forward clutch piston.

NOTICE:

Make sure to install in the correct direction.

(b) Install the No. 1 clutch balancer to the forward clutch piston.

NOTICE:

Be careful not to damage the lip seal of the forward clutch piston.

(c) Place SST on the No. 1 clutch balancer and compress the rear clutch piston return compression spring with a press.

SST: 09387-00020

NOTICE:

Stop the press when the rear clutch piston return compression spring is flush with the snap ring groove.

(a) Install the 5 forward multiple disc clutch clutch plates, 5 front clutch clutch discs and forward clutch flange to the clutch drum sub-assembly.

NOTICE:

• Be careful during assembly because there are 2 types of forward multiple disc clutch clutch plate with different thicknesses.
• Assemble the forward clutch flange with its tapered surface facing toward the front clutch clutch disc.

(b) Using a screwdriver with its tip wrapped in protective tape, install the snap ring to the clutch drum sub-assembly.

NOTICE:

• Be careful not to damage the clutch drum sub-assembly.
• Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.

(a) Install the C-1 clutch assembly to the sun gear input hub sub-assembly.

(a) Coat the No. 6 thrust bearing race with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

No. 6 Thrust Bearing Race Diameter:

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

Thrust Needle Roller Bearing Diameter:

(a) Install the front planetary ring gear flange to the front planetary ring gear.

(b) Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front planetary ring gear.

NOTICE:

Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

(c) Install the front planetary ring gear with front planetary ring gear flange to the C-1 clutch assembly.

(a) Apply a small amount of MP grease to the entire circumference of the rear input shaft oil seal ring installation groove portion.

HINT:

By applying MP grease, the wobble within the rear input shaft oil seal ring installation groove will be eliminated, preventing damage to the rear input shaft oil seal ring at the time of front planetary gear assembly installation.

(a) Apply a small amount of MP grease to the entire circumference of the input shaft oil seal ring installation groove portion.

HINT:

By applying MP grease, the wobble within the input shaft oil seal ring installation groove will be eliminated, preventing damage to the input shaft oil seal ring at the time of front oil pump assembly and torque converter clutch assembly installation.

(a) Coat the No. 7 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.

No. 7 Thrust Bearing Race Diameter:

NOTICE:

Securely insert the claw of the No. 7 thrust bearing race into the hole of the front planetary gear assembly.

HINT:

When installing the front planetary gear assembly, if the No. 7 thrust bearing race falls off, coat the front planetary gear assembly installation surface with MP grease and install the parts.

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

Thrust Needle Roller Bearing Diameter:

(a) Install the front planetary gear assembly to the front planetary ring gear.

(a) Coat the No. 8 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

No. 8 Thrust Bearing Race Diameter:

(a) Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

Thrust Needle Roller Bearing Diameter:

(a) Coat the No. 9 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

No. 9 Thrust Bearing Race Diameter:

(a) Install the planetary sun gear to the front planetary gear assembly.

(a) Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.

NOTICE:

Securely insert each protrusion of the No. 2 planetary carrier thrust washer into each indentation of the front planetary gear assembly.

(a) Install the C-3 and C-4 clutch assembly to the front planetary gear assembly.

(a) Install the planetary carrier thrust washer to the C-3 and C-4 clutch assembly.

NOTICE:

Securely insert the protrusion of the planetary carrier thrust washer into the indentation of the C-3 and C-4 clutch assembly.

(a) Install the front oil pump assembly to the automatic transaxle case sub-assembly with the 7 bolts.

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

Bolt Length:

(a) Install the manual detent spring sub-assembly to the front oil pump assembly with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

NOTICE:

• Securely insert the claw of the manual detent spring sub-assembly into the hole of the front oil pump assembly.
• Check that the roller portion of the manual detent spring sub-assembly is engaged with the manual valve lever shaft sub-assembly.

(a) Install the oil pump sprocket rear thrust washer to the front oil pump assembly.

NOTICE:

Securely insert the protrusion of the oil pump sprocket rear thrust washer into the indentation of the front oil pump assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, align the cutout of the front oil pump drive gear with the position (*a) shown in the illustration.

NOTICE:

Do not pry with excessive force when aligning the cutout of the front oil pump drive gear.

(b) Install the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly to the front oil pump assembly.

NOTICE:

• To avoid damaging the bush of the front oil pump assembly, install the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.
• Align the cutout of the oil pump drive shaft sub-assembly and the cutout of the front oil pump drive gear, and install the parts.

(a) Install the oil pump sprocket front thrust washer to the transmission oil pump drive sprocket.

NOTICE:

Securely insert the long protrusion of the oil pump sprocket rear thrust washer into the slot of the oil pump sprocket front thrust washer.

(a) Apply a small amount of MP grease to the entire circumference of the clutch drum oil seal ring installation groove portion.

HINT:

By applying MP grease, the wobble within the clutch drum oil seal ring installation groove will be eliminated, preventing damage to the clutch drum oil seal ring at the time of torque converter clutch assembly installation.

(a) Install the differential case assembly to the automatic transaxle case sub-assembly.

(a) Install the transmission lube apply tube to the transaxle housing.

NOTICE:

Insert the transmission lube apply tube until its spool portion is contacting the transaxle housing.

(b) Install the clamp to the transaxle housing with the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(a) Install the differential gear lube apply tube to the transaxle housing.

NOTICE:

Insert the differential gear lube apply tube until its spool portion is contacting the transaxle housing.

(a) Install the 3 transmission oil cleaner magnets to the transaxle housing oil separator.

(a) Install the transaxle housing oil separator to the transaxle housing with the 3 bolts.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

*a

TMC Made

*b

TMMWV Made

(b) Clean the 21 bolts and bolt holes in the automatic transaxle case sub-assembly.

Area to be Cleaned

(d) Apply seal packing to the automatic transaxle case sub-assembly as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Standard Seal Diameter:

1.8 mm (0.0709 in.)

NOTICE:

After applying seal packing, install the transaxle housing within 3 minutes and tighten the bolts within 20 minutes of applying the seal packing.

(e) Coat 5 new transaxle case gaskets with Toyota Genuine ATF WS and install it to the front oil pump assembly.

(1) Install the transaxle housing to the automatic transaxle case sub-assembly with the 9 bolts (A) and 12 bolts (B).

Torque:

29.4 N·m {300 kgf·cm, 22 ft·lbf}

Bolt Length:

(1) Install the transaxle housing to the automatic transaxle case sub-assembly with the 6 bolts (A) and 12 bolts (B).

Torque:

Bolt (A) and (B) :

29.4 N·m {300 kgf·cm, 22 ft·lbf}

Bolt Length:

(2) Apply adhesive to 2 or 3 threads on the end of the 3 bolts (C).

Bolt Length:

40 mm (1.57 in.)

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

HINT:

The 3 bolts (C) are in the locations shown in the following step.

(3) Install the 3 bolts (C).

Torque:

Bolt (C) :

22.7 N·m {231 kgf·cm, 17 ft·lbf}

(a) Install the transmission revolution sensor (NC) and spacer to the counter drive gear sub-assembly with the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(a) Install the transmission revolution sensor (NT) to the automatic transaxle case sub-assembly with the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(a) Coat 2 new transaxle case gaskets with Toyota Genuine ATF WS and install them to the automatic transaxle case sub-assembly.

(e) Align the slit portion of the manual valve and the manual valve lever sub-assembly as shown in the illustration, and install the transmission valve body assembly to the automatic transaxle case sub-assembly with the 9 bolts.

Torque:

10.8 N·m {110 kgf·cm, 8 ft·lbf}

NOTICE:

Be careful that the transmission revolution sensor (NC) wire is not pinched.

Do not let transmission revolution sensor (NC) wire ride up over this area.

(a) Coat the O-ring of the transmission wire with Toyota Genuine ATF WS.

(b) Install the transmission wire to the automatic transaxle case sub-assembly with the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(c) Connect the transmission revolution sensor (NT) connector and transmission revolution sensor (NC) connector.

*a

Transmission Wire (Temperature Sensor Wire)

*b

Transmission Revolution Sensor (NC) Wire

Do not let transmission wire protrude into this area.

(f) Engage the clamp to connect the transmission wire to the solenoid lock plate.

*a

TMC Made

*b

TMMWV Made

Area to be Cleaned

(b) Temporarily install a new transmission case side cover to the automatic transaxle case sub-assembly with the 2 bolts (A and B).

NOTICE:

To avoid damaging the gasket, prevent it from contacting the surrounding area during installation procedures.

(d) Fully tighten the 10 bolts in the order shown in the illustration.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

*a

TMC Made

*b

TMMWV Made

Area to be Cleaned

(b) Clean the 3 bolt holes shown in the illustration.

(c) Apply adhesive to 2 or 3 threads on the end of the bolt (A) and 2 bolts (D).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

HINT:

The bolt (A) and 2 bolts (D) are in the locations shown in the following step.

(d) Temporarily install a new transmission case side cover to the automatic transaxle case sub-assembly with the 2 bolts ((A) and (B)).

NOTICE:

• Bolt (A) is an adhesive-coated bolt.
• To avoid damaging the gasket, prevent it from contacting the surrounding area during installation procedures.

(f) Fully tighten the 10 bolts in the order shown in the illustration.

Torque:

Bolt (A) and Bolt (D) :

6.5 N·m {66 kgf·cm, 58 in·lbf}

Bolt (B) and Bolt (C) :

7.0 N·m {71 kgf·cm, 62 in·lbf}

(b) Engage each claw to install a new No. 1 breather plug (ATM) to the automatic transaxle case sub-assembly.

NOTICE:

Securely push in the automatic transaxle case sub-assembly until the No. 1 breather plug (ATM) is engaged.

HINT:

Install the No. 1 breather plug (ATM) with its detent aligned with the indented portion of the automatic transaxle case sub-assembly.

(a) Coat a new O-ring with Toyota Genuine ATF WS and install it to the No. 1 oil cooler outlet tube sub-assembly.

NOTICE:

Ensure that the O-ring is not twisted.

(b) Using a 19 mm union nut wrench, install the No. 1 oil cooler outlet tube sub-assembly to the automatic transaxle case sub-assembly.

Torque:

Specified tightening torque :

31.1 N·m {317 kgf·cm, 23 ft·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

  Click here

• When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

  26.7 N*m (272 kgf*cm, 20 ft.*lbf)

(a) Pass the oil cooler union sub-assembly through 2 new gaskets and temporarily install it to the automatic transaxle case sub-assembly.

(a) Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube to the transaxle housing.

Torque:

1.7 N·m {17 kgf·cm, 15 in·lbf}

(a) Using a 10 mm socket hexagon wrench, install the overflow plug and a new gasket to the transaxle housing.

Torque:

50 N·m {510 kgf·cm, 37 ft·lbf}

NOTICE:

To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

(a) Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.

Torque:

49 N·m {500 kgf·cm, 36 ft·lbf}

NOTICE:

To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

(a) Temporarily install the park/neutral position switch assembly to the automatic transaxle case sub-assembly with the 2 bolts.

(b) Temporarily install the transmission control shaft lever to the manual valve lever shaft sub-assembly.

(c) Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

(e) Align the protrusion with the neutral basic line.

(a) Install the transmission control shaft lever to the manual valve lever shaft sub-assembly with the washer and nut.

NOTICE:

Be careful of the assembly direction of the transmission control shaft lever.

Torque:

12.7 N·m {130 kgf·cm, 9 ft·lbf}