Part 2

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY

12. INSTALL 1-WAY CLUTCH SLEEVE OUTER

(a) Install the 1-way clutch outer sleeve into the 2nd brake cylinder.

NOTICE:
Check the positioning direction of the outer sleeve.

13. INSTALL 1-WAY CLUTCH ASSEMBLY

(a) Install the inner race into the 1-way clutch.

NOTICE:
Check the direction of the inner race.

(b) Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in illustration.

Standard bearing diameter:

NOTICE:
Install the thrust bearing properly so that no colored race will be visible.

14. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the No. 1 planetary carrier thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.

(b) Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

Standard bearing diameter:

15. INSTALL 2ND BRAKE CLUTCH DISC

(a) Install the 3 discs and 3 plates onto the transaxle.

Install in order:

P - D - P - D - P - D

HINT
P = Plate

D = Disc

(b) Temporarily install the snap ring.

(c) Using a vernier caliper, measure the distance between the disc surface and snap ring surface.

(d) Select an appropriate flange so that the piston stroke will meet the specified value.

Standard pack clearance:

0.62 to 0.91 mm (0.0244 to 0.0358 in.)

HINT
Piston stroke = Clearance - Flange thickness -Snap ring thickness 1.6 mm (0.063 in.)

Standard flange thickness:

(e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

NOTICE:
Secure the snap ring so that the gap is visible through the groove of the transaxle case.

16. INSTALL DIRECT CLUTCH

(a) Install the bearing race onto the direct clutch.

Standard bearing diameter:

(b) Install the direct clutch and thrust needle roller bearing onto the rear planetary sun gear.

NOTICE:
The disc in the direct clutch should completely align with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

(c) Clean the connector part of the transaxle case and rear cover.

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

(e) Measure the 2 places on the rear cover as shown in the illustration and calculate dimension C using the following formula.

HINT
Dimension C = Dimension (1) - Dimension (2)

(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.

End play:

0.198 to 0.936 mm (0.00800 to 0.03685 in.)

NOTICE:
Make sure that the colored race side is facing the direct clutch assembly.

HINT
End play = Dimension C - Dimension B

Standard bearing thickness and diameter:

17. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Install 2 new apply gaskets onto the transaxle.

18. INSTALL FRONT CLUTCH APPLY TUBE

(a) Install the clamp onto the front clutch apply tube.

NOTICE:
Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

19. INSTALL BRAKE APPLY TUBE

(a) Install the clamp onto the brake apply tube.

NOTICE:
Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

(b) Install the 2 apply tubes into the transaxle with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

NOTICE:
Each pipe should be securely inserted until it reaches the stopper.

20. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

(a) Using SST and a press, press in the bearing.

SST : 09950-60010

09951-00230

09951-00350

Standard depth:

12.05 to 12.75 mm (0.4744 to 0.5020 in.)

NOTICE:
* Face the inscribed mark side of the bearing race up.
* Repeat the press-fit until the specified value is obtained.

(b) Apply adhesive to the 2 screws.

Adhesive:

Toyota Genuine Adhesive 1344,

Three Bond 1344 or Equivalent

(c) Using a T30 ''TORX'' socket, install the transaxle rear cover plate with the 2 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(d) Coat 2 new oil seal rings with ATF, and install them onto the transaxle rear cover.

(e) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle.

(f) Apply seal packing to the cover.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or Equivalent

(g) Coat the needle roller bearing with ATF.

(h) Apply adhesive to the threads of the bolts labeled A.

Adhesive:

Toyota Genuine Adhesive 1344,

Three Bond 1344 or Equivalent

(i) Install the 11 bolts.

Torque : 19 Nm (190 kgf-cm, 14 ft-lbf) for bolt A

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf) for other bolt

21. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Install 2 new oil seals onto the transaxle.

22. INSTALL UNDERDRIVE BRAKE PISTON

(a) Wind vinyl tape around SST 4.0 mm (0.157 in.) above the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).

SST : 09550-60010

09951-00320

NOTICE:
Clean SST to remove any oil deposits before winding a vinyl tape.

(b) Using SST and a press, press the needle-roller bearing into the transaxle until the wound vinyl tape contacts the transaxle case.

SST : 09550-60010

09951-00320

SST : 09950-70010

09951-07100

SST : 09387-00020

(c) Coat 2 new O-rings with ATF, and install them onto the underdrive brake piston.

(d) Install the underdrive brake piston into the transaxle.

23. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Install the underdrive brake return spring into the underdrive brake piston.

(b) Using SST, a snap ring expander and press, press the return spring and install the snap ring into the transaxle.

SST : 09387-00020

NOTICE:
Do not apply excessive pressure.