Part 3

44. ADJUST COUNTER DRIVEN GEAR PRELOAD

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

SST : 09564-33010

Turning torque:

Differential side bearing preload 3.3 to 6.0 N*m (34 to 61 kgf*cm, 29 to 53 in.*lbf)

(b) If the turning torque is not within the specified range, refer to the table below to select a shim of the counter driven gear front tapered roller bearing outer race so that the turning torque is within the specified range.

Shim Thickness: mm (in.)

45. INSTALL NO. 1 CLUTCH DISC

(a) Install the clutch flange, 4 clutch discs and 4 clutch plates to the direct multiple disc clutch assembly.

Text in Illustration

NOTICE:
Make sure that the flange, discs and plates are installed in the correct order.

(b) Using a screwdriver, install the 2 snap rings to the direct multiple disc clutch assembly.

NOTICE:
Confirm that the snap rings are correctly located in the groove of the direct multiple disc clutch assembly.

46. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC Transaxle Unit

47. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the thrust needle roller bearing and thrust needle roller race with ATF, and install them to the direct multiple disc clutch assembly.

Bearing and Race Diameter: mm (in.)

Text in Illustration

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

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

48. INSTALL NO. 2 CLUTCH DISC

(a) Install the clutch flange, 3 clutch discs and 3 clutch plates to the direct multiple disc clutch assembly.

Text in Illustration

NOTICE:
Make sure that the flange, discs and plates are installed in the correct order.

49. INSTALL DIRECT MULTIPLE DISC CLUTCH SNAP RING

(a) Coat a new O-ring with ATF and install it to the direct multiple disc clutch assembly.

Text in Illustration

(b) Coat a new intermediate shaft oil seal with ATF and install it to the direct multiple disc clutch assembly.

Text in Illustration

NOTICE:
Be sure to engage the claws on the direct multiple disc clutch assembly in the grooves on the No. 2 direct clutch piston.

(d) Using a screwdriver, install the snap ring to the direct multiple disc clutch assembly.

NOTICE:
* Position the opening of the snap ring as shown in the illustration.
* Confirm that the snap ring is correctly located in the groove of the direct multiple disc clutch assembly.
50. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC Transaxle Unit

51. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF and install it on the transaxle case.

Text in Illustration

Bearing Diameter: mm (in.)

(b) Install the direct multiple disc clutch assembly to the transaxle case.

Text in Illustration

(c) Clean the contact surfaces of the transaxle case and rear transaxle cover sub-assembly.

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

(e) Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).

(f) Calculate the end play value using the following formula:

End play = Dimension B - Dimension A

End play:

0.007 to 1.113 mm (0.000275 to 0.0438 in.)

52. INSTALL REAR TRANSAXLE COVER SUB-ASSEMBLY

(a) Using SST and a hammer, install a new needle roller bearing into the rear transaxle cover sub-assembly.

SST : 09950-60010

09951-00220

SST : 09950-70010

09951-07100

Installation depth:

21.5 to 21.9 mm (0.846 to 0862 in.)

(b) Apply adhesive to the 2 "TORX" screws.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using a "TORX" wrench (T30), install the rear transaxle cover plate to the rear transaxle cover sub-assembly with the 2 "TORX" screws.

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

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

Bearing Diameter: mm (in.)

Text in Illustration

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

Text in Illustration

(f) Coat 3 new O-rings with ATF and install them to the transaxle case.

NOTICE:
Ensure that the O-rings are not twisted.

(g) Remove packing material from the contact surfaces between the rear transaxle cover sub-assembly and transaxle case.

NOTICE:
Make sure that there is no ATF on the contact surfaces.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

(h) Install the rear transaxle cover sub-assembly to the transaxle case with the 14 bolts.

Bolt A - Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

Bolt B - Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

(i) Install a new gasket to the refill plug.

(j) Install the refill plug to the rear transaxle cover sub-assembly.

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

(k) Coat 2 new O-rings with ATF and install them to the 2 No. 1 automatic transaxle case plugs.

(l) Install the 2 No. 1 automatic transaxle case plugs to the rear transaxle cover sub-assembly.

Torque : 7.4 Nm (75 kgf-cm, 65 in-lbf)