Part 3

U241E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: REASSEMBLY (Continued)

41. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Install the parking lock rod onto the manual valve lever.

42. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

(a) Install a new spacer and manual valve lever shaft into the transaxle.

(b) Using a pin punch and hammer, tap in a new pin.

(c) Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.

(d) Using a pin punch, stake the spacer through the small hole.

(e) Check that the spacer does not turn.

43. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING

(a) Using needle-nose pliers, install the retainer spring.

44. INSTALL PARKING LOCK PAWL BRACKET

(a) Install the parking lock pawl bracket with the 2 bolts.

Torque : 20 Nm (205 kgf-cm, 15 ft-lbf)

Bolt length:

25 mm (0.984 in.)

45. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY

(a) Install the manual detent spring with the 2 bolts.

NOTICE:
Make sure to install the manual detent spring and cover in this order.

Torque : 20 Nm (205 kgf-cm, 15 ft-lbf) for bolt A

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf) for bolt B

HINT
Each bolt length is indicated below.

Bolt length:

27 mm (1.063 in.) for bolt A

16 mm (0.630 in.) for bolt B

46. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it onto the B-3 accumulator piston.

(b) Coat the accumulator B-3 piston and spring with ATF, and install them to the transaxle.

Standard accumulator spring:

47. INSTALL C-1 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them onto the C-1 accumulator piston.

(b) Coat the accumulator C-1 piston with ATF, and install it into the transaxle.

Standard accumulator spring:

48. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it onto the C-3 accumulator piston.

(b) Coat the C-3 accumulator piston with ATF, and install it into the transaxle.

49. INSTALL CHECK BALL BODY

(a) Install the check ball body and spring.

50. INSTALL BRAKE DRUM GASKET

(a) Coat a new brake drum gasket with ATF, and install it into the transaxle.

51. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET

(a) Coat a new transaxle case 2nd brake gasket with ATF, and install it into the transaxle.

52. INSTALL NO. 1 GOVERNOR APPLY GASKET

(a) Coat a new No. 1 governor apply gasket with ATF, and install it into the transaxle.

53. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF and install it onto the transmission wire.

(b) Pass the transmission wire through the transaxle case.

(c) Install the transmission wire with the bolt.

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

54. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve with the pin of the lever.

(b) Install the transmission valve body assembly with the 17 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

NOTICE:
* Push the valve body against the accumulator piston springs and check ball body to install the valve body.
* First, temporarily tighten the bolts marked with (1) in the illustration because they are positioning bolts.

Bolt length:

25 mm (0.984 in.) for Bolt A

41 mm (1.614 in.) for Bolt B

45 mm (1.771 in.) for Bolt C

(c) Coat the O-ring on the ATF temperature sensor with ATF.

(d) Install the ATF temperature sensor with the lock plate and bolt.

Torque : 6.6 Nm (67 kgf-cm, 58 in-lbf)

(e) Connect the 5 shift solenoid valve connectors.

55. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF, and install it into the valve body oil strainer assembly.

(b) Install the valve body oil strainer assembly with the 3 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

56. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Install the 2 oil cleaner magnets onto the automatic transaxle oil pan sub-assembly, as shown in the illustration.

(b) Install the automatic transaxle oil pan sub-assembly and a new oil pan gasket with the 18 bolts.

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

57. INSTALL NO. 1 TRANSAXLE CASE PLUG

(a) Coat 8 new O-rings with ATF, and install them into the 8 No. 1 transaxle case plugs.

(b) Install the 4 No. 1 transaxle case plugs onto the transaxle case.

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

(c) Install the 2 No. 1 transaxle case plugs onto the transaxle housing.

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

(d) Install the 2 No. 1 transaxle case plugs onto the transaxle rear cover.

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

58. INSTALL SPEED SENSOR NT

(a) Coat a new O-ring with ATF, and install it into the speed sensor NT.

(b) Install the speed sensor NT with the bolt.

Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)

59. INSTALL SPEED SENSOR NC

(a) Coat a new O-ring with ATF, and install it into the speed sensor NC.

(b) Clean the bolt and bolt hole.

(c) Apply adhesive to 2 or 3 threads of the bolt.

Adhesive::

Toyota Genuine Adhesive 1324, Three Bond 1324or equivalent

(d) Install the speed sensor NC with the bolt.

Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)

60. INSTALL INLET OIL COOLER TUBE UNION

(a) Coat a new O-ring with ATF, and install it into the inlet oil cooler tube union.

(b) Install the inlet oil cooler tube union into the transaxle case.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

61. INSTALL OUTLET OIL COOLER TUBE UNION

(a) Coat a new O-ring with ATF, and install it into the outlet oil cooler tube union.

(b) Install the outlet oil cooler tube union into the transaxle case.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

62. INSTALL BREATHER PLUG HOSE

(a) Install the breather plug hose to the breather plug.

63. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch assembly onto the manual valve lever shaft.

(b) Provisionally install the 2 bolts.

(c) Replace the lock plate with a new one and tighten the manual valve shaft nut.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

(d) Provisionally install the control shaft lever.

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

(f) Remove the control shaft lever.

(g) Align the groove with the neutral basic line.

(h) Hold the switch in this position and tighten the 2 bolts.

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

(i) Using a screwdriver, stake the nut with the lock plate.

(j) Install the control shaft lever with the nut.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)