TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

Transcription

1 016 INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL ABBREVIATIONS USED IN MANUAL 0103C06 Abbreviations ASSY Assembly ATF Automatic Transaxle Fluid B 3 U/D Brake C 2 Reverse Clutch C 3 U/D Clutch FIPG Formed In Place Gasket O/D Overdrive SSM Special Service Materials Special Service Tools U/D Underdrive w/ With w/o Without 1st First 2nd Second Meaning 6

2 40102 FRONT DIFFERENTIAL ASSY (U250E) COMPONENTS FRONT DIFFERENTIAL ASSY (U250E) 401FR01 Transaxle Housing Oil Seal Transaxle Housing Front Differential Pinion Shaft Straight Pin Front Differential Pinion Thrust Washer Front Differential Pinion Shaft No.1 Front Differential Side Gear Front Differential Side Gear Thrust Washer No.1 Front Differential Pinion Front Differential Ring Gear FR Differential Case Front Tapered Roller Bearing Outer Race FR Differential Case Front Tapered Roller Bearing 95.1 (970, 70) x10 Front Differential Case Differential Side Bearing Oil Seal Front Differential Case Rear Shim FR Differential Case Rear Tapered Roller Bearing FR Differential Case Rear Tapered Roller Bearing Outer Race N m (kgf cm, ft lbf) : Specified torque Nonreusable part MP grease G

3 4098 TRANSMISSION VALVE BODY ASSY (U250E) TRANSMISSION VALVE BODY ASSY (U250E) COMPONENTS 401FQ01 Shift Solenoid Valve S4 Solenoid Lock Plate No.3 Shift Solenoid Valve SR 10.8 (110, 8) 10.8 (110, 8) 6.6 (67, 58 in. lbf) Solenoid Lock Plate No.2 Line Pressure Control Solenoid Assy Shift Solenoid Valve SL2 Shift Solenoid Valve SL3 6.6 (67, 58 in. lbf) 10.8 (110, 8) Solenoid Lock Plate Shift Solenoid Valve DSL Shift Solenoid Valve SL1 Manual Valve N m (kgf cm, ft lbf) : Specified torque G

4 UNDERDRIVE PLANETARY GEAR ASSY (U250E) UNDERDRIVE PLANETARY GEAR ASSY (U250E) COMPONENTS FP01 Differential Drive Pinion Parking Lock Gear Cylindrical Roller Bearing Race Inner Front Planetary Gear Nut 280 (2,855, 207) Underdrive Angular Ball Bearing Inner Race (rear side) Counter Driven Gear Underdrive Angular Ball Bearing (front side) Underdrive Angular Ball Bearing (rear side) Underdrive Angular Ball Bearing Inner Race (front side) Counter Drive Gear Hole Snap Ring Underdrive Angular Ball Bearing Outer Race Underdrive Planetary Ring Hole Snap Ring Underdrive Planetary Gear Assy Underdrive Planetary Ring Gear N m (kgf cm, ft lbf) : Specified torque Nonreusable part G

5 4084 UNDERDRIVE CLUTCH ASSY (U250E) COMPONENTS UNDERDRIVE CLUTCH ASSY (U250E) 401FO01 Underdrive Clutch Plate No.1 Underdrive Clutch Flange No.1 Underdrive Clutch Drum Subassy Underdrive Clutch Piston Set Underdrive Clutch Disc No.1 Underdrive Clutch Flange No.2 Hole Snap Ring Clutch Balancer Underdrive Clutch Drum Oring Underdrive Clutch Return Spring Subassy Underdrive Return Spring Shaft Snap Ring Nonreusable part G

6 SECOND BRAKE PISTON ASSY (U250E) SECOND BRAKE PISTON ASSY (U250E) COMPONENTS FN01 2nd Brake Cylinder 2nd Brake Piston 2nd Brake Piston Return Spring Seat Shaft Snap Ring 2nd Brake Piston Oring 2nd Brake Piston Return Spring Subassy Nonreusable part D

7 DIRECT CLUTCH ASSY (U250E) COMPONENTS DIRECT CLUTCH ASSY (U250E) FM01 Direct Multiple Disc Clutch Clutch Disc Direct Multiple Disc Clutch Clutch Cushion Plate Direct Clutch Flange Hole Snap Ring Direct Clutch Flange Overdrive Clutch Plate Direct Multiple Disc Clutch Clutch Plate Overdrive Direct Clutch Hole Snap Ring Overdrive Direct Clutch Balancer Overdrive Clutch Flange Overdrive Direct Clutch Piston Overdrive Direct Clutch Disc Overdrive Direct Clutch Oring Overdrive Direct Clutch Return Spring Shaft Snap Ring Nonreusable part Overdrive Direct Clutch Drum Subassy Overdrive Clutch Return Spring Subassy Intermediate Shaft Subassy G

8 FORWARD CLUTCH ASSY (U250E) COMPONENTS FORWARD CLUTCH ASSY (U250E) FL01 Forward Clutch Return Spring Subassy Input Shaft Subassy Forward Clutch Piston Subassy Clutch Balancer No.1 Input Shaft Oil Seal Ring Forward Clutch Piston Return Spring Shaft Snap Ring Forward Clutch Flange Hole Snap Ring Forward Clutch Flange Forward Clutch Flange Forward Multiple Disc Clutch Clutch Disc Nonreusable part C

9 OIL PUMP ASSY (U250E) 4061 OIL PUMP ASSY (U250E) COMPONENTS 401FK01 Front Oil Pump Driven Gear 9.8 (100, 87 in. lbf) FR Oil Pump & Gear Body Subassy Front Oil Pump Body Oring x11 Clutch Drum Oil Seal Ring Stator Shaft Assy Front Oil Pump Drive Gear Front Oil Pump Oil Seal N m (kgf cm, ft lbf) : Specified torque Nonreusable part MP grease G

10 AUTOMATIC TRANSAXLE ASSY (U250E) AUTOMATIC TRANSAXLE ASSY (U250E) COMPONENTS FI (90, 78 in. lbf) 11 (110, 8) 5.4 (55, 48 in. lbf) Speed Sensor Speed Sensor Hose Breather Plug No.2 (ATM) ORing Transmission Wire Oil Cooler Tube Union (Inlet Oil Cooler Union) 27 (275, 20) ORing Automatic Transaxle Case No.1 Plug 7.4 (75, 65 in. lbf) ORing 6.6 (67, 58 in. lbf) Lock Plate ORing 7.4 (75, 65 in. lbf) Automatic Transaxle Case No.1 Plug ORing ORing ORing Automatic Transaxle Case No.1 Plug 7.4 (75, 65 in. lbf) Oil Cooler Tube Union (Outlet Oil Cooler Union) 27 (276, 20) Drain Plug Gasket Drain Plug 49 (500, 36) N m (kgf cm, ft lbf) : Specified torque Nonreusable part Precoated part G

11 402 AUTOMATIC TRANSAXLE ASSY (U250E) Automatic Transaxle Case No.1 Plug 7.4 (75, 65 in. lbf) 29 (295, 21) Underdrive Output Shaft Oil Seal Ring Cylindrical Roller Bearing Automatic Transaxle Case Subassy Transaxle Rear Cover Bolt A: 19 (190, 14) Other bolt: 25 (250, 18) x 11 ORing x 3 29 (296, 21) 11 (110, 8) Valve Body Oil Strainer Assy Automatic Transaxle Oil Pan Gasket x 8 x 5 22 (225, 16) Transaxle Housing Transmission Valve Body Assy x 17 ORing ORing 9.8 (100, 87 in. lbf) Differential Gear Lube Apply Tube Spacer Parking Lock Rod Subassy 11 (110, 8 ) Transmission Oil Cleaner Magnet Manual Detent Spring Subassy Transaxle Apply Tube Clamp Manual Valve Lever Subassy 20 (205, 15) Transaxle Case 2nd Brake Gasket Manual Valve Lever Shaft Retainer Spring Slotted Spring Pin Manual Valve Lever Shaft Park/Neutral Position Switch Parking Lock Pawl Bracket Spring Check Ball Body 12 (120, 9) Manual Valve Lever Shaft Oil Seal 5.4 (55, 48 in. lbf) 20 (205, 15) Compression Spring ORing Brake Drum Gasket Nut Stopper Governor Apply Gasket No (70, 61 in. lbf) C3 Accumulator Piston ORing Automatic Transaxle Case No.1 Plug 7.4 (75, 65 in. lbf) ORing x 4 Control Shaft Lever 13 (130, 9) Washer Compression Spring Automatic Transaxle Oil Pan Subassy N m (kgf cm, ft lbf) : Specified torque Nonreusable part Precoated part MP grease x (80, 69 in. lbf) Reverse Clutch Accumulator Piston ORing ORing Compression Spring B3 Accumulator Piston G

12 AUTOMATIC TRANSAXLE ASSY (U250E) 403 Oil Pump Assy Thrust Needle Roller Bearing Forward Clutch Assy Thrust Needle Roller Bearing Counter Drive Gear Overdrive Brake Gasket 22 (225, 16) Multiple Disc Clutch Clutch Hub x 7 1st & Reverse Brake Piston ORing Thrust Needle Roller Bearing Washer Counter Drive Angular Ball Bearing (Front Side) Nut 185 (1,886, 136) to 350 (3,569, 258) Flange Thrust Bearing Race No.1 Snap Ring Plate Front Planetary Gear Assy Snap Ring Counter Drive Angular Ball Bearing (Rear Side) Second Brake Piston Assy 1st & Reverse Brake Return Spring Flange Plate 1st & Reverse Brake Disc Snap Ring Brake Hub Front Planetary Ring Gear Rear Planetary Sun Gear Assy Thrust Bearing Race 2nd Brake Disc 1W ay Clutch Assy 1W ay Clutch Snap Ring Sleeve Outer Thrust Bearing Race No.3 Rear Planetary Gear Assy Thrust Bearing Race No.2 Input Sun Gear Thrust Needle Roller Bearing Thrust Bearing Snap Ring Direct Clutch Assy 1W ay Clutch Inner Race Planetary Carrier Thrust Washer No.1 Thrust Bearing Thrust Needle Roller Bearing Planetary Carrier Thrust Washer No.2 Thrust Needle Roller Bearing Transaxle Rear Cover Thrust Bearing Race O/D Direct Clutch Hub Subassy Needle Roller Bearing Rear Clutch Oil Seal Ring Outer N m (kgf cm, ft lbf) : Specified torque Nonreusable part G

13 404 AUTOMATIC TRANSAXLE ASSY (U250E) Underdrive Planetary Gear Assy Underdrive Clutch Assy Flange Underdrive 1W ay Clutch Assy Snap Ring Underdrive Cluth Disc No.2 Underdrive Brake Piston Needle Roller Bearing Thrust Bearing Underdrive Race No.2 Thrust Needle Roller Bearing Thrust Needle Roller Bearing Snap Ring Outer Race Retainer Thrust Bearing Race Plate Underdrive Clutch Drum Snap Ring Oil Seal Ring ORing Underdrive Clutch Return Spring Subassy Differential Gear Assy Parking Lock Pawl Shaft Parking Lock Pawl Tension Spring Clutch Apply Tube Brake Apply Tube 9.8 (100, 87 in. lbf) Parking Lock Pawl Pin Pawl Shaft Clamp 5.4 (55, 48 in. lbf) Transaxle Apply Tube Clamp N m (kgf cm, ft lbf) : Specified torque Nonreusable part Governor Apply Gasket No.1 G

14 INTRODUCTION GLOSSARY OF SAE AND TOYOTA TERMS TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL This glossary lists all SAEJ1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )ABBREVIATIONS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure CAC Charge Air Cooler Inter cooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft position Cam Angle CPP Clutch Pedal Position CTOX Continuous Trap Oxidizer CTP Closed Throttle Potion DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Communication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Control Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only (EEPROM), Memory Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Distributorless Ignition (DI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control FEEPROM Flash Electrically Erasable Programmable Read Only Memory FEPROM Flash Erasable Programmable Read Only Memory FF Flexible Fuel FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection Indirect Injection IFS Inertia FuelShutoff D11 7

15 018 INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL ISC Idle Speed Control KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Light MST Manifold Surface Temperature MVZ Manifold Vacuum Zone NVRAM NonVolatile Random Access Memory O2S Oxygen Sensor Oxygen Sensor, O 2 Sensor (O 2 S) OBD OnBoard Diagnostic OnBoard Diagnostic (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CC 0 OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module PNP Park/Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter SRI Service Reminder Indicator SRT System Readiness Test ST Scan Tool TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU (Electronic Control Unit) TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC ThreeWay Catalytic Converter ThreeWay Catalytic (TWC) CC RO TWC+OC ThreeWay + Oxidation Catalytic Converter CC R + CC O VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) WOT Wide Open Throttle Full Throttle 8

16 INTRODUCTION TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL 019 WUOC Warm Up Oxidation Catalytic Converter WUTWC Warm Up ThreeWay Catalytic Converter Manifold Converter 3GR Third Gear 4GR Fourth Gear 9

17 SERVICE SPECIFICATIONS HOW TO DETERMINE NUT STRENGTH STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL HU01 Nut Type Present Standard Old Standard Hexagon Nut Hexagon Nut Cold Forging Nut Cutting Processed Nut Class 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N 10N (7T) No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more B

18 SERVICE SPECIFICATIONS STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL 031 STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL HOW TO DETERMINE BOLT STRENGTH 032HS01 Mark Class Mark Class Hexagon head bolt Bolt head No T 5T 6T 7T Hexagon flange bolt w/ washer hexagon bolt 4 Protruding lines 9T T 9T 10T 11T Hexagon flange bolt w/ washer hexagon bolt 5 Protruding lines 10T No mark 4T Hexagon flange bolt w/ washer hexagon bolt 6 Protruding lines 11T Hexagon flange bolt Stud bolt No mark w/ washer hexagon bolt No mark 4T 4T Hexagon head bolt 2 Protruding lines 5T Grooved Hexagon flange bolt w/ washer hexagon bolt 2 Protruding lines 6T 6T Hexagon head bolt 3 Protruding lines 7T Welded bolt Hexagon head bolt 4 Protruding lines 8T 4T V

19 INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is made in accordance with SAE J2008. (b) Generally repair operations can be separated in the following 3 main processes: 1. Diagnosis 2. Removal and Installation, Replacement, Disassembly, Installation and Check, and Adjustment 3. Final Inspection (c) This manual explains Removal and Installation, Replacement, Disassembly, Installation and Check, and Adjustment, but Final inspection is omitted. (d) The following essential operations are not written in this manual, however these operations must be done in the practical situation. (1) Operation with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the book as a reference to help find the item to be repaired. 3. PREPARATION (a) Use of special service tools () and special service materials (SSM) may be required, depending on the repairing condition. Be sure to use and SSM when they are required and follow the working procedure properly. A list of and SSM is in the Preparation section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Illustrations of the parts catalog are placed as the disassembled parts drawing so that it enables you to understand the fitting condition of the components. (c) Nonreusable parts, grease applied parts, precoated parts and tightening torque are specified in the component illustrations. Example: A09 Stator Shaft Assy Oil Seal Ring Oil Pump Drive Gear Oil Seal x13 10 (100, 7) Oil Pump Driven Gear Oring N m (kgf cm, ft lbf) : Specified torque Nonreusable part D

20 012 INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL (d) Tightening torque, oil applying position, and nonreusable parts are described as important points in the procedure. There are cases where such information can only be indicated by an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (e) The installation procedures are the reverse order of the removal procedures. However, only installation procedures requiring additional information are included. (f) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (g) Illustrations of similar vehicle models are sometimes used. In these cases, specific details may be different from the actual vehicle. (h) The procedures are presented in a stepbystep format: (1) The illustration shows what to do and where to do. (2) The task heading tells what to do. (3) The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Illustration: what to do and where Task heading: what to do 87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using and a press, install the front differential case tapered roller bearing front inner race to the differential case ( ) Detailed text: how to do task Set part No. Component part No. D26831 HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task heading can be read at a glance when necessary, and the text below provides detailed information. Important specifications and warnings always stand out in bold type. 5. SERVICE SPECIFICATIONS (a) Specifications are presented in bold type throughout the manual. The specifications are also found in the Service Specifications section for quick reference. 6. TERMS DEFINITION CAUTION NOTICE HINT Indicates the possibility of injury to you or other people. Indicates the possibility of damage to the components being repaired. Provides additional information to help you perform the repair efficiently. 2

21 INTRODUCTION HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR MANUAL SI UNIT (a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English system. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) 3

22 034 SERVICE SPECIFICATIONS AXLE AXLE SERVICE DATA 031I703 Oil pump Body clearance Tip clearance Side clearance Drive gear thickness Driven gear thickness Pump body bushing inside diameter Stator shaft bushing inside diameter Multiple disc clutch clutch hub Inside diameter Over direct clutch drum subassy Inside diameter Forward clutch Pack clearance Return spring free length Flange thickness Reverse clutch Pack clearance: Flange thickness STD Max. STD Max. STD Max. Mark A B C D E Mark A B C D E STD Max. STD Max. STD Max. STD Max. Mark Mark to 0.17 mm ( to in.) 0.17 mm ( in.) 0.07 to 0.15 mm ( to in.) 0.15 mm ( in.) 0.02 to 0.05 mm ( to in.) 0.05 mm ( in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) to mm ( to in.) mm ( in.) to mm ( to in.) mm ( in.) to mm ( to in.) mm ( in.) to mm ( to in.) mm ( in.) 0.85 to 1.25 mm ( to in.) mm ( in.) 2.85 mm ( in.) 3.00 mm ( in.) 3.15 mm ( in.) 3.30 mm ( in.) 3.45 mm ( in.) 3.60 mm ( in.) 3.75 mm ( in.) 0.60 to 0.82 mm ( to in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) 3.6 mm (0.142 in.) 20

23 SERVICE SPECIFICATIONS AXLE 035 Direct clutch & O/D clutch Pack clearance Return spring free length Flange thickness 2nd brake Pack clearance Return spring free length Flange thickness 2nd brake piston Inside diameter U/D clutch Pack clearance U/D clutch drum bushing inside diameter Return spring free length Flange thickness U/D clutch No.2 Pack clearance Return spring free length Flange thickness Mark Mark STD Max. Mark K A G B H C J Mark Y A B C D 0.52 mm ( in.) mm ( in.) 2.5 mm (0.098 in.) 2.6 mm (0.102 in.) 2.7 mm (0.106 in.) 2.8 mm (0.110 in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 0.53 to 0.91 mm ( to in.) mm ( in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) 3.6 mm (0.142 in.) 3.7 mm (0.146 in.) More than 167 mm (6.57in.) 1.42 to 1.71 mm ( to in.) to mm ( to in.) mm ( in.) mm ( in.) 2.9 mm (0.114 in.) 3.0 mm (0.118 in.) 3.1 mm (0.122 in.) 3.2 mm (0.126 in.) 3.3 mm (0.130 in.) 3.4 mm (0.134 in.) 3.5 mm (0.138 in.) to 2.20 mm ( to in.) mm ( in.) 2.8 mm (0.110 in.) 3.0 mm (0.118 in.) 3.2 mm (0.126 in.) 3.4 mm (0.134 in.) 3.6 mm (0.142 in.) 21

24 036 SERVICE SPECIFICATIONS AXLE 1st & reverse brake Pack clearance Return spring free length Flange thickness U/D planetary gear Preload (at 60 rpm) Front planetary gear Turning torque (at 60 rpm) Input shaft End play Direct clutch to transaxle rear cover End play Mark to 1.21 mm ( to in.) mm ( in.) 1.8 mm (0.071 in.) 1.9 mm (0.075 in.) 2.0 mm (0.079 in.) 2.1 mm (0.083 in.) 2.2 mm (0.087 in.) 2.3 mm (0.091 in.) 2.4 mm (0.094 in.) 2.5 mm (0.098 in.) 0.28 to 0.89 N m (2.9 to 9.1 kgf cm, to in. lbf) 0.19 to 0.4 N m (1.9 to 4.1 kgf cm, 1.7 to 3.5 in. lbf) to mm ( to in.) to mm ( to in.) U/D planetary gear assy to U/D cylindrical roller bearing End play Race thickness Less than mm (02890in.) mm (0.2890in.) or more Transaxle rear cover Bearing press fit depth to mm ( to in.) 3.5 mm (0.138in.) 3.8 mm (0.150in.) to mm ( to in.) Transmission valve body Valve body installation bolt length A B C 25 mm (0.984 in.) 57 mm (2.244 in.) 41 mm (1.614 in.) Accumulator Spring Free length/outer diameter Color B3 Inner Outer (2.4409) / (0.610) (2.9224) / (0.854) Purple Purple Reverse clutch (2.3999) / (0.555) Yellow C (2.8425) / 19.0 (0.748) Colorless Manual valve lever shaft oil seal Oil seal drive depth Front differential Backlash Thrust washer thickness Mark to 0.5 mm ( to in.) 0.05 to 0.20 mm ( to in.) mm ( in.) mm ( in.) mm ( in.) mm ( in.) 22

25 SERVICE SPECIFICATIONS AXLE 037 Preload (at 60 rpm) Flange thickness New bearing Used bearing Mark A B C D E F G H J 0.20 to 1.0 N m (2.0 to 10.2 kgf cm, 1.8 to 8.9 in. lbf) 0.10 to 0.35 N m (1.0 to 3.6 kgf cm, 0.9 to 3.1 in. lbf) 1.90 mm ( in.) 1.95 mm ( in.) 2.00 mm ( in.) 2.05 mm ( in.) 2.10 mm ( in.) 2.15 mm ( in.) 2.20 mm ( in.) 2.25 mm ( in.) 2.30 mm ( in.) 2.35 mm ( in.) 2.40 mm ( in.) 2.45 mm ( in.) 2.50 mm ( in.) 2.55 mm ( in.) 2.60 mm ( in.) 2.65 mm ( in.) 2.70 mm ( in.) 2.75 mm ( in.) 2.80 mm ( in.) 23

26 032 SERVICE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR MANUAL 032HT01 Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt N m kgf cm ft lbf N m kgf cm ft lbf in. lbf in. lbf in. lbf in. lbf in. lbf in. lbf V

27 PREPARATION 021 PREPARATION 0247U Oil Seal & Bearing Replacer AUTOMATIC TRANSAXLE Oil Seal Puller AUTOMATIC TRANSAXLE OIL PUMP FRONT DIFFERENTIAL Transfer Bearing Replacer AUTOMATIC TRANSAXLE Transfer Bearing Replacer UNDERDRIVE PLANETARY GEAR TOYOTA Automatic Transmission Tool Set OIL PUMP UNDERDRIVE CLUTCH ( ) No.2 Piston Spring Compressor UNDERDRIVE CLUTCH ( ) Oil Seal Replacer OIL PUMP Direct Clutch Wrench AUTOMATIC TRANSAXLE FORWARD CLUTCH DIRECT CLUTCH Counter Drive Gear Holding Tool AUTOMATIC TRANSAXLE Bearing Puller Assembly AUTOMATIC TRANSAXLE ( ) Claw No.1 AUTOMATIC TRANSAXLE ( ) Claw No.2 AUTOMATIC TRANSAXLE 10

28 022 PREPARATION ( ) Pin AUTOMATIC TRANSAXLE ( ) Bearing Puller Body AUTOMATIC TRANSAXLE Under Drive Gear Puller UNDERDRIVE PLANETARY GEAR Second Brake Wrench SECOND BRAKE PISTON First & Reverse Brake Wrench AUTOMATIC TRANSAXLE Counter Drive Gear Nut Wrench AUTOMATIC TRANSAXLE Axle Hub Oil Seal Replacer UNDERDRIVE PLANETARY GEAR Bearing Replacer AUTOMATIC TRANSAXLE Rear Axle Shaft Bearing Replacer UNDERDRIVE PLANETARY GEAR Rear Axle Hub Guide Tool AUTOMATIC TRANSAXLE Rear Axle Shaft Bearing Remover AUTOMATIC TRANSAXLE Differential Side Bearing Replacer FRONT DIFFERENTIAL ( ) Replacer 48 FRONT DIFFERENTIAL 11

29 PREPARATION Differential Preload Adaptor FRONT DIFFERENTIAL Steering Knuckle Oil Seal Replacer FRONT DIFFERENTIAL Steering Knuckle Oil Seal Replacer FRONT DIFFERENTIAL Steering Knuckle Tool AUTOMATIC TRANSAXLE Base FRONT DIFFERENTIAL Lower Control Arm Bushing Replacer FRONT DIFFERENTIAL Lower Control Shaft Bearing Replacer UNDERDRIVE PLANETARY GEAR Alternator Rotor Rear Bearing Replacer AUTOMATIC TRANSAXLE Drive Shaft Nut Chisel UNDERDRIVE PLANETARY GEAR ( ) Handle UNDERDRIVE PLANETARY GEAR ( ) Nut Chisel UNDERDRIVE PLANETARY GEAR Bearing Remover AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL Bearing Remover Attachment AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL 12

30 024 PREPARATION Puller B Set AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Slide Arm AUTOMATIC TRANSAXLE ( ) Arm 25 AUTOMATIC TRANSAXLE ( ) Claw No. 6 AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL ( ) Attachment AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Holder FRONT DIFFERENTIAL Puller C Set AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL ( ) Hanger 150 AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL ( ) Slide Arm FRONT DIFFERENTIAL ( ) Center Bolt 150 AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL ( ) Claw No. 2 FRONT DIFFERENTIAL ( ) Adapter No.1 FRONT DIFFERENTIAL 13

31 PREPARATION Replacer Set AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Replacer 23 AUTOMATIC TRANSAXLE ( ) Replacer 26 UNDERDRIVE PLANETARY GEAR ( ) Replacer 32 AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR ( ) Replacer 36 AUTOMATIC TRANSAXLE ( ) Replacer 45 AUTOMATIC TRANSAXLE ( ) Replacer 48 FRONT DIFFERENTIAL ( ) Replacer 50 AUTOMATIC TRANSAXLE ( ) Replacer 59 AUTOMATIC TRANSAXLE ( ) Replacer 63 FRONT DIFFERENTIAL ( ) Adapter AUTOMATIC TRANSAXLE Replacer Set No. 2 AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Replacer 72 AUTOMATIC TRANSAXLE 14

32 026 PREPARATION ( ) Replacer 75 FRONT DIFFERENTIAL ( ) Replacer 78 AUTOMATIC TRANSAXLE ( ) Replacer 79 FRONT DIFFERENTIAL ( ) Replacer 81 AUTOMATIC TRANSAXLE ( ) Replacer 89 UNDERDRIVE PLANETARY GEAR Handle Set AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Handle 100 AUTOMATIC TRANSAXLE UNDERDRIVE PLANETARY GEAR FRONT DIFFERENTIAL ( ) Handle 150 AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL ( ) Handle 200 AUTOMATIC TRANSAXLE FRONT DIFFERENTIAL 15

33 PREPARATION 027 Recommended Tools Pin Punch AUTOMATIC TRANSAXLE Torx Socket T30 OIL PUMP Snap Ring No. 1 Expander AUTOMATIC TRANSAXLE FORWARD CLUTCH DIRECT CLUTCH Snap Ring Pliers UNDERDRIVE PLANETARY GEAR ( ) Claw Set UNDERDRIVE PLANETARY GEAR Deep Socket Wrench 41 UNDERDRIVE PLANETARY GEAR Equipment Dial indicator with magnetic base Feeler gauge Vernier calipers Torque wrench Plastic hammer Straight edge Press Lubricant item U250E Automatic transaxle fluid Dry fill Drain and refill SSM (Special Service Materials) 8.0 liter (8.5 USqts, 7.0 lmp.qts) 3.5 liter (3.7 USqts, 3.1 lmp.qts) ATF type TIV Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 16

34 038 SERVICE SPECIFICATIONS TORQUE SPECIFICATION AXLE Part Tightened N m kgf cm ft lbf Differential gear lube apply tube x Transaxle housing in. lbf Front planetary gear lock nut Brake apply tube clamp x Transaxle case in. lbf Transaxle case No. 1 plug x Transaxle rear cover in. lbf Transaxle case No.1 plug x Transaxle housing in. lbf Transaxle case No.1 plug x Transaxle case in. lbf Transaxle rear cover x Transaxle case Bolt A Other bolt Pawl shaft clamp x Transaxle case in. lbf Oil pump assy x Transaxle case Transaxle housing x Transaxle case Bolt A Bolt B Bolt C Parking lock pawl bracket x Transaxle case Manual detent spring x Transaxle case Bolt A Bolt B Transmission wire x Transaxle housing in. lbf Transmission valve body x Transaxle case ATF temperature sensor clamp x Transmission valve body in lbf Valve body oil strainer assy x Transmission valve body Automatic transaxle oil pan subassy x Transaxle case in. lbf Drain plug x Automatic transaxle oil pan subassy Speed sensor x Transaxle case Bolt A Bolt B in. lbf 8 Oil cooler tube union x Transaxle case Park/neutral start switch x nut in. lbf Park/neutral start switch x Bolt in. lbf Park/neutral start switch x Control shaft lever Oil pump body x Stator shaft assy in. lbf Line pressure control solenoid assy x Transmission valve body assy in. lbf Shift solenoid valve SL1x Transmission valve body assy in. lbf Shift solenoid valve SL2x Transmission valve body assy Shift solenoid valve SL3x Transmission valve body assy in. lbf Shift solenoid valve S4x Transmission valve body assy Shift solenoid valve DSL x Transmission valve body assy Front differential case x Front differential ring gear Front planetary gear nut I803 24

35 FRONT DIFFERENTIAL ASSY (U250E) OVERHAUL 4006M04 Matchmarks Front Differential Ring Gear 1. REMOVE FRONT DIFFERENTIAL RING GEAR (a) Put the matchmarks on the front differential ring gear and differential case. G35951 Front Differential Ring Gear (b) Remove the 10 bolts. G35952 (c) Using a plastic hammer, tap on the front differential ring gear to remove it from the case. Front Differential Ring Gear G35953 Hold Turn 2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using, remove the front differential case front differential tapered roller bearing from the differential case , , ( ), ( ) G

36 40104 FRONT DIFFERENTIAL ASSY (U250E) (b) Using, remove the front differential case front tapered roller bearing outer race D25596 Hold Turn G REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using, remove the front differential case rear tapered roller bearing from the differential case , , ( , , ), ( , , , , ), ( ), ( ) (b) Using, remove the front differential case rear tapered roller bearing outer race (c) Remove the front differential case rear shim. D REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, remove the straight pin. Before removing the straight pin, unstake it with a pin punch. G35961 Differential Case 5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO.1 (a) Remove the front differential pinion shaft No.1 from the differential case. Front Differential Pinion Shaft No.1 G

37 FRONT DIFFERENTIAL ASSY (U250E) Front Differential Side Gear 6. REMOVE FRONT DIFFERENTIAL SIDE GEAR (a) Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case. Front Differential Side Gear G REMOVE TRANSAXLE HOUSING OIL SEAL (a) Using, remove the oil seal ( ), ( ) G REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using, remove the oil seal ( ), G35960 Front Differential Side Gear 9. INSTALL FRONT DIFFERENTIAL SIDE GEAR (a) Coat the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case. Front Differential Side Gear G35958 Differential Case 10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1 (a) Coat the front differential pinion shaft No.1 with ATF, and install it to the differential case. Front Differential Pinion Shaft No.1 G

38 40106 FRONT DIFFERENTIAL ASSY (U250E) C INSPECT BACKLASH (a) Using a dial indicator, inspect the backlash of the side gear. Standard backlash: 0.05 to 0.20 mm ( to in.) Thrust washer thickness Mark Thickness mm ( in.) mm ( in.) mm ( in.) mm ( in.) 12. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN (a) Using a pin punch and hammer, install the pinion shaft straight pin. Align the holes, and install the pinion shaft straight pin. G35962 (b) Using a chisel and hammer, stake the differential case. Stake it after adjusting the backlash. G35963 G INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (a) Using and a press, install the front differential case rear tapered roller bearing to the differential case ( ), ( ), Do not damage the bearing cage during bearing inner race installation. 130

39 FRONT DIFFERENTIAL ASSY (U250E) (b) Using and a hammer, install the front differential case front tapered roller bearing outer race to the transaxle housing ( ), ( ) C83736 G INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (a) Using and a press, install the front differential case rear tapered roller bearing to the differential case , ( ), ( ) Do not damage the bearing cage during bearing inner race installation. D26449 (b) Install the front differential case rear shim. (c) Using and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing ( ), ( ) Ensure that there is no clearance between the bearing and transaxle housing. 15. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD (a) Install the differential assy to the transaxle case. G

40 40108 FRONT DIFFERENTIAL ASSY (U250E) C C C A B A D33498 (b) (c) Clean the matching surfaces of the transaxle case and transaxle housing. Install the transaxle housing to the transaxle case with the 16 bolts. Torque: Bolt A: 22 N m (224 kgf cm, 16 ft lbf) Bolt B: 29 N m (296 kgf cm, 21 ft lbf) Bolt C: 29 N m (296 kgf cm, 21 ft lbf) Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) D25604 (d) Using, turn the differential assy right and left 2 or 3 times to settle the bearing (e) Using and a torque wrench, measure the turning torque of the differential Turning torque at 60 rpm: New bearing 0.20 to 1.00 N m (2.0 to 10.2 kgf cm, 1.8 to 8.9 in. lbf) Used bearing 0.10 to 0.35 N m (1.0 to 3.6 kgf cm, 0.9 to 3.1 in. lbf) HINT: If the turning torque is not within the specified values, refer to the table below to select a shim which turning torque is within the specified values. Shim thickness: mm (in.) Mark Thickness Mark Thickness (0.0748) A 2.40 (0.0945) (0.0768) B 2.45 (0.0965) (0.0787) C 2.50 (0.0984) (0.0807) D 2.55 (0.1004) (0.0827) E 2.60 (0.1024) (0.0846) F 2.65 (0.1043) (0.0866) G 2.70 (0.1063) (0.0886) H 2.75 (0.1083) (0.0906) J 2.80 (0.1102) (0.0925) 132

41 FRONT DIFFERENTIAL ASSY (U250E) (f) Remove the 16 bolts and the transaxle housing. D26384 Differential Assy (g) Remove the differential assy. G to 100 C (194 to 230 F) 16. INSTALL FRONT DIFFERENTIAL RING GEAR (a) Using ATF and a heater, heat the front differential ring gear to 90 to 110 C (194.0 to F). Do not heat the ring gear to more than 110 C (230.0 F). (b) Clean the contact surface of the front differential case. D25215 Matchmarks Front Differential Ring Gear (c) Align the matchmarks, and install the front differential ring gear case quickly. Do not install the bolts while the ring gear is hot. G35951 (d) Tighten the 10 bolts. Torque: 95.1 N m (970 kgf cm, 70 ft lbf) Tighten the bolts a little at a time in diagonal order. G

42 FRONT DIFFERENTIAL ASSY (U250E) 17. INSTALL TRANSAXLE HOUSING OIL SEAL (a) Using and a hammer, install a new oil seal. (b) Coat the lip of the oil seal with a little MP grease. Oil seal drive in depth: mm ( in.) ( ), D INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using and a hammer, install a new oil seal. (b) Coat the lip of the oil seal with a little MP grease. Oil seal drive in depth: mm ( in.) ( ), G

43 TRANSMISSION VALVE BODY ASSY (U250E) 4099 OVERHAUL 4010J02 1. REMOVE SHIFT SOLENOID VALVE SL3 (a) Remove the bolt, solenoid lock plate No.3 and shift solenoid valve SL3 from the valve body assy. 2. REMOVE LINE PRESSURE CONTROL SOLENOID ASSY (a) Remove the line pressure control solenoid from the valve body assy. C REMOVE SHIFT SOLENOID VALVE S4 (a) Remove the bolt and shift solenoid valve S4 from the valve body assy. D REMOVE SHIFT SOLENOID VALVE SR (a) Remove the shift solenoid valve SR from the valve body assy. D REMOVE SHIFT SOLENOID VALVE DSL (a) Remove the bolt and shift solenoid valve DSL from the valve body assy. D

44 40100 TRANSMISSION VALVE BODY ASSY (U250E) 6. REMOVE SHIFT SOLENOID VALVE SL2 (a) Remove the bolt, solenoid lock plate No.2 and shift solenoid valve SL2 from the valve body assy. C REMOVE SHIFT SOLENOID VALVE SL1 (a) Remove the bolt, solenoid lock plate and shift solenoid valve SL1 from the valve body assy. C REMOVE MANUAL VALVE (a) Remove the manual valve from the valve body assy. 9. INSTALL MANUAL VALVE (a) Install the manual valve to the valve body assy. 10. INSTALL SHIFT SOLENOID VALVE SL1 (a) Install the shift solenoid valve SL1 and solenoid lock plate to the valve body assy with the bolt. Torque: 6.6 N m (67 kgf cm, 58 in. lbf) C89115 C INSTALL LINE PRESSURE CONTROL SOLENOID ASSY (a) Install the line pressure control solenoid assy to the valve body assy. 12. INSTALL SHIFT SOLENOID VALVE SL3 (a) Install the shift solenoid valve SL3 and solenoid lock plate No.3 to the valve body assy with the bolt. Torque: 6.6 N m (67 kgf cm, 58 in. lbf) 124

45 TRANSMISSION VALVE BODY ASSY (U250E) INSTALL SHIFT SOLENOID VALVE SL2 (a) Install the shift solenoid valve SL2 and solenoid lock plate No.2 to the valve body assy with the bolt. Torque: 10.8 N m (110 kgf cm, 8 ft lbf) C INSTALL SHIFT SOLENOID VALVE DSL (a) Install the shift solenoid valve DSL to the valve body assy with the bolt. Torque: 10.8 N m (110 kgf cm, 8 ft lbf) D INSTALL SHIFT SOLENOID VALVE SR (a) Install the shift solenoid valve SR to the valve body assy. D INSTALL SHIFT SOLENOID VALVE S4 (a) Install the shift solenoid valve S4 to the valve body assy with the bolt. Torque: 10.8 N m (110 kgf cm, 8 ft lbf) D

46 4092 UNDERDRIVE PLANETARY GEAR ASSY (U250E) OVERHAUL 4006K04 Underdrive Planetary Gear 1. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD (a) Using, fix the underdrive planetary gear assy , G35975 G35976 (b) Using and a torque wrench, measure the turning torque of the underdrive planetary gear assy while rotating the torque wrench at 60 rpm , Turning torque at 60 rpm.: 0.28 to 0.89 N m (2.9 to 9.1 kgf cm, to in. lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.). 2. REMOVE FRONT PLANETARY GEAR NUT (a) Using, loosen the staked part of the gear nut ( , ), , D03686 Underdrive Planetary Gear (b) Clamp the underdrive planetary gear in a soft jaw vise. Be careful not to damage the differential drive pinion. G

47 UNDERDRIVE PLANETARY GEAR ASSY (U250E) 4093 Underdrive Planetary Gear (c) Using a socket wrench, remove the gear nut. G35978 Hold Turn 3. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER (a) Using, remove the cylindrical roller bearing race inner , , ( ), ( ) D REMOVE UNDERDRIVE PLANETARY GEAR ASSY (a) Using and a press, remove the differential drive pinion, parking lock gear, counter driven gear with the underdrive planetary ring gear and angular ball bearing inner race (front side) , , ( ), ( ) G35979 Hold Turn (b) (c) Clamp the underdrive planetary gear in a soft jaw vise. Using, remove the angular ball bearing inner race (rear side) from the underdrive planetary gear , , ( ), ( ) G REMOVE UNDERDRIVE PLANETARY RING GEAR (a) Using snap ring pliers, remove the snap ring. Snap Ring G

48 4094 UNDERDRIVE PLANETARY GEAR ASSY (U250E) Underdrive Planetary Ring Gear (b) Remove the underdrive planetary ring gear from the counter driven gear. Counter Driven Gear G INSTALL UNDERDRIVE PLANETARY RING GEAR (a) Install a new snap ring to a new outer race of the angular ball bearing. HINT: When replacing the bearing, also replace the counter driven gear with a new one. Snap Ring D08112 (b) Using a piston ring compressor, squeeze the snap ring. D08113 (c) Using and a press, press in the outer race of the angular ball bearing ( ), ( ), Be sure not to damage the snap ring during outer race installation. G35983 Underdrive Planetary Ring Gear (d) Install the underdrive planetary ring gear to the counter driven gear. Counter Driven Gear G

49 UNDERDRIVE PLANETARY GEAR ASSY (U250E) 4095 Snap Ring (e) Using snap ring pliers, install the snap ring ( ), ( ), G INSTALL UNDERDRIVE PLANETARY GEAR ASSY (a) Using and a press, press the angular ball bearing inner race (rear side) into the underdrive planetary gear ( ), ( ), Press the bearing until it becomes flat at the bottom. G35985 (b) Install the counter driven gear with the planetary ring gear to the underdrive planetary gear. G35986 (c) Using and a press, press in the angular ball bearing inner race (front side) ( ), ( ), Press the counter driven gear while rotating it. G35987 (d) Using a press, press in the parking lock gear. Press the counter driven gear while rotating it ( ), ( ), G

50 4096 UNDERDRIVE PLANETARY GEAR ASSY (U250E) Differential Drive Pinion 8. INSTALL DIFFERENTIAL DRIVE PINION (a) Using a press, press the differential drive pinion , ( ), ( ) Press the counter driven gear while rotating it. D INSTALL CYLINDRICAL ROLLER BEARING RACE INNER (a) Using a press, press the cylindrical roller bearing race inner. Press the counter driven gear while rotating it , ( ), ( ) G35989 Underdrive Planetary Gear G INSTALL FRONT PLANETARY GEAR NUT (a) Clamp the underdrive planetary gear in a soft jaw vise. Be careful not to damage the differential drive pinion. (b) Using a socket wrench, install a new gear nut. Torque: 280 N m (2,855 kgf cm, 207 ft. lbf) HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.). Underdrive Planetary Gear G INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD (a) Using and a torque wrench, measure the turning torque of the underdrive planetary gear assy while rotating the torque wrench at 60 rpm , Turning torque at 60 rpm.: 0.28 to 0.89 N m (2.9 to 9.1 kgf cm, to in. lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.). 120

51 UNDERDRIVE PLANETARY GEAR ASSY (U250E) 4097 (b) Using a pin punch and hammer, stake the gear nut. Make sure that there are no cracks on the nut. C

52 UNDERDRIVE CLUTCH ASSY (U250E) 4085 OVERHAUL 400H INSPECT UNDERDRIVE PACK CLEARANCE (a) Install the underdrive clutch to the transaxle case. Be careful not to damage the oil seal rings. (b) Install a dial indicator as shown in the illustration. (c) Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kpa, 4.0 kgf/ cm 2, 57 psi). Pack clearance: 1.42 to 1.71 mm ( to in.) If the pack clearance is not within specification, inspect the discs, plates and flange. G35968 Snap Ring 2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2 HOLE SNAP RING (a) Using a screwdriver, remove the underdrive clutch flange No.2 hole snap ring. D03701 Underdrive Clutch Drum 3. REMOVE UNDERDRIVE CLUTCH DISC NO.1 (a) Remove the flange, 3 discs and 3 plates from the underdrive clutch drum. G

53 4086 UNDERDRIVE CLUTCH ASSY (U250E) 4. INSPECT UNDERDRIVE CLUTCH DISC NO.1 (a) Check to see if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the discs comes off or discolors, or a groove is damaged, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. D INSPECT UNDERDRIVE CLUTCH DRUM SUBASSY (a) Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing. Standard drum bushing: to mm ( to in.) Maximum drum bushing: mm ( in.) If the inside diameter is greater than the maximum, replace the underdrive clutch drum. D08129 Snap Ring D REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUBASSY (a) Place on the clutch balancer and compress the spring with a press ( ) (b) Using a snap ring expander, remove the snap ring. Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to in.) from the snap ring groove.this prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Clutch Balancer (c) Remove the clutch balancer from the underdrive clutch drum. Underdrive Clutch Drum C

54 UNDERDRIVE CLUTCH ASSY (U250E) 4087 (d) Remove the return spring from the underdrive clutch drum. C INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUBASSY (a) Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: mm ( in.) D REMOVE UNDERDRIVE CLUTCH PISTON SET (a) Install the underdrive clutch to the transaxle case. Be careful not to damage the oil seal rings. (b) Holding the underdrive clutch piston by hand, apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the transaxle case to remove the underdrive clutch piston. D REMOVE UNDERDRIVE CLUTCH DRUM ORING (a) Using a screwdriver, remove the Oring from the underdrive clutch drum. Oring D INSTALL UNDERDRIVE CLUTCH DRUM ORING (a) Coat a new Oring with ATF, and install it to the underdrive clutch drum. Ensure that the Oring is not twisted or pinched. Oring D

55 4088 UNDERDRIVE CLUTCH ASSY (U250E) 11. INSTALL UNDERDRIVE CLUTCH PISTON SET (a) Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum. Be careful not to damage the Oring. Be careful not to damage the lip seal of the piston. D03860 Underdrive Clutch Return Spring Underdrive Clutch Drum 12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUBASSY (a) Install the return spring to the underdrive clutch drum. C56360 Clutch Balancer Underdrive Clutch Drum (b) Coat the clutch balancer with ATF. (c) Install the clutch balancer to the underdrive clutch drum. Be careful not to damage the lip seal of the clutch balancer. When installing the return spring, ensure that all springs are fit in the clutch balancer correctly. C56359 D03703 (d) Place on the clutch balancer and compress the piston return spring with a press ( ) (e) Using a snap ring expander, install the snap ring to the underdrive clutch drum. Stop the press when the spring sheet is lowered to the place 1 to 2 mm (0.039 to in.) from the snap ring grove.this prevents the spring sheet from being deformed. Do not expand the snap ring excessively. 112