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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–193
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Torque: Turning torque at 60 rpm
0.5 to 1.0 N*m (5.1 to 10.0 kgf*cm, 4.4 to
8.7 in.*lbf) for new
0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to
4.4 in.*lbf) for used
(f) Using a chisel and hammer, stake the front
planetary gear washer.
9. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, bearing race and front
planetary sun gear to the planetary gear.
Standard bearing race diameter
10. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the bearing race with ATF, and install it to the
rear planetary gear.
Standard bearing race diameter
(b) Install the planetary carrier thrust washer to the
planetary gear.
D008074E02
D003873E03
Item Inside Outside
Bearing 34.6 mm (1.362 in.) 52.2 mm (2.055 in.)
Race 40.3 mm (1.587 in.) 58.0 mm (2.283 in.)
Bearing 38.6 mm (1.520 in.) 60.0 mm (2.362 in.)
D003593E01
Item Inside Outside
Race 38.6 mm (1.520 in.) 58.0 mm (2.283 in.)
D003910E01
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(c) Install the rear planetary gear to the rear planetary
ring gear.
(d) Using a screwdriver, install the snap ring to the
brake hub.
11. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT:
P = Plate
D = Disc
(b) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the piston
stroke will meet the specified value.
Pack clearance:
1.02 to 1.21 mm (0.0402 to 0.0476 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
D008062E01
D003616E02
C129389E01
D003618E01
Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
Page 1299 of 2000
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(d) Install the flange.
12. INSPECT PACK CLEARANCE OF 1ST AND
REVERSE BRAKE
13. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch outer sleeve to the 2nd
brake cylinder.
NOTICE:
Check the positioning direction of the outer
sleeve.
14. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the inner race to 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.
(c) Install the 1-way clutch and bearing to the 1-way
clutch outer race sleeve.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that no
colored race will be visible.
D003815E01
D008078E01
D003909E02
D009638E02
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
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15. 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
(c) Install the rear planetary sun gear to the rear
planetary gear.
16. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to 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.)
D003908E01
D003791E01
Item Inside Outside
Bearing 33.8 mm (1.331 in.) 48.2 mm (1.898 in.)
D003587E01
C129390E01
D009163E01
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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 its gap is visible
through the groove of the transaxle case.
17. INSTALL DIRECT CLUTCH
(a) Install the bearing race to the direct clutch.
Standard bearing diameter
(b) Install the direct clutch and thrust needle roller
bearing to 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).
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in.) 8 -
D003623E02
D003802E01
Item Inside Outside
Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.)
D003586E01
D003624E01
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(e) Measure the 2 places of the rear cover as shown in
the illustration and calculate a 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
18. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new apply gaskets to the transaxle.
19. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to 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.
20. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to 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.
D003922E01
Thickness Inside Outside
3.58 mm (0.1409 in.) 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
3.88 mm (0.1528 in.) 53.6 mm (2.110 in.) 70.18 mm (2.763 in.)
D003591E01
D003923E01
D003923E01
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(b) Install the 2 apply tubes to the transaxle with the
bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
Each pipe should be securely inserted until it
reaches the stopper.
21. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
22. INSTALL TRANSAXLE REAR 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 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
D025510E01
C134984
D009193E01
C083140E01
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(d) Coat 2 new oil seal rings with ATF, and install them
to 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 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolt
23. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Install 2 new oil seals to the transaxle.
24. INSTALL UNDERDRIVE BRAKE PISTON
(a) Wind a vinyl tape around SST at the 4.0 mm (0.157
in.) above from 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 deposited oil before
winding a vinyl tape.
D009194E01
D009946E02
D009943E01
D003914E04
D003809E01