2002 Chevrolet Prizm

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

2001-02 AUTOMATIC TRANSMISSIONS

A245E Overhaul

APPLICATION

CAUTION: Flush oil cooler and oil cooler lines prior to transaxle
installation. Oil cooling system contamination may cause
premature transaxle failure.

TRANSAXLE APPLICATION
Application Transaxle Model
Chevrolet Prizm (LSi) A245E (1)
Toyota Corolla 1.8L A245E
(1) RPO code is MS7.

IDENTIFICATION
TRANSAXLE

Transaxles may be identified by using the Vehicle Identification Number (VIN). VIN locations
are on top left corner of instrument panel or on driver's door post. See Fig. 1 . On Prizm,
transaxle identification number is located on transaxle, above transaxle rear cover.

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Fig. 1: Locating Vehicle Identification Number Plate & Certification Label

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

GEAR RATIOS

TRANSAXLE GEAR RATIOS

Gear Range Gear Ratio
1st 3.643:1
2nd 2.008:1
3rd 1.296:1
OD 0.892:1
Reverse 2.977:1

DESCRIPTION & OPERATION

Transaxles have 4 forward speeds and reverse. Transaxle assemblies consists of a lock-up torque
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converter clutch, oil pump, valve body assembly, forward clutch, direct clutch, underdrive clutch,
differential, 3 planetary gear sets and 3 one-way clutches. See Fig. 2 .

The A245E transaxle shifting and torque converter clutch lock-up are controlled by an Engine
Control Module (ECM) on Corolla or a Powertrain Control Module (PCM) on Prizm.

To minimize possibility of incorrect operation of vehicle transaxle, a shift lock mechanism is

used. For more information, see appropriate SHIFT INTERLOCK SYSTEMS article.

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Fig. 2: Identifying Transaxle Internal Component Locations

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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LUBRICATION

NOTE: See appropriate SERVICING article.

TROUBLE SHOOTING

NOTE: Transmission malfunctions may be caused by poor engine

performance, improper adjustments, fluid condition or failure of
hydraulic, mechanical or electronic components. Ensure all
concerns have been properly checked prior to transmission
overhaul. See appropriate DIAGNOSIS article.

COMPONENT TESTS
TORQUE CONVERTER

NOTE: Torque converter is a sealed unit and must be serviced as complete

assembly. Perform following tests to check converter condition.
Torque converter and oil cooler lines must be thoroughly cleaned
and flushed if transaxle fluid is contaminated.

One-Way Clutch Test

1. Install turner and stopper of One-Way Clutch Tester (09350-32014) in torque converter.
See Fig. 3 . Turner fits in inner race of one-way clutch. Stopper fits in notch of converter
hub and outer race of one-way clutch.
2. Clutch should lock when rotated counterclockwise, and turn freely when rotated clockwise.
If necessary, clean converter and retest clutch. Replace converter if clutch does not test as
described.

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Fig. 3: Checking Torque Converter One-Way Clutch

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Drive Plate Runout Test

Measure drive plate runout. See Fig. 4 . If runout exceeds .008" (.20 mm), or if ring gear is
damaged, replace drive plate. If installing a new drive plate, note position of spacers. Tighten
bolts to 47 ft. lbs. (64 N.m).
Converter Sleeve Runout Test

1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle
resting on converter sleeve. See Fig. 5 . Rotate converter. If runout exceeds .012" (.30 mm),
ensure converter is properly mounted to drive plate.
2. If converter is properly mounted and runout exceeds specification, replace torque converter.
Mark position of converter on drive plate to ensure correct installation. Remove converter
from drive plate.

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Fig. 4: Checking Drive Plate Runout

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 5: Checking Converter Sleeve Runout

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE DISASSEMBLY

1. Remove oil cooler pipes, breather hose, manual shift lever and park/neutral position switch.
Remove filler tube and dipstick. Remove throttle cable retaining bolt. Remove solenoid
harness connector retaining bolt.
2. Remove oil pan and gasket. Remove magnet(s) from oil pan. Remove oil strainer (filter).
See Fig. 6 . Remove manual detent spring. Disconnect solenoid connectors. Remove valve
body assembly bolts. Note bolt length and location. See Fig. 7 . Remove throttle cable.
Disconnect manual valve connecting rod. Remove valve body assembly.
3. Remove solenoid sub-harness from transaxle case. Remove check ball body and spring, next
to 2nd brake accumulator. See Fig. 8 . Remove 2nd brake apply gasket. Remove 2nd brake
drum seal. See Fig. 9 and Fig. 10 .
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4. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove underdrive clutch
accumulator piston and spring. See Fig. 11 . Apply 14 psi (1 kg/cm2 ) of compressed air to
oil passage at base of piston housing to remove forward clutch accumulator piston and
springs. See Fig. 12 . Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove
direct clutch accumulator piston and spring. See Fig. 13 .
5. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove 2nd brake accumulator
piston and spring. See Fig. 14 .

NOTE: If manual shift linkage is damaged or needs to be

disassembled, see MANUAL SHIFT LINKAGE under
COMPONENT DISASSEMBLY & REASSEMBLY.

6. Remove transaxle housing bolts. Remove transaxle housing. Remove differential assembly.
Remove oil tube bracket and tubes. Remove plate. Remove apply gasket. See Fig. 15 .
Unbolt and remove oil pump assembly.

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Fig. 6: Exploded View Of Transaxle Case Valve Body & Accumulators

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 7: Identifying Valve Body Assembly Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 8: Identifying Check Ball Location

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 9: Removing 2nd Brake Apply Gasket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 10: Removing 2nd Brake Drum Seal

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 11: Removing Underdrive Clutch Accumulator Piston & Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 12: Removing Forward Clutch Accumulator Piston & Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 13: Removing Direct Clutch Accumulator Piston & Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 14: Removing 2nd Brake Accumulator Piston & Spring

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 15: Removing & Installing Apply Gasket

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

7. Apply mark to 2nd coast brake servo apply piston rod where it meets case. Apply air 57-
114 psi (4-8 kg/cm2 ) and measure piston rod travel (stroke). See Fig. 16 . Piston rod travel
should be .059-.138" (1.50-3.50 mm). If rod travel is not within specification, inspect band
further during disassembly. Remove apply tube. See Fig. 17 .
8. Remove 2nd coast brake piston snap ring. Apply 14 psi (1 kg/cm2 ) of compressed air to oil
passage to remove 2nd coast brake cover. Remove 2nd coast brake piston and spring. See
Fig. 18 .
9. Remove direct clutch with forward clutch from transaxle case. Remove direct clutch from
forward clutch. Remove thrust washer, bearings and races from forward clutch. See Fig.
19 .
10. Pull 2nd coast brake band pin and remove. Remove 2nd coast brake band. Remove front
planetary ring gear. Remove race and bearing from ring gear. See Fig. 19 .
11. Remove front planetary gear. Remove bearings and races from both sides of planetary gear.
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Remove sun gear, sun gear input drum, thrust washer, 2nd brake hub and No. 1 one-way
clutch. Using compressed air, confirm 2nd brake piston operates smoothly. See Fig. 20 .
Remove 2nd coast brake band guide.
12. Remove 2nd brake drum retaining snap ring. Remove 2nd brake drum. Remove thrust
washer and 2nd brake piston return spring. Remove plates, discs and flange. Note number
and location of components for reassembly reference. Remove No. 2 one-way clutch
retaining snap ring. Remove No. 2 one-way clutch and rear planetary gear. See Fig. 19 .
13. Remove thrust washers from both sides of planetary gear. Remove rear planetary ring gear
with bearing and races. Using feeler gauge, measure 1st and reverse pack clearance. See
Fig. 21 . Clearance should be .047-.093" (1.19-2.35 mm).
14. Remove flange retaining snap ring. Remove flange, plates and discs. Note number and
location of components for reassembly reference. Remove transaxle rear cover bolts. Tap
rear cover using a plastic hammer. Remove cover. Using chisel, release staked area of
intermediate shaft lock nut.
15. Secure counterdriven gear with appropriate holder. Remove intermediate shaft lock nut. See
Fig. 22 . Remove intermediate shaft. Press out counterdrive gear. Using chisel, release
staked area of countershaft lock nuts. Remove both lock nuts. See Fig. 23 .

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Fig. 16: Checking 2nd Coast Brake Piston Stroke

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 17: Exploded View Of Transaxle Housing & Case Components

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 18: Removing 2nd Coast Brake Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 19: Exploded View Of Transaxle Case Internal Components

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 20: Checking & Removing 2nd Brake Piston

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 21: Check 1st & Reverse Brake Clutch Pack Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 22: Removing Intermediate Shaft Lock Nut

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 23: Removing Countershaft Lock Nuts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

16. Using appropriate puller, remove counterdriven gear with thrust bearing. Remove
countershaft assembly. Remove thrust bearing and race from countershaft. Remove
underdrive clutch drum and anti-rattle clip. See Fig. 24 . Using compressed air, confirm
underdrive brake piston operates smoothly. See Fig. 25 . Remove oil seal rings. Using
appropriate press and adapter, carefully remove underdrive brake snap ring.

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Fig. 24: Identifying Underdrive Clutch Drum Anti-Rattle Clip

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

17. Remove flange, plates and discs. Note number and location of components for reassembly
reference. Remove piston return spring. Using compressed air, remove underdrive brake
piston. See Fig. 25 . Using appropriate compressor, gradually compress 1st and reverse
spring assembly and remove snap ring. See Fig. 26 .
18. Remove return spring assembly. Apply compressed air to oil passage in transaxle case and
remove 1st and reverse brake piston. See Fig. 27 . If piston does not pop out, remove using
needle-nose pliers.
19. Remove parking lock pawl stopper plate, torsion spring and spring guide. Remove pawl
shaft clamp, shaft and lock pawl. Remove parking lock sleeve and cam guide bracket. See
Fig. 17 . Remove underdrive brake accumulator piston cover and gasket. Remove
accumulator piston and spring.
20. Using appropriate puller, remove bearing from transaxle housing. Remove 3 bolts and oil
tube clamps inside transaxle housing. Remove 2 oil tubes. Remove bearing retainer bolt and
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retainer. Using appropriate puller, remove bearing from transaxle housing.

Fig. 25: Checking Underdrive Brake & Clutch Piston Operation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 26: Compressing 1st & Reverse Brake Piston Return Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 27: Checking & Removing 1st & Reverse Piston

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP

Disassembly

1. Remove race from stator shaft. Remove "O" ring and oil seal rings from oil pump body and
stator shaft. Remove clutch drum thrust washer from stator shaft.
2. Mark stator shaft and oil pump body for reassembly reference. Remove stator shaft bolts.
Separate stator shaft and oil pump body. Mark gear location for reassembly reference.
Remove pump gears. Using screwdriver, remove front seal. See Fig. 28 .
Inspection

1. Note position of oil pump gears. Clean all parts with solvent. Dry parts using compressed
air. Ensure oil passages are clear. Check driven gear-to-body clearance. Push driven gear
against one side of oil pump. Measure clearance between driven gear and oil pump body.
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See Fig. 29 . Replace oil pump body if clearance is not within specification. See OIL
PUMP CLEARANCE SPECIFICATIONS table.
2. Measure tip clearance between driven gear and crescent-shaped part of oil pump body. See
Fig. 30 . Replace oil pump body if clearance is not within specification. See OIL PUMP
CLEARANCE SPECIFICATIONS table.
3. Using feeler gauge and straightedge, measure side clearance of both gears. See Fig. 31 .
Replace oil pump body if clearance is not within specification. See OIL PUMP
CLEARANCE SPECIFICATIONS table.
4. Using a dial indicator, measure inside diameter of oil pump body bushing. Maximum inside
diameter should be 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil
pump body.
5. Measure inside diameter of stator shaft bushings. See Fig. 32 . Maximum front side bushing
inside diameter should be .849" (21.57 mm). Maximum rear side bushing inside diameter
should be 1.066" (27.07 mm). If inside diameter exceeds specification, replace stator shaft.

OIL PUMP CLEARANCE SPECIFICATIONS

Application In. (mm)
Driven Gear-To-Pump Body
Standard .0030-.0059 (.075-.149)
Maximum .012 (.30)
Gear-To-Crescent
Standard .0002-.0098 (.004-.248)
Maximum .012 (.30)
Gear Side Clearance
Standard .0008-.0020 (.020-.050)
Maximum .004 (.10)

Reassembly

1. Install NEW oil seal. Seal must be even with edge of oil pump body. Coat all components
with ATF. Install pump gears aligning reference marks. Install stator shaft on pump body.
Align bolt holes and tighten bolts to 89 INCH lbs. (10 N.m).
2. Coat thrust washer with petroleum jelly. Install thrust washer on oil pump body. Align
washer tab with oil pump body. Install oil seal rings. Use care not to over expand rings.
Using screwdrivers, check drive gear for smooth rotation. Install "O" ring. Install race on
stator shaft. See Fig. 28 .

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Fig. 28: Exploded View Of Oil Pump Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 29: Checking Oil Pump Driven Gear Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 30: Checking Oil Pump Gear Tip Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 31: Checking Oil Pump Gear Side Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 32: Measuring Stator Shaft Bushing Diameter

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DIRECT CLUTCH

Disassembly

1. Remove snap ring from direct clutch drum. Remove flange, discs and plates. Note number
and location of components for reassembly reference. See Fig. 33 . Using appropriate spring
compressor, compress spring retainer and springs. Remove snap ring, clutch spring
compressor, spring retainer and piston return springs.
2. Install direct clutch on oil pump. Apply compressed air to oil pump oval shaped oil passage
to remove piston. See Fig. 34 . Remove direct clutch from oil pump. Remove clutch piston
"O" rings.
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check
ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage
around piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled
or discolored, replace discs as necessary. Replace all damaged components as necessary.
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NOTE: New discs must be soaked in ATF for 15 minutes prior to

reassembly.

2. Measure inside diameter of direct clutch bushing. Inside diameter should be 1.900" (48.27
mm). If inside diameter exceeds specification, replace direct clutch.
Reassembly

1. Install NEW "O" rings on piston and coat with ATF. Using hand pressure, press direct
clutch piston into clutch drum with cup side upward. Use care not to damage "O" rings.
Install piston return springs, retainer and snap ring. Compress return springs and retainer
using clutch spring compressor.
2. Ensure snap ring gap does not align with spring retainer claw. Install 3 plates and 3 discs in
reverse order of removal. Install flange with flat side facing downward. Install snap ring.
Ensure snap ring gap does not align with drum cutout.
3. Install direct clutch on oil pump. Using a dial indicator, measure direct clutch pack
clearance. Apply compressed air to oil pump passage and note dial indicator reading. See
Fig. 34 . Clutch pack clearance should be .019-.035" (.49-.89 mm). If clearance is not as
specified, select appropriate flange to obtain correct piston stroke. Flanges are available in
thicknesses of .102-.126" (2.60-3.20 mm) in .008" (.20 mm) increments.

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Fig. 33: Exploded View Of Direct Clutch Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 34: Checking & Removing Direct Clutch Piston

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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FORWARD CLUTCH

Disassembly

1. Remove thrust washer. Remove thrust bearings and races from both sides of clutch. Remove
clutch drum snap ring. Remove flange, discs and plates. Note number and location of
components for reassembly reference. See Fig. 35 . Using appropriate spring compressor,
compress spring retainer and return springs.
2. Remove snap ring. Remove spring compressor, spring retainer and return springs. To
remove piston from clutch drum, apply compressed air to oil passage (hole nearest piston)
on rear of forward clutch shaft. Remove "O" rings from piston. If necessary, remove oil seal
rings.
Inspection

Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is
free in piston. Apply low air pressure to small hole in piston to check for air leakage around
piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or
discolored, replace discs as necessary. Replace all damaged components as necessary.

NOTE: New discs must be soaked in ATF for 15 minutes prior to

reassembly.

Reassembly

1. Install NEW oil seal rings (if necessary). DO NOT over expand seal rings. Install NEW "O"
rings on piston and coat with ATF. Using hand pressure, install piston in clutch drum with
cup side upward. Use care not to damage "O" rings. Install piston return springs, retainer
and snap ring. Compress return springs and retainer using clutch spring compressor. Install
snap ring so ring gap does not align with spring retainer claw.
2. Install 4 plates and 4 discs in reverse order of removal. Install flange with flat side facing
inward. Install snap ring. Ensure end gap of snap ring is not aligned with drum cutout.
Position dial indicator on piston flange. Measure piston stroke by applying compressed air
to oil passage (hole nearest piston) on rear of forward clutch shaft and note dial indicator
reading. See Fig. 36 .
3. Piston stroke should be .056-.071" (1.42-1.81 mm). If piston stroke is not as specified,
select appropriate flange to obtain correct piston stroke.
4. Flanges are available in thicknesses of .110-.142" (2.80-3.60 mm) in .008" (.20 mm)
increments. Coat thrust washer, races and bearings with petroleum jelly and install
components. See Fig. 35 .
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Fig. 35: Exploded View Of Forward Clutch

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 36: Measuring Forward Clutch Piston Stroke

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

FRONT PLANETARY GEAR

Disassembly

1. Check No. 1 one-way clutch operation. Hold sun gear (shell) and turn hub. Hub should
rotate freely clockwise and lock when turned counterclockwise. See Fig. 37 . Remove 2nd
brake hub and No. 1 one-way clutch from sun gear.
2. Remove thrust washer from sun gear input drum. Remove snap ring. Remove sun gear input
drum. Remove shaft snap ring from sun gear. Remove one-way clutch retainer if clutch
requires replacement. Remove one-way clutch from hub. See Fig. 38 .
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Check thrust bearings, races
and one-way clutch for wear or damage. Replace if necessary.
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2. Measure inside diameter of sun gear flange bushing. Standard inside diameter should
be .867-.868" (22.03-22.05 mm). Maximum inside diameter is .870" (22.10 mm). If inside
diameter exceeds specification, replace flange.
3. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-
.020" (.20-.50 mm). Maximum clearance is .020" (.50 mm). If clearance exceeds
specification, replace planetary gear. See Fig. 39 .
4. Measure inside diameter of ring gear flange bushing. Standard inside diameter should
be .749-.750" (19.03-19.05 mm). If inside diameter exceeds specification, replace flange.
Reassembly

Install shaft snap ring to sun gear. Install sun gear to drum. Install snap ring to drum. Install thrust
washer to sun gear input drum. See Fig. 38 . Rotate hub clockwise. Install one-way clutch and
2nd brake hub. Check one-way clutch operation. Hold sun gear and rotate hub. Hub should rotate
freely clockwise and lock counterclockwise.

Fig. 37: Checking No. 1 One-Way Clutch

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 38: Exploded View Of Front Planetary Gear

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 39: Measuring Planetary Gear Thrust Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR PLANETARY GEAR

Disassembly

1. Check No. 2 one-way clutch operation. Hold outer race and rotate hub. Hub should rotate
freely counterclockwise and lock clockwise. See Fig. 40 .
2. Remove thrust washers from both sides of planetary gear. Separate No. 2 one-way clutch
and planetary gear. Remove snap rings and side retainers from No. 2 one-way clutch. Note
position of No. 2 one-way clutch and remove from outer race. See Fig. 41 .
Inspection

Clean all parts with solvent. Dry parts using compressed air. Check thrust washers and one-way
clutch for wear or damage. Replace damaged parts as necessary. Measure planetary pinion gear
thrust clearance. Standard clearance should be .008-.020" (.20-.50 mm). Maximum clearance
is .020" (.50 mm). If clearance exceeds specification, replace planetary gear. See Fig. 39 .
Reassembly

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1. Coat all parts with ATF. Install one-way clutch into outer race. Flanged side should face
inward away from shiny side of outer race. See Fig. 40 . Install side retainers and snap
rings.
2. Install planetary gear into one-way clutch. Planetary gear inner race should face inward
from back side of outer race. Check operation of one-way clutch. See Fig. 40 . Coat thrust
washers with petroleum jelly. Install thrust washers on both sides of gear, aligning thrust
washer tab with hollow area in gear.

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Fig. 40: Installing & Checking No. 2 One-Way Clutch

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 41: Exploded View Of Rear Planetary Gear

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1ST & REVERSE BRAKE PISTON

Disassembly

1. Using appropriate compressor, compress springs. See Fig. 42 . Remove spring retainer snap
ring and compressor.
2. Remove piston return spring assembly. Apply compressed air to oil passage in transaxle case
to remove piston. See Fig. 27 . Remove piston "O" rings.
Inspection

Clean all parts with solvent. Dry parts using compressed air. Inspect piston for roughness or
damage. Replace as necessary.
Reassembly

1. Install NEW "O" rings on piston and coat with ATF. Install piston in transaxle case with
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spring seats facing upward. Position piston return spring assembly and snap ring in place.
See Fig. 42 .
2. Using clutch spring compressor, compress piston return springs. Avoid bending spring
retainer or damaging transaxle case by overtightening compressor. Push snap ring into place
with fingers.
3. Ensure snap ring is fully seated and centered by spring retainer lugs. Ensure snap ring end
gap is not aligned with cutouts. Remove spring compressor.

Fig. 42: Exploded View Of 1st & Reverse Brake Piston

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2ND COAST BRAKE

Disassembly

1. Prior to disassembly, check brake piston stroke. Apply paint to piston rod at point rod meets
transaxle case. Apply compressed air to oil passage and measure piston stroke using
appropriate wire gauge set. Piston stroke should be .059-.138" (1.50-3.50 mm). See Fig.
16 .
2. If piston stroke exceeds specification, check brake band. If brake band is serviceable but
piston rod stroke is not within specification, select NEW piston rod. Piston rod is available
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in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm).

3. Remove oil seal from piston. Remove "E" ring while pushing piston with needle-nose pliers.
Remove spring, washer and piston rod. See Fig. 43 .
Inspection

Replace brake band if lining is peeled or discolored or printed numbers are defaced. Before
assembling NEW band, soak in ATF for 15 minutes.
Reassembly

Install washer and spring to piston rod. Install "E" ring. Install oil seal ring. DO NOT expand oil
seal ring ends more than necessary for installation. See Fig. 43 .

Fig. 43: Exploded View Of 2nd Coast Brake

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2ND BRAKE PISTON

Disassembly & Reassembly

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Apply compressed air to oil passage and remove 2nd brake piston. See Fig. 20 . Remove "O"
rings from piston. Coat NEW "O" rings with ATF and install. Carefully press 2nd brake piston
into 2nd brake drum. See Fig. 44 .

Fig. 44: Exploded View Of 2nd Brake Piston

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COUNTERSHAFT ASSEMBLY

Disassembly

1. Remove planetary sun gear from countershaft. Remove snap ring from sun gear and
countershaft assembly. Remove underdrive planetary gear, thrust bearing and race. See Fig.
45 .
2. Remove drive pinion with output flange, outer bearing, race and spacer. Note thickness and
size of bearing race. Remove ring gear retaining snap ring. Remove ring gear from
countershaft.
3. Remove remaining bearing from countershaft. Remove outer bearing race from drive pinion
using a brass punch and hammer. Note size of bearing and bearing race.
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Inspect bearings, races, thrust
bearing and race, drive pinion and gears for wear or damage. Replace components as
necessary.
2. Measure inside diameter of planetary sun gear bushing. Standard diameter should be 1.173-
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1.174" (29.80-29.83 mm). Maximum inside diameter is 1.176" (29.87 mm). If clearance
exceeds specification, replace planetary sun gear.
3. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-
.020" (.20-.50 mm). See Fig. 39 . If clearance exceeds specification, replace planetary gear
assembly.
Reassembly

1. Press bearing of thick inner race on countershaft. Install ring gear and snap ring to
countershaft. Install bearing outer races to drive pinion. Press thick bearing race into flange
side of drive pinion. Using adapters, press thin bearing race on remaining side of drive
pinion. See Fig. 45 .
2. Install NEW spacer on countershaft. Install drive pinion on countershaft. Using bearing
installer, install remaining countershaft bearing. Ensure clearance exists between output
flange and bearing. Install inner race.
3. Temporarily install counterdriven gear on countershaft. Secure counterdriven gear. Install
NEW lock nut. DO NOT use old lock nut. Countershaft bearing preload must be checked.
Tighten lock nut to 130-159 ft. lbs. (177-216 N.m).
4. Using Countershaft Adapter (09351-32170) and a spring scale, measure starting torque of
countershaft. Before measuring starting torque, turn countershaft firmly to seat bearing.
Starting torque should be 2.6-4.4 lbs. (1.2-2.0 kg). Replace spacer if starting torque exceeds
specification. Recheck starting torque. See Fig. 46 .
5. Using a punch and hammer, stake lock nut. Remove counterdriven gear. Install thrust
bearing and race "H". See Fig. 75 . Install underdrive planetary gear and snap ring. Install
snap ring to sun gear. Install planetary sun gear to countershaft. See Fig. 45 .

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Fig. 45: Exploded View Of Countershaft Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 46: Measuring Countershaft Torque

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

UNDERDRIVE CLUTCH & NO. 3 ONE-WAY CLUTCH

Disassembly

1. Remove one-way clutch and thrust washer from underdrive clutch drum. Remove snap ring
from underdrive clutch drum. See Fig. 47 . Remove flange, discs and plates from clutch
drum. Note number and location of components for reassembly reference. Using appropriate
spring compressor, compress return spring plate.
2. Remove snap ring. Remove return spring and spring plate. Install oil seal rings to transaxle
case (if necessary). Install underdrive clutch to transaxle case. Apply compressed air to oil
passage in transaxle case to remove piston. See Fig. 25 . Remove "O" rings from piston.
Inspection

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1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and
plates for wear or burnt areas. If discs are peeled or discolored, replace discs as necessary.
2. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check
for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. Replace
all damaged components.

NOTE: New discs must be soaked in ATF for 15 minutes prior to

installation.

3. Measure inside diameter of underdrive clutch drum bushing. Standard diameter for front
side of bushing should be 1.831-1.832" (46.50-46.53 mm). Standard diameter for rear side
of bushing should be 2.165-2.167" (55.00-55.03 mm). Maximum inside diameter should be
1.833" (46.57 mm) for front side and 2.169" (55.08 mm) for rear side. Replace underdrive
clutch drum if not within specification.
Reassembly

1. Coat "O" rings with ATF. Install "O" rings on piston. Carefully install underdrive clutch
into clutch drum. Install spring plate and return spring to underdrive clutch. Compress return
spring and install snap ring.
2. Ensure snap ring end does not align with spring retainer claw. Install 3 plates and 3 discs in
reverse order of disassembly, ending with disc. Install flange with round end facing inward.
Install snap ring.
3. Measure underdrive clutch piston stroke. Mount dial indicator so tip rests on underdrive
clutch assembly. Apply air pressure to activate piston. See Fig. 25 . Piston stroke should
be .059-.075" (1.50-1.90 mm). If piston stroke is not within specification, replace flange.
4. Flanges are available in thicknesses of .080" (2.04 mm), .087" (2.20), .094" (2.40 mm)
and .098" (2.50 mm). Install appropriate flange to obtain correct clearance.
5. Install thrust washer on underdrive clutch drum. Install underdrive one-way clutch on
underdrive clutch drum. Retainer claw must be facing upward. Check operation of one-way
clutch. Hold clutch drum and rotate one-way clutch. One-way clutch should turn freely
counterclockwise and lock clockwise. See Fig. 47 .

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Fig. 47: Exploded View Of Underdrive Clutch & No. 3 One-Way Clutch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

UNDERDRIVE BRAKE & ACCUMULATOR

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Disassembly

1. Compress return spring and remove snap ring. Remove plates, discs and flange. Note
number and location of components for reassembly reference. Remove return spring.
Remove oil seal rings (if necessary).
2. Apply compressed air to oil passage in transaxle case to remove underdrive piston from
transaxle case. See Fig. 25 . Remove "O" rings from piston. Remove oil gallery cover and
gasket. Remove accumulator piston and spring from transaxle case. Remove "O" ring from
piston. See Fig. 48 .
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and
plates for wear or burnt areas. If discs are peeled or discolored, replace discs as necessary.
2. Inspect underdrive brake piston. Ensure check ball is free by shaking piston. Ensure valve
does not leak by applying low pressure compressed air to small hole in piston.

NOTE: New discs must be soaked in ATF for 15 minutes prior to

reassembly.

Reassembly

1. Coat NEW "O" ring with ATF and install on accumulator piston. Install accumulator piston
and spring. Install oil gallery gasket and cover. Tighten bolts to 89 INCH lbs. (10 N.m).
Apply thread sealant to screws for oil gallery cover. Install screws and tighten to 65 INCH
lbs. (7.4 N.m).
2. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in
transaxle case with cupped side upward. Use care not to damage "O" rings. Install brake
piston return spring. Install 3 plates and 3 discs. Install flange with flat end facing inward.
3. Using spring compressor, compress return spring. Install snap ring. Ensure snap ring end gap
is not aligned with cutout. Using compressed air, ensure underdrive brake piston operates
smoothly. See Fig. 25 .

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Fig. 48: Exploded View Of Underdrive Brake & Accumulator

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VALVE BODY ASSEMBLY

NOTE: All valve body assembly components must be installed in original

location. Arrange components in sequence during removal for
reassembly reference. Throttle pressure is changed according to
number of adjusting rings. When assembling valve body, install
same number of adjusting rings as were removed. Some valve
bodies do not have adjusting rings.

CAUTION: Note position of throttle valve adjusting screw before

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disassembly. Note which step at end of primary regulator

valve sleeve contacts valve body prior to removal. Line
pressure is affected by plunger location. See Fig. 49 .

Disassembly

Remove throttle cam. Remove solenoids. Remove pressure relief valve. Remove 19 bolts from
lower valve body. See Fig. 50 . Hold plate against lower valve body and carefully remove lower
valve body. DO NOT lose check balls. Note location of check balls, retainers, pins and plugs in
valve body. Remove plate and gasket. See Fig. 51 .

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Fig. 49: Identifying Adjusting Screw & Plunger Sleeve Locations

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 50: Identifying Lower Valve Body Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 51: Exploded View Of Valve Body Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
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1. Clean all parts with solvent. Dry parts with compressed air. When disassembling upper or
lower valve body, maintain parts in order for reassembly reference. Ensure each valve is
kept with corresponding spring. For upper and lower valve body exploded views, see Fig.
52 .
2. Ensure all valve body oil passages are clear. Inspect valves for scoring or roughness. Inspect
valve springs for damage, squareness, rust and collapsed coils. Measure spring free length
and outer diameter.
3. Replace spring if not within specification. See appropriate VALVE BODY SPRING
SPECIFICATIONS table. Ensure valve body springs correspond with appropriate valve.
Ensure check balls, pins, retainers, strainers and vibrating stopper are installed in
appropriate locations. See Fig. 53 and Fig. 54 .

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Fig. 52: Exploded View Of Upper & Lower Valve Bodies

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 53: Upper Valve Body Check Ball Locations

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 54: Locating Lower Valve Body Strainers

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VALVE BODY SPRING SPECIFICATIONS (LOWER)

Application Color Free Length - In. (mm)
Cooler By-Pass Valve None .965 (24.50)
Pressure Relief Valve Red .709 (18.00)
2-3 Shift Valve Red 1.004 (25.50)
2nd Coast Modulator Valve White 1.268 (32.20)
Cut-Back Valve None .740 (18.80)
Primary Regulator Valve Red 1.638 (41.60)
1-2 Shift Valve Red 1.004 (25.50)
Reverse Control Valve None 1.008 (25.60)

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Accumulator Control Valve Pink 1.154 (29.30)

Low Coast Modulator Valve Blue 1.122 (28.50)

VALVE BODY SPRING SPECIFICATIONS (UPPER)

Application Color Free Length - In. (mm)
Secondary Regulator Valve None 1.449 (36.80)
Lock-Up Relay Valve None .740 (18.80)
3-4 Shift Valve Red 1.004 (25.50)
Downshift Plug Yellow 1.075 (27.30)
Throttle Valve Red .689 (17.50)

Reassembly

1. Coat all components with ATF. To reassemble, reverse disassembly procedure. Position
NEW No. 2 gasket, plate and NEW No. 1 gasket on lower valve body. Ensure gaskets are
installed in correct locations. See Fig. 55 .
2. Place lower valve body with plate and gaskets on upper valve body. DO NOT let
components separate. Align each bolt hole in valve bodies with gaskets and plate. Turn
assembly over and install lower valve body cover.
3. Install and finger tighten bolts in lower valve body to secure upper valve body. See Fig. 50 .
Tighten valve body bolts to specifications. See TORQUE SPECIFICATIONS . Install
NEW "O" rings on solenoids. Lubricate "O" rings with ATF and install solenoids. Tighten
torque converter clutch solenoid bolt to 58 INCH lbs. (6.5 N.m). Tighten No. 2 solenoid
bolt to 89 INCH lbs. (10 N.m).

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Fig. 55: Identifying Valve Body Gaskets

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MANUAL SHIFT LINKAGE

Disassembly & Reassembly

Unstake manual valve shaft spacer and remove. Drive out roll pin. Remove retaining hitch pin.
Slide out shaft and remove manual valve lever and washer. Replace shaft seal as needed. To
reassemble, reverse disassembly procedure. See Fig. 6 .

DIFFERENTIAL

Disassembly

1. Mark ring gear and differential case for reassembly reference. Remove ring gear bolts and
lock tabs. Using brass hammer, tap ring gear from differential case. Remove bearings from
differential case using appropriate bearing splitter and puller. Remove speedometer drive
gear.
2. Use a dial indicator to check side gear backlash. Hold one pinion against differential case.
Measure side gear backlash. See Fig. 56 . Backlash should be .002-.008" (.05-.20 mm). If
backlash is not within specification, side gear thrust washers must be replaced.
3. Drive out pinion shaft lock pin from ring gear side. Remove pinion shaft, pinion gears, side
gears, and thrust washers. See Fig. 57 . Remove oil seals from transaxle housing and
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transaxle case. Remove bearing outer races and shims from transaxle case and housing.
Inspection

Clean all parts with solvent. Dry parts using compressed air. Check bearings and gears for wear
or damage. Replace parts as necessary.
Reassembly

1. Install bearing outer races and original shims in transaxle housing and case. Select thrust
washers that will ensure correct side gear backlash. Thrust washers are available
in .002" (.05 mm) increments, in thicknesses from .037-.047" (.95-1.20 mm). Install thrust
washers and side gears in differential case.
2. If possible, install same size thrust washers on both sides. Install pinion gears and pinion
shaft. Check gear backlash to ensure proper thrust washers are used. When backlash is
correct, drive lock pin through differential case and into pinion shaft. Stake differential case
to retain lock pin.
3. Press side bearing on differential case. Install speedometer drive gear on differential case.
Install remaining side bearing on differential case.
4. Install differential in transaxle case. Install transaxle housing. Install bolts in correct
locations and tighten bolts to 21 ft. lbs. (29 N.m). See Fig. 58 . Measure differential bearing
preload, using Differential Preload Adapter (09564-32011) and an INCH-lb. torque
wrench. See Fig. 59 .
5. Preload must be within specification. See DIFFERENTIAL PRELOAD
SPECIFICATIONS table. If preload is incorrect, remove differential from transaxle case
and replace adjusting shim under bearing. Adjusting shims are available in thicknesses
of .079-.114" (2.00-2.90 mm) in .002" (.05 mm) increments. Preload will change
approximately 2.6-3.5 INCH lbs. (.3-.4 N.m) with each shim thickness.
6. When correct preload is obtained, remove differential from transaxle case. Install ring gear
on differential case. Clean ring gear and mounting surface. Heat ring gear to 212°F (100°C)
in an oil bath. DO NOT heat ring gear to temperatures greater than 230°F (110°C). Align
ring gear on differential case and install NEW bolts. Tighten bolts evenly in crisscross
pattern to 72 ft. lbs. (97 N.m).
7. Stake locking tabs. Stake one tab flush with flat surface of nut. Stake 2nd tab against corner
of nut on tightening side. Coat lip of oil seals with multipurpose grease.

DIFFERENTIAL PRELOAD SPECIFICATIONS

Application INCH Lbs. (N.m)
New Bearings 7.1-12.4 (.8-1.4)
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Used Bearings 3.5-6.2 (.4-.7)

Fig. 56: Measuring Differential Pinion Gear Backlash

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 57: Exploded View Of Differential Assembly

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 58: Installing Transaxle Housing Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 59: Measuring Differential Bearing Preload

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE REASSEMBLY

NOTE: Coat all oil seal rings, discs, plates, rotating parts and sliding
surfaces with ATF prior to reassembly. Use petroleum jelly to hold
bearings and races in place. Discs should be soaked in ATF for at
least 15 minutes prior to installation.

NOTE: For bearing race and thrust bearing specifications and location, see
Fig. 75 .

1. Install oil tube apply cover and gasket (if equipped). Install oil tubes. Install oil tube
clamps. Install underdrive brake accumulator piston and spring. See Fig. 17 .
2. Install oil gallery cover and gasket. Tighten bolts to 89 INCH lbs. (10 N.m). Apply thread
sealant to screws for oil gallery cover. Install screws and tighten to 65 INCH lbs. (7.0 N.m).
3. Install cam guide bracket. Install parking lock rod in guide bracket. Install parking lock
sleeve with raised portion up. Install stopper plate on raised portion of lock sleeve. Install
guide sleeve and spring. Install parking lock pawl, pawl shaft and shaft clamp. See Fig. 17 .
4. Install NEW "O" rings on 1st and reverse brake piston. Lubricate "O" rings with ATF.
Using appropriate compressor, press 1st and reverse brake piston into transaxle case.
5. Install piston return spring and snap ring. Avoid bending spring retainer by overtightening
bolt. See Fig. 26 . Ensure snap ring is fully seated and centered by 3 lugs on spring retainer.
Ensure end gap of snap ring is not aligned with spring retainer claw.
6. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in
transaxle case with cup side upward. Use care not to damage "O" rings. Install brake piston
return spring. Install 3 plates and 3 discs. Start with plate and alternate with disc ending
with disc. Install flange with flat end down.
7. Using appropriate compressor, compress return spring. Install snap ring. Ensure snap ring
end gap is not aligned with cutout. Using compressed air, confirm underdrive brake piston
moves smoothly. See Fig. 25 . Install oil seal rings to transaxle case.
8. Place counterdrive gear on press platform with NEW spacer installed. Place case on gear.
Press bearing onto counterdrive shaft until seated. Install intermediate shaft. Install lock nut.
Secure counterdrive gear from turning and tighten lock nut to 131 ft. lbs. (177 N.m).
9. Using INCH-lb. torque wrench, measure starting torque of intermediate shaft at
counterdrive gear lock nut. See Fig. 60 . Starting torque for new bearings is 2.7-6.2 INCH
lbs. (.3-.7 N.m). Starting torque for used bearings is 1.8-3.5 INCH lbs. (.2-.4 N.m).
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Fig. 60: Measuring Drive Gear Turning Torque

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

10. If starting torque is less than specification, replace spacer and recheck. Stake lock nut in
place.
11. Install underdrive one-way clutch assembly. Install anti-rattle clip. See Fig. 24 . Align
clutch disc tabs in underdrive brake and install underdrive clutch assembly. Check operation
of underdrive one-way clutch. Clutch should turn freely counterclockwise and lock
clockwise. See Fig. 62 .
12. Measure clutch assembly height from sleeve to inner race. Height should be .681-
.717" (17.29-18.21 mm). See Fig. 63 . Check underdrive clutch piston stroke. Position dial
indicator stem on underdrive clutch assembly. See Fig. 64 . Apply compressed air to oil
passage in transaxle case. See Fig. 25 .
13. Piston stroke should be .059-.075" (1.50-1.90 mm). If piston stroke is not within
specification, install correct flange. Flanges are available in thicknesses of .080" (2.04 mm),
.087" (2.20 mm), .094" (2.40 mm) and .098" (2.50 mm). Install thrust bearing "G". See Fig.
75 . Install sun gear in transaxle case.
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14. Align clutch disc tabs in underdrive clutch. Install countershaft assembly. Check
countershaft height. Measure distance from tip of countershaft to bolt seat of clutch support.
See Fig. 65 . Countershaft height should be 1.193-1.280" (30.30-32.50 mm).
15. Install thrust bearing "F". See Fig. 75 . Press in counterdriven gear. Install NEW lock nut.
Using holder and adapter, tighten lock nut to 133 ft. lbs. (180 N.m). Stake lock nut. Using a
dial indicator, measure countershaft end play. See Fig. 61 . End play should be .008-
.035" (.20-.89 mm).

Fig. 61: Checking Countershaft End Play

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

16. Apply gasket sealer to rear cover sealing areas. Install transaxle rear cover and bolts. Ensure
bolts are installed in correct locations. See Fig. 66 . Tighten bolts to 89 INCH lbs. (10
N.m). Ensure intermediate shaft turns smoothly.

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Fig. 62: Checking Underdrive Clutch Operation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 63: Measuring Underdrive Clutch Assembly Height

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 64: Measuring Underdrive Clutch Piston Stroke

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 65: Measuring Height Of Countershaft

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 66: Identifying Transaxle Rear Cover Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

17. Install 1st and reverse brake components in transaxle case. Install 6 discs and 6 plates. Start
with plate, alternate with disc, ending with disc. Install outer flange with flat area facing
inward. Install snap ring in groove. Ensure end gap does not align with transaxle case
cutout.
18. Check 1st and reverse brake clutch pack clearance. See Fig. 21 . Clearance should be .047-
.093" (1.19-2.35 mm). Install thrust bearing and races "A" in rear planetary ring gear. See
Fig. 75 . Align disc tabs. Install thrust washer on rear planetary gear. Ensure tabs align with
grooves of gear.
19. Align spline of planetary gear with tabs of 1st and reverse brake discs. Install rear planetary
gear into 1st and reverse brake. Ensure inner surface of rear planetary gear is below upper
surface of flange. See Fig. 68 . Install No. 2 one-way clutch with shiny side upward. Rotate
planetary gear clockwise while installing No. 2 one-way clutch.
20. Check No. 2 one-way clutch operation. Planetary gear should rotate clockwise and lock
counterclockwise. See Fig. 69 . Install thrust washer on planetary gear. Install snap ring.
Ensure end gap of snap ring is not aligned with case cutouts.
21. Install 2nd brake flange with flat end facing upward. Install 3 discs and 3 plates, starting
with disc, alternating with plate and ending with plate. Install piston return spring assembly
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with springs over case protrusions. Install 2nd brake band guide with tip contacting
transaxle case. Align 2nd brake drum groove with bolt in transaxle case.
22. Install 2nd brake drum. Install snap ring in groove while compressing piston return springs
with hammer handles. Ensure end gap of snap ring is not aligned with transaxle case cutouts.
Install 2nd brake drum gasket in center oil passage until it contacts 2nd brake drum. Apply
compressed air into 2nd brake oil passage in transaxle case. Ensure 2nd brake piston
operates smoothly. See Fig. 20 .
23. Align 2nd brake disc tabs. Install No. 1 one-way clutch and 2nd brake hub. Check distance
between surface of 2nd brake hub and rear planetary gear. See Fig. 70 . Distance should be
approximately .20" (5.0 mm). Install thrust washer on sun gear input drum. Install sun gear
and sun gear input drum. Rotate sun gear clockwise while installing gear into one-way
clutch.
24. Install thrust bearing and race "B" on front planetary gear. See Fig. 75 . Install planetary
gear. Install thrust bearing and race "C" on front planetary ring gear. See Fig. 75 . Install
front planetary ring gear. Install intermediate shaft oil seal ring.
25. If components installed in transaxle case are correctly installed, end of ring gear flange
bushing will be even or slightly lower than intermediate shaft shoulder. See Fig. 71 . Install
thrust bearing and races "D" on tip of ring gear flange. Install 2nd coast brake band into
transaxle case. Install pin.
26. Install thrust bearing and race "E" on forward clutch drum. See Fig. 75 . Install clutch drum
thrust washer on direct clutch drum with oil groove facing upward. Align clutch disc tabs.
Install direct clutch into forward clutch. If tabs are aligned with hub correctly, end of direct
clutch drum bushing will be flush with surfaces of forward clutch.
27. Rotate forward clutch to mesh with front planetary gear and discs. Install direct clutch and
forward clutch into transaxle case. Check installation of direct/forward clutch assembly.
Measure distance between direct clutch and sun gear drum (shell). See Fig. 72 . Distance
should be .118" (3.0 mm).
28. Install spring, 2nd coast brake piston and cover into bore. Install snap ring. Ensure front end
of piston rod contacts center of 2nd brake band depression.
29. Measure 2nd coast brake piston stroke by applying compressed air to oil passage in
transaxle case. See Fig. 16 . Piston stroke should be .059-.138" (1.50-3.50 mm). Replace
rod if stroke is not within specification. Rod lengths are available in lengths of
2.811" (71.40 mm) and 2.870" (72.90 mm). Install apply gasket in transaxle case. See Fig.
15 .
30. Install differential. Install apply tube if removed. Apply gasket sealer (Three Bond 1281 or
equivalent) to transaxle housing. Install transaxle housing. Install mounting bolts in original
locations. Apply thread sealant to 1.38" (35 mm) bolt threads. See Fig. 58 . Tighten bolts to
21 ft. lbs. (29 N.m). Check differential side bearing preload. See DIFFERENTIAL under
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COMPONENT DISASSEMBLY & REASSEMBLY.

31. Install race on stator shaft. Install "O" ring on oil pump. Install oil pump. Hold input shaft
and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch
drum. Install and tighten bolts to 18 ft. lbs. (25 N.m).

NOTE: DO NOT apply excessive pressure on oil pump. Seal rings will
stick to direct clutch drum if excessive pressure is used.

32. Ensure input shaft rotates smoothly. Using a dial indicator, measure input shaft end play. See
Fig. 67 . End play should be .012-.035" (.30-.90 mm). Replace oil pump race if end play is
incorrect. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40
mm).

Fig. 67: Measuring Input Shaft End Play

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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33. Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons.
Measure spring free length and replace as necessary. See ACCUMULATOR SPRING
SPECIFICATIONS (A245E) table. Install pistons and springs in transaxle case. See Fig.
73 .

ACCUMULATOR SPRING SPECIFICATIONS (A245E) (1)

Application Color Free Length - In. (mm)
Direct Blue 2.768 (70.30)
Clutch (C2)
Forward Clutch (C1)
Inner Red 1.437 (36.50)
Spring
Outer Red 2.480 (63.00)
Spring
Underdrive Clutch (C3)
Inner Yellow 1.969 (50.00)
Spring
Outer White 2.815 (71.50)
Spring
2nd Brake Brown 2.547 (64.70)
(B2)
(1) For accumulator spring locations, refer to illustration.
See Fig. 73 .

34. Install 2nd brake apply gasket. See Fig. 9 . Install check ball body and spring in passage
next to 2nd brake accumulator. See Fig. 8 . Install throttle cable. Use care not to damage
"O" ring. Ensure cable is fully seated in transaxle case. Install solenoid wire(s) in transaxle
case.
35. Hold valve body cam downward and install throttle cable in slot. Install manual valve
connecting rod. Install valve body assembly. Ensure kickdown switch wire is not pinched
under valve body assembly. Install valve body assembly.
36. Install valve body assembly bolts finger tight. Ensure proper length bolts are installed in
correct location. See Fig. 7 . Tighten bolts to 89 INCH lbs. (10 N.m). Connect solenoid
connector(s).
37. Install manual detent spring and cover. Install bolt and tighten bolt to 89 INCH lbs. (10
N.m). Ensure manual valve lever is in contact with center of roller at tip of detent spring.
Install oil tubes. Install oil tube clamp and bracket. Tighten bolts to 89 INCH lbs. (10 N.m).
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Install oil strainer (filter) with NEW gasket.

38. Install magnet(s) in oil pan. Install NEW oil pan gasket and install oil pan. Tighten oil pan
bolts to 46 INCH lbs. (5.2 N.m). Install throttle cable and solenoid lock plates.
39. Install oil cooler pipe unions (if necessary). Install park/neutral position switch to manual
valve shaft. Install packing, nut, stopper and nut. Tighten nut to 106 INCH lbs. (12 N.m).
Adjust park/neutral position switch (if necessary) and tighten adjusting bolts to 48 INCH
lbs. (5.4 N.m). See appropriate SERVICING article. Stake nut to stopper. Install manual
shift lever and tighten nut. Install filler tube and dipstick. Install oil cooler pipes.
40. Install torque converter on transaxle. Using a straightedge and calipers, measure torque
converter installed depth. For torque converter depth specifications, see TORQUE
CONVERTER DEPTH SPECIFICATIONS table. See Fig. 74 .

TORQUE CONVERTER DEPTH SPECIFICATIONS

Application In. (mm)
Corolla .528 (13.40)
Prizm .906 (23.00)

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Fig. 68: Checking Rear Planetary Installation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 69: Checking No. 2 One-Way Clutch Operation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 70: Checking 2nd Brake Hub Installation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 71: Checking Front Planetary Ring Gear Installation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 72: Checking Direct/Forward Clutch Drum Assembly Installation

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 73: Identifying Accumulator Pistons & Springs

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 74: Measuring Torque Converter Depth

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 75: Identifying Bearing Race & Thrust Bearing Locations

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Bearing Retainer Bolt 13 (17)
Converter-To-Drive Plate Bolt
Corolla 18 (25)
Prizm 14 (19)
Countershaft Gear Lock Nut 131-159 (177-216)
Drain Plug 13 (17)
Drive Plate Bolt
Corolla 47 (64)
Prizm 61 (83)
Oil Cooler Union Nut 22 (30)
Oil Pump Bolt 18 (25)
Ring Gear Bolt 72 (97)
Transaxle Housing Bolt 21 (29)
INCH Lbs. (N.m)
Accumulator Cover Bolt 89 (10)
Apply Pipe Bracket Bolt 48 (5.4)
Brake Band Guide Bolt 48 (5.4)
Manual Detent Spring Bolt 89 (10)
Oil Gallery Cover Bolt 89 (10)
Oil Pan Bolt
Corolla 48 (5.4)
Prizm 43 (4.9)
Oil Pump Stator Shaft Bolt 89 (10)
Oil Strainer Bolt 89 (10)
Oil Tube Clamp Bolt 89 (10)
Park/Neutral Position Switch
Adjusting Bolt 106 (12)
Retaining Nut 48 (5.4)
Parking Lock Pawl Bracket Bolt 65 (7.4)
Parking Lock Pawl Spring Bolt 115 (13)
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Pressure Relief Valve 57 (6.4)

Sensor Bracket Bolt 115 (13)
Sensor Cover Bolt 48 (5.4)
Solenoid Bolt
Single Solenoid 58 (6.5)
Other Solenoids 89 (10)
Speed Sensor Bolt 48 (5.4)
Transaxle Rear Cover Bolt 89 (10)
Upper-To-Lower Valve Body Bolt 58 (6.5)
Underdrive Brake Accumulator
Bolt 89 (10)
Screw 65 (7.4)
Valve Body-To-Transaxle Bolt 89 (10)

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS
Application In. (mm)
Assembly Height (Underdrive Clutch) .681-.717 (17.29-18.21)
Bushing Inside Diameter
Direct Clutch 1.900 (48.27)
Oil Pump Body 1.503 (38.18)
Planetary Sun Gear
Standard 1.173-1.174 (29.80-
29.83)
Maximum 1.176 (29.87)
Ring Gear Flange .749-.750 (19.03-19.05)
Stator Shaft
Front .849 (21.57)
Rear 1.066 (27.07)
Sun Gear Flange .867-.868 (22.03-22.05)
Underdrive Clutch (Front)
Standard 1.831-1.832 (46.50-
46.53)
Maximum 1.833 (46.57)
Underdrive Clutch (Rear)
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Standard 2.165-2.167 (55.00-

55.03)
Maximum 2.169 (55.08)
Countershaft End Play .008-.035 (.20-.89)
Countershaft Height 1.193-1.280 (30.30-32.50)
Direct Clutch Pack Clearance .019-.035 (.49-.89)
Input Shaft End Play .012-.035 (.30-.90)
Piston Stroke
Forward Clutch .056-.071 (1.42-1.81)
Underdrive Clutch .059-.075 (1.50-1.90)
2nd Coast Brake .059-.138 (1.50-3.50)
Planetary Pinion Gear
Thrust Clearance .008-.020 (.20-.50)
Side Gear Backlash .002-.008 (.05-.20)
Underdrive Brake Clutch Pack Clearance .042-.081 (1.07-2.05)
1st & Reverse Brake Pack Clearance .047-.094 (1.19-2.38)

CLUTCH DISC & PLATE QUANTITY

Application Disc Plate
Direct Clutch 3 3
Forward Clutch 4 4
Underdrive Brake 3 3
Underdrive Clutch 3 3
1st & Reverse Brake 6 6
2nd Brake 3 3

THRUST BEARING & RACE SPECIFICATIONS (1) , (2)

Application O.D. - In. (mm) I.D. - In. (mm)
"A"
Front Race 1.646 (41.8) 1.181 (30.0)
Bearing 1.728 (43.9) 1.220 (31.0)
"B"
Bearing 1.728 (43.9) 1.220 (31.0)
"C"
Bearing 2.283 (58.0) 1.614 (41.0)
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"D"
Bearing 1.811 (46.0) Or 1.209 (30.7)
1.823 (46.3) Or
47.1 (1.854)
"E"
Bearing 1.654 (42.0) 1.016 (25.8)
Rear Race 1.555 (39.5) 1.024 (26.0)
"F"
Bearing 1.496 (38.0) .866 (22.0)
Rear Race 1.378 (35.0) .748 (19.0)
"G"
Bearing 1.772 (45.0) 1.106 (28.1)
"H"
Front Race 1.480 (37.6) .949 (24.1)
Bearing 1.480 (37.6) .870 (22.1)
(1) For bearing race and thrust bearing specifications and location, see Fig. 75 .

(2) O.D. = Outside Diameter; I.D. = Inside Diameter.

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