K121 CVT  CONTINUOUSLY VARIABLE TRANSAXLE UNIT  REASSEMBLY  

Check the position and installation direction of each bearing.

3.083,3.146 3.281,3.396 0.198,0.25 10 false A 2.031,7.563 2.229,7.813 0.198,0.25 10 false B 3.521,6.927 3.719,7.177 0.198,0.25 10 false C

Install the 2 straight pins to the transaxle case sub-assembly.

Protrusion Height:

7.0 to 8.0 mm (0.276 to 0.315 in.)

1.438,2.26 0.813,2.083 0.813,2.083 1.531,1.823 false 0.823,2.083 1.438,2.083 false 0.49,2.01 0.823,2.219 0.333,0.208 10 true SST

Using SST and a press, install a new differential case rear tapered roller bearing (inner race) to the differential case sub-assembly.

SST

09523-36010  
09950-60011  (09951-00560)
09950-70010  (09951-07150)

NOTICE:

·

Do not damage the differential case rear tapered roller bearing (inner race) cage when installing the differential case rear tapered roller bearing (inner race).

·

Be sure to install the differential case rear tapered roller bearing (inner race) so that there is no clearance between the differential case rear tapered roller bearing (inner race) and the differential case sub-assembly. If there is any clearance, the turning torque of the differential case sub-assembly cannot be measured correctly.

1.448,2.229 0.958,2.073 0.958,2.073 1.521,1.688 false 0.979,2.073 1.448,1.938 false 0.625,2 0.969,2.208 0.344,0.208 10 true SST

Using SST and a press, install a new differential case front tapered roller bearing (inner race) to the differential case sub-assembly.

SST

09523-36010  
09950-60011  (09951-00560)
09950-70010  (09951-07150)

NOTICE:

·

Do not damage the differential case front tapered roller bearing (inner race) cage when installing the differential case front tapered roller bearing (inner race).

·

Be sure to install the differential case front tapered roller bearing (inner race) so that there is no clearance between the differential case front tapered roller bearing (inner race) and the differential case sub-assembly. If there is any clearance, the turning torque of the differential case sub-assembly cannot be measured correctly.

0.979,1.385 0.458,0.948 0.458,0.948 1.052,1.177 true 0.156,0.854 0.521,1.073 0.365,0.219 10 false SST

Using SST and a hammer, install a new differential case rear tapered roller bearing (outer race) to the transaxle case sub-assembly.

SST

09950-60021  (09951-00790)
09950-70010  (09951-07100)

NOTICE:

Be sure to install the differential case rear tapered roller bearing (outer race) so that there is no clearance between the differential case rear tapered roller bearing (outer race) and the transaxle case sub-assembly. If there is any clearance, the turning torque of the differential case sub-assembly cannot be measured correctly.

Install the shim to the transaxle housing.

0.865,1.479 0.396,1.594 0.396,1.594 1.01,1.156 true 0.083,1.521 0.406,1.76 0.323,0.24 10 false SST

Using SST and a hammer, install a new differential case front tapered roller bearing (outer race) to the transaxle housing.

SST

09950-60021  (09951-00730)
09950-70010  (09951-07100)

NOTICE:

Be sure to install the differential case front tapered roller bearing (outer race) so that there is no clearance between the differential case front tapered roller bearing (outer race), shim and the transaxle housing. If there is any clearance, the turning torque of the differential case sub-assembly cannot be measured correctly.

Install the differential case sub-assembly to the transaxle case sub-assembly.

Install the transaxle housing to the transaxle case sub-assembly with the 21 bolts.

Torque:

29.4 N*m (300 kgf*cm, 22 ft.*lbf)

0.5,1.5 1.458,1.5 true 0.198,1.417 0.573,1.646 0.375,0.229 10 false SST

Using SST, turn the differential case sub-assembly right and left 2 or 3 times to settle the bearings.

SST

09564-50010  

0.552,1.51 1.448,1.51 true 0.25,1.417 0.625,1.635 0.375,0.219 10 false SST

Using SST and a torque wrench, measure the turning torque of the differential case tapered roller bearing while rotating SST at 10 rpm.

SST

09564-50010  

Standard Turning Torque:

1.65 to 2.66 N*m (17 to 27 kgf*cm, 15 to 23 in.*lbf)

If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

Shim Thickness:

Part Number	Thickness mm (in.)	Mark
90564-66038	1.76 (0.0693)	A
90564-66039	1.79 (0.0705)	B
90564-66067	1.82 (0.0717)	C
90564-66068	1.85 (0.0728)	D
90564-66069	1.88 (0.0740)	E
90564-66070	1.91 (0.0752)	F
90564-66071	1.94 (0.0764)	G
90564-66072	1.97 (0.0776)	H
90564-66073	2.00 (0.0787)	J
90564-66074	2.03 (0.0799)	K
90564-66075	2.06 (0.0811)	L
90564-66076	2.09 (0.0823)	M
90564-66077	2.12 (0.0835)	N
90564-66078	2.15 (0.0846)	P
90564-66079	2.18 (0.0858)	Q
90564-66080	2.21 (0.0870)	R
90564-66081	2.24 (0.0882)	S
90564-66082	2.27 (0.0894)	T
90564-66083	2.30 (0.0906)	U
90564-66084	2.33 (0.0917)	V

1.146,2.083 1.49,2.083 false 0.844,2 1.208,2.219 0.365,0.219 10 false SST

Using SST and a press, install a new reduction driven gear rear tapered roller bearing (inner race) to the reduction driven gear.

SST

09330-50010  

NOTICE:

·

Do not damage the reduction driven gear rear tapered roller bearing (inner race) cage when installing the reduction driven gear rear tapered roller bearing (inner race).

·

Be sure to install the reduction driven gear rear tapered roller bearing (inner race) so that there is no clearance between the reduction driven gear rear tapered roller bearing (inner race) and the reduction driven gear. If there is any clearance, the turning torque of the reduction driven gear cannot be measured correctly.

1.188,1.594 1.49,1.781 false 1.625,3.177 1.677,3.271 1.677,3.271 2.552,3.271 true 0.885,1.5 1.25,1.708 0.365,0.208 10 false SST 2.594,3.167 2.958,3.375 0.365,0.208 10 false SST

Using SST and a press, install a new reduction driven gear front tapered roller bearing (inner race) to the reduction driven gear.

SST

09330-50010  
09950-60011  (09951-00270)

NOTICE:

·

Do not damage the reduction driven gear front tapered roller bearing (inner race) cage when installing the reduction driven gear front tapered roller bearing (inner race).

·

Be sure to install the reduction driven gear front tapered roller bearing (inner race) so that there is no clearance between the reduction driven gear front tapered roller bearing (inner race) and the reduction driven gear. If there is any clearance, the turning torque of the reduction driven gear cannot be measured correctly.

1.229,1.625 0.635,1.229 0.635,1.229 1.302,1.448 true 0.323,1.146 0.677,1.354 0.354,0.208 10 false SST

Using SST and a hammer, install a new reduction driven gear rear tapered roller bearing (outer race) to the transaxle case sub-assembly.

SST

09950-60011  (09951-00560)
09950-70010  (09951-07100)

NOTICE:

Be sure to install the reduction driven gear rear tapered roller bearing (outer race) so that there is no clearance between the reduction driven gear rear tapered roller bearing (outer race) and the transaxle case sub-assembly. If there is any clearance, the turning torque of the reduction driven gear cannot be measured correctly.

Install the shim to the transaxle housing.

1.344,1.688 0.719,0.854 0.719,0.854 1.417,1.406 true 0.417,0.76 0.875,0.958 0.458,0.198 10 false SST

Using SST and a hammer, install a new reduction driven gear front tapered roller bearing (outer race) to the transaxle housing.

SST

09950-60011  (09951-00500)
09950-70010  (09951-07100)

NOTICE:

Be sure to install the reduction driven gear front tapered roller bearing (outer race) so that there is no clearance between the reduction driven gear front tapered roller bearing (outer race), shim and the transaxle housing. If there is any clearance, the turning torque of the reduction driven gear cannot be measured correctly.

Turn the reduction driven gear right and left 2 or 3 times to settle the bearings.

Install SST.

i.

Set SST to the parking lock gear as shown in the illustration.

3.792,2.073 5.74,1.167 5.74,1.167 4.323,1.385 true 3.792,0.708 4.146,0.708 false 5.792,1.073 6.25,1.271 0.458,0.198 10 false SST 4.188,0.604 4.5,0.875 0.313,0.271 10 false *a

*a

SST (Center Bolt)

-

-

SST

09950-40011  (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
09950-60011  (09951-00360, 09951-00250, 09952-06010)

NOTICE:

Do not tighten SST (center bolt) more than is necessary to hold SST in place or the parking lock gear or bearing may unseat.

ii.

1.177,0.563 1.521,0.563 false 1,0.458 1.281,0.688 0.281,0.229 10 false *a

*a	SST (Center Bolt)

Tighten SST (center bolt).

HINT:

Torque: 0.5 N*m (5 kgf*cm, 4 in.*lbf)

Using a torque wrench, measure and note the turning torque (T1) of the reduction driven gear while rotating SST at 10 rpm.

HINT:

No specified range is provided for T1 as it is only used for calculating the total preload of the differential case sub-assembly and reduction driven gear.

Install the differential case sub-assembly to the transaxle case sub-assembly.

Install the reduction driven gear to the transaxle case sub-assembly.

Install the transaxle housing to the transaxle case sub-assembly with the 21 bolts.

Torque:

29.4 N*m (300 kgf*cm, 22 ft.*lbf)

0.5,1.5 1.458,1.5 true 0.198,1.417 0.573,1.646 0.375,0.229 10 false SST

Using SST, turn the differential case sub-assembly right and left 2 or 3 times to settle the bearings.

SST

09564-50010  

0.552,1.51 1.448,1.51 true 0.25,1.417 0.625,1.635 0.375,0.219 10 false SST

Using a torque wrench, measure and note the turning torque (T2) of the differential case tapered roller bearing while rotating SST at 10 rpm.

SST

09564-50010  

1.75,2.396 2.667,2.844 2.667,2.844 2.177,2.271 true 2.719,2.76 3.094,2.979 0.375,0.219 10 false SST

Using SST and a hammer, install a new front drive shaft oil seal LH to the transaxle case sub-assembly.

SST

09950-70010  (09951-07150)
09649-17010  

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:

·

Make sure that the front drive shaft oil seal LH is installed in the correct direction.

·

Make sure to install the front drive shaft oil seal LH as specified, otherwise malfunctions such as a fluid leak will occur.

·

Do not damage the lip of the front drive shaft oil seal LH.

Coat 2 new O-rings with Toyota Genuine CVT fluid FE and install them to the reverse brake piston.

NOTICE:

Ensure that the O-rings are not twisted.

Install the reverse brake piston to the transaxle case sub-assembly.

Install the 1st and reverse brake return spring sub-assembly to the transaxle case sub-assembly.

1.792,0.927 2.927,0.625 2.927,0.625 2.042,1.281 true 2.979,0.521 3.365,0.74 0.385,0.219 10 false SST

Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.

SST

09350-32014  (09351-32040)
09950-70010  (09951-07200)

NOTICE:

Do not compress the 1st and reverse brake return spring sub-assembly excessively.

Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly.

NOTICE:

Be careful not to damage the transaxle case sub-assembly.

3.083,1.354 3.25,1.354 3.25,1.354 3.25,2.917 false 3.083,1.854 3.25,1.854 false 3.083,2.354 3.25,2.354 false 2,1.167 2,2.167 2,2.167 2.177,2.167 false 2.177,1.167 1.833,1.167 false 2.177,1.625 2,1.625 false 1.875,0.771 2.208,0.771 false 1.688,0.688 1.865,0.896 0.177,0.208 10 true *1 1.646,1.063 1.813,1.281 0.167,0.219 10 true *2 3.156,2.958 3.344,3.198 0.188,0.24 10 false *3

*1	Brake Flange
*2	No. 1 Brake Disc
*3	No. 1 Brake Plate

Install the brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates to the transaxle case sub-assembly.

Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the transaxle case sub-assembly.

5.385,0.104 5.656,0.333 0.271,0.229 10 false *a

*a

Snap ring opening within this area.

-

-

NOTICE:

Be careful not to damage the transaxle case sub-assembly.

Install the planetary ring gear thrust washer to the transaxle case sub-assembly.

Install the front planetary ring gear sub-assembly to the transaxle case sub-assembly.

Coat the thrust needle roller bearing with Toyota Genuine CVT fluid FE and install it to the front planetary ring gear sub-assembly.

Coat the thrust needle roller bearing with Toyota Genuine CVT fluid FE and install it to the planetary gear assembly.

Install the planetary gear assembly to the front planetary ring gear sub-assembly.

1.021,0.302 1.302,0.49 0.281,0.188 10 false *1 2.625,1.844 2.896,2.042 0.271,0.198 10 false *2

*1	O-Ring
*2	D-Ring

Coat a new O-ring and a new D-ring with Toyota Genuine CVT fluid FE and install them to the forward clutch piston.

NOTICE:

Ensure that the O-ring and D-ring are not twisted.

Install the forward clutch piston to the forward clutch drum sub-assembly.

Install the forward clutch return spring sub-assembly to the forward clutch drum sub-assembly.

Coat a new D-ring with Toyota Genuine CVT fluid FE and install it to the No. 1 clutch balancer.

NOTICE:

Ensure that the D-ring is not twisted.

Install the No. 1 clutch balancer to the forward clutch drum sub-assembly.

1.906,0.917 2.396,0.917 false 2.448,0.823 2.833,1.094 0.385,0.271 10 false SST

Place SST on the No. 1 clutch balancer and compress the forward clutch return spring sub-assembly with a press.

SST

09387-00020  

NOTICE:

Do not compress the forward clutch return spring sub-assembly excessively.

Using a snap ring expander, install the snap ring to the forward clutch drum sub-assembly.

3.146,1.292 3.292,1.292 3.292,1.292 3.292,2.792 false 2.021,2.156 1.833,2.156 1.833,2.156 1.833,1.021 false 1.625,1.021 2.031,1.021 false 1.833,1.583 2.021,1.583 false 3.167,1.885 3.292,1.885 false 3.156,2.49 3.292,2.49 false 1.625,0.698 2.031,0.698 false 1.469,0.604 1.771,0.823 0.302,0.219 10 false *1 1.469,0.927 1.76,1.156 0.292,0.229 10 false *2 3.229,2.792 3.417,3.01 0.188,0.219 10 false *3

*1	Forward Clutch Flange
*2	Forward Multiple Disc Clutch Clutch Disc
*3	Forward Multiple Disc Clutch Clutch Plate

Install the forward clutch flange, 3 forward multiple disc clutch clutch discs and 3 forward multiple disc clutch clutch plates to the forward clutch drum sub-assembly.

Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the forward clutch drum sub-assembly.

NOTICE:

Be careful not to damage the forward clutch drum sub-assembly.

Install the thrust bearing race to the forward multiple disc clutch assembly.

Install the forward multiple disc clutch assembly to the planetary gear assembly.

1.979,1.177 2.177,0.229 2.177,0.229 2.302,0.229 false 2.323,0.135 2.521,0.323 0.198,0.188 10 false *a

*a

Adhesive

Apply adhesive to 2 or 3 threads on the end of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

Install the stay to the No. 1 gear shift fork assembly with the bolt.

Torque:

10.5 N*m (107 kgf*cm, 8 ft.*lbf)

Install the No. 1 gear shift fork assembly to the 1st gear sub-assembly.

Move the No. 1 gear shift fork assembly as shown in the illustration.

Install the 1st gear sub-assembly with the No. 1 gear shift fork assembly to the No. 1 gear shift fork shaft.

1.969,1.219 2.094,0.406 2.094,0.406 2.26,0.406 false 2.302,0.292 2.594,0.552 0.292,0.26 10 false *a

*a

Adhesive

Apply adhesive to 2 or 3 threads on the end of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

In order to ensure proper sealing of the bolt, apply adhesive to the bolt and install it within 10 minutes of adhesive application.

Install the bolt to connect the No. 1 gear shift fork assembly to the No. 1 gear shift fork shaft.

Torque:

15.7 N*m (160 kgf*cm, 12 ft.*lbf)

Install 2 new clutch drum oil seal rings to the stator (CVT) shaft assembly.

NOTICE:

Do not expand the gap of the clutch drum oil seal ring excessively.

0.438,0.25 0.594,0.427 0.156,0.177 10 true A 3.01,1.771 3.167,1.969 0.156,0.198 10 true B 2.771,0.458 2.927,0.656 0.156,0.198 10 true A 0.292,0.771 0.448,0.969 0.156,0.198 10 true B 0.406,1.198 0.563,1.396 0.156,0.198 10 true A 0.49,1.833 0.646,2.031 0.156,0.198 10 true A 3,1.083 3.156,1.281 0.156,0.198 10 true A

Install the stator (CVT) shaft assembly to the transaxle case sub-assembly with the 7 bolts.

Torque:

29.4 N*m (300 kgf*cm, 22 ft.*lbf)

Bolt Length:

Bolt (A)	Bolt (B)
30 mm (1.18 in.)	40 mm (1.57 in.)

Install the oil reservoir lock plate to the transaxle case sub-assembly with the 2 bolts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

Install the transmission case plate sub-assembly to the transaxle case sub-assembly with the 2 bolts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

Coat a new O-ring with Toyota Genuine CVT fluid FE and install it to the oil strainer assembly.

NOTICE:

Ensure that the O-ring is not twisted.

Install the oil strainer assembly to the front oil pump assembly with the 2 bolts.

Torque:

9.8 N*m (100 kgf*cm, 87 in.*lbf)

Coat a new front oil pump cover gasket with Toyota Genuine CVT fluid FE and install it to the transaxle case sub-assembly.

0.771,0.417 0.927,0.615 0.156,0.198 10 true A 1.385,1.99 1.542,2.177 0.156,0.188 10 true B 2.5,1.844 2.656,2.042 0.156,0.198 10 true A 2.698,0.906 2.854,1.094 0.156,0.188 10 true B

Install the front oil pump assembly to the transaxle case sub-assembly with the 4 bolts.

Torque:

22.1 N*m (225 kgf*cm, 16 ft.*lbf)

Bolt Length:

Bolt (A)	Bolt (B)
30 mm (1.18 in.)	40 mm (1.57 in.)

Install the No. 1 transmission oil pump separator plate to the front oil pump assembly with the 2 bolts.

Torque:

9.8 N*m (100 kgf*cm, 87 in.*lbf)

Install the snap ring to the front oil pump assembly.

1.135,0.302 1.729,0.302 true 2.073,0.469 2.552,0.469 true 0.969,0.208 1.25,0.448 0.281,0.24 10 false *1 2.594,0.365 2.875,0.604 0.281,0.24 10 false *2

*1	Drive Sprocket
*2	Transmission Drive Chain

Install the drive sprocket and transmission drive chain.

Install the thrust needle roller bearing to the drive sprocket.

Attach the 4 claws to install the No. 2 transmission oil pump separator plate to the No. 1 transmission oil pump separator plate.

Install the differential case sub-assembly to the transaxle case sub-assembly.

Install the reduction driven gear to the transaxle case sub-assembly.

0.677,1.125 0.927,1.125 false 0.354,1.042 0.667,1.26 0.313,0.219 10 true SST

Using SST and a hammer, install the transaxle housing type T oil seal to the transaxle housing.

SST

09223-00010  

Standard Depth:

-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

NOTICE:

Make sure that the transaxle housing type T oil seal is installed in the correct direction.

Install the parking lock sleeve to the transaxle housing.

Install the parking lock pawl to the transaxle housing.

1.021,0.198 1.521,0.198 false 1.125,0.688 1.333,0.5 1.333,0.5 1.521,0.5 false 1.563,0.094 1.844,0.313 0.281,0.219 10 false *1 1.563,0.396 1.885,0.615 0.323,0.219 10 false *2

*1	Parking Lock Pawl Shaft
*2	Torsion Spring

Install the parking lock pawl shaft and torsion spring to the transaxle housing.

Install the cam guide sleeve to the transaxle housing with the 2 bolts.

Torque:

12 N*m (122 kgf*cm, 9 ft.*lbf)

Coat a new O-ring with Toyota Genuine CVT fluid FE and install it to the C-2 clutch pressure apply tube sub-assembly.

NOTICE:

Ensure that the O-ring is not twisted.

Install the C-2 clutch pressure apply tube sub-assembly to the transaxle housing.

Coat a new O-ring with Toyota Genuine CVT fluid FE and install it to the secondary shaft lube apply tube.

NOTICE:

Ensure that the O-ring is not twisted.

Install the secondary shaft lube apply tube to the transaxle housing.

3.49,0.865 3.583,0.99 3.583,0.99 4,0.99 true 4.74,1.458 5.177,1.458 5.177,1.458 5.406,1.073 true 4.031,0.896 4.313,1.156 0.281,0.26 10 false *a 4.573,1.375 4.802,1.552 0.229,0.177 10 false *b

*a

Protrusion

*b

Cutout

NOTICE:

Align the cutout of the transaxle housing with the protrusion of the secondary shaft lube apply tube.

Using a snap ring plier, install the snap ring to the transaxle housing.

Install the differential gear lube apply tube to the transaxle housing with the bolt.

Torque:

5.4 N*m (55 kgf*cm, 48 in.*lbf)

Install the 3 oil cleaner (CVT) magnets to the oil reservoir lock plate.

Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.

Torque:

9.8 N*m (100 kgf*cm, 87 in.*lbf)

Install the solenoid oil strainer to the transaxle case sub-assembly.

Coat 5 new O-rings with Toyota Genuine CVT fluid FE and install them to the transaxle case sub-assembly.

NOTICE:

Ensure that the O-rings are not twisted.

0,0 0,0 false

Seal Packing Start and End Point Range

Apply seal packing to the transaxle case sub-assembly.

Seal Packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Standard Seal Diameter:

1.2 mm (0.0472 in.)

NOTICE:

·

Make sure to overlap the start and end points of the seal packing.

·

Make sure that the start and end points of the seal packing are within the shaded area shown in the illustration.

·

Apply seal packing in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

·

After applying seal packing, install the transaxle housing to the transaxle case sub-assembly within 3 minutes and tighten the bolts within 10 minutes.

Install the transaxle housing to the transaxle case sub-assembly with the 21 bolts.

Torque:

29.4 N*m (300 kgf*cm, 22 ft.*lbf)

Using a 6 mm hexagon socket wrench, install the overflow (CVT) tube to the transaxle case sub-assembly.

Torque:

0.8 N*m (8 kgf*cm, 7 in.*lbf)

Using a 10 mm hexagon socket wrench, install the overflow plug to the transaxle case sub-assembly.

Torque:

49 N*m (500 kgf*cm, 36 ft.*lbf)

Install the refill plug to the rear transaxle case sub-assembly.

Torque:

49 N*m (500 kgf*cm, 36 ft.*lbf)