AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A01DWV1E01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A 74.3 to 74.6 mm (2.93 to 2.94 in.)/87.4 to 87.7 mm (3.44 to 3.45 in.) 72.0 to 72.3 mm (2.83 to 2.85 in.)/85.3 to 85.6 mm (3.36 to 3.37 in.) -
    B 37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.) 34.7 to 34.9 mm (1.366 to 1.374 in.)/51.6 to 51.9 mm (2.03 to 2.04 in.) -
    C - 21.4 to 21.6 mm (0.841 to 0.850 in.)/40.8 to 41.0 mm (1.606 to 1.614 in.) 22.7 to 22.9 mm (0.892 to 0.902 in.)/60.0 to 60.4 mm (2.36 to 2.38 in.)
    D 33.3 to 33.5 mm (1.31 to 1.32 in.)/56.3 to 56.6 mm (2.22 to 2.23 in.) 38.5 to 38.7 mm (1.515 to 1.524 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) -
    E - 42.6 to 42.8 mm (1.68 to 1.69 in.)/60.8 to 61.1 mm (2.39 to 2.41 in.) -
    F 38.0 to 38.2 mm (1.496 to 1.504 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) 43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.4 mm (2.28 to 2.30 in.) -
    G - 55.8 to 56.0 mm (2.197 to 2.204 in.)/76.1 to 76.4 mm (2.996 to 3.008 in.) 53.8 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.)
    H 33.4 to 33.6 mm (1.31 to 1.32 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.) 32.2 to 32.3 mm (1.268 to 1.272 in.)/49.0 to 49.2 mm (1.93 to 1.94 in.) 32.2 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)
    I - 21.5 to 21.8 mm (0.846 to 0.858 in.)/40.5 to 40.8 mm (1.59 to 1.61 in.) -
    J - 43.6 to 43.9 mm (1.72 to 1.73 in.)/60.6 to 60.9 mm (2.39 to 2.40 in.) 47.2 to 47.4 mm (1.86 to 1.87 in.)/66.9 to 67.1 mm (2.63 to 2.64 in.)

  2. ASSEMBLE NO. 4 BRAKE PISTON AND BRAKE REACTION SLEEVE

    A01E00FE09

    1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.

    2. Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.

    3. Install the No. 4 brake piston to the reaction sleeve.

  3. INSTALL NO. 4 BRAKE PISTON WITH BRAKE REACTION SLEEVE

    A01DXN1E03

    1. Install the No. 4 brake piston with brake reaction sleeve to the transmission case

      Note


      • Do not damage the O-rings.

      • Make sure the No. 4 brake piston is underneath the brake reaction sleeve.

  4. INSTALL 1ST AND REVERSE BRAKE PISTON

    A01E2O0E03

    1. Coat a new O-ring with ATF.

    2. Install the O-ring to the 1st and reverse brake piston.

    3. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

      Note

      Be careful not to damage the O-ring.

    4. A01DZQYE01

      Place the brake return spring onto the 1st and reverse brake piston.

  5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

    A01DX4IE01

    1. Place SST on a new spring retainer, and compress the return spring.

      SST
      09350-30020   ( 09350-07050 )

    2. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY

    A01E2FOE02

    1. Install the No. 9 thrust bearing race.

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 9 Race 47.2 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.)
    2. A01DWT9E01

      Coat the 2 thrust needle roller bearings with petroleum jelly, and install them to the rear planetary gear.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing J 43.6 to 43.9 mm (1.72 to 1.73 in.) 60.6 to 60.9 mm (2.39 to 2.40 in.)
      Bearing I 21.5 to 21.8 mm (0.846 to 0.858 in.) 40.5 to 40.8 mm (1.59 to 1.61 in.)
    3. A01DVC5

      Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

    A01E064E01

    1. Make sure the 1st and reverse brake piston moves smoothly when applying and releasing compressed air into the transmission case.

    2. A01DX3ME01

      Using a vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.

      Note

      The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.

      Tech Tips

      Length A = 36.35 to 37.09 mm (1.43 to 1.46 in.)

    3. A01E0B2E03

      Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, 7 No. 4 brake plates and 8 No. 4 brake discs all together at both ends across a diameter, and calculate the average.

      Tech Tips

      Pack clearance = Length A - Length B - 0.25 mm (0.00984) - 1.8 mm (0.0709 in.)

      Length B = 36.04 to 37.14 mm (1.42 to 1.46 in.)

      Standard pack clearance
      0.8 to 1.1 mm (0.0315 to 0.0433 in.)

      If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

      H Thickness
      No. Thickness
      0 0 mm (0 in.)
      2 0.15 to 0.25 mm (0.00590 to 0.00984 in.)
      4 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
      6 0.55 to 0.65 mm (0.0217 to 0.0256 in.)
      8 0.75 to 0.85 mm (0.0295 to 0.0335 in.)
      10 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      12 1.15 to 1.25 mm (0.0453 to 0.0492 in.)
      14 1.35 to 1.45 mm (0.0531 to 0.0571 in.)

  8. INSTALL NO. 4 BRAKE DISC

    A01E0WPE01

    1. Install the 2 flanges, 8 discs and 7 plates.

      Install in order
      F - D - P - D - P - D - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

  9. INSTALL BRAKE PLATE STOPPER SPRING

    A01E022E01

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01E2G3E11

    1. Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft.

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      No. 7 Race 33.4 to 33.6 mm (1.31 to 1.32 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)
      Bearing 32.2 to 32.3 mm (1.268 to 1.272 in.) 49.0 to 49.2 mm (1.93 to 1.94 in.)
      No. 8 Race 32.2 to 32.4 mm (1.27 to 1.28 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)

  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

    A01DUXXE01

    1. Install the 1-way clutch and 1-way clutch inner race to the intermediate shaft.

  12. INSTALL INTERMEDIATE SHAFT

    A01E17TE01

    1. Install the intermediate shaft with No. 3 1-way clutch assembly to the case.

    2. A01E2IRE03

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

    A01E0JQE01

    1. Install the planetary sun gear and center planetary gear to the case.

    2. Coat the No. 6 thrust bearing race with petroleum jelly, and install it to the center planetary gear.

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race 53.8 to 54.0 mm (2.12 to 2.13 in.) 73.7 to 74.0 mm (2.90 to 2.91 in.)

  14. INSTALL NO. 2 BRAKE PISTON


    1. A01E1OXE07

      Coat 2 new O-rings with ATF, and install them to the brake piston.

    2. Press the brake piston into the brake cylinder with both hands.

      Note

      Be careful not to damage the O-rings.

    3. Install the No. 2 brake piston to the case.

  15. INSTALL NO. 2 BRAKE DISC

    A01DZO1E04

    1. Install the brake piston return spring.

    2. Install the 3 plates, 3 discs and flange.

      Install in order
      D - P - D - P - D - P - F

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

    3. A01DY9TE03

      Using SST and a press, compress the return spring and install the No. 2 brake spring snap ring.

      SST
      09351-40010

  16. INSTALL NO. 1 BRAKE PISTON

    A01DZIUE10

    1. Coat 2 new O-rings with ATF, and install them to the brake piston.

    2. Press the brake piston into the brake cylinder with both hands.

      Note

      Be careful not to damage the O-rings.

  17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01E1PBE01

    1. Install the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder to the transmission case.

  18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

    A01DXN5E04

    1. Using SST and a press, compress the return spring and install the brake piston return spring snap ring.

      SST
      09351-40010

  19. INSTALL NO. 1 BRAKE DISC

    A01E0BVE04

    1. Install the 3 plates, 3 discs and flange.

      Install in order
      P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

  20. INSTALL CENTER PLANETARY RING GEAR


    1. A01DYBAE01

      Install the center planetary ring gear and front planetary ring gear flange to the front planetary ring gear.

    2. A01E285E01

      Using a screwdriver, install the snap ring.

  21. INSTALL FRONT PLANETARY RING GEAR

    A01DZWCE01

    1. Install the front planetary ring gear and thrust needle roller bearing to the case.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing 55.8 to 56.0 mm (2.197 to 2.204 in.) 76.1 to 76.4 mm (2.996 to 3.008 in.)

  22. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    A01E0MEE04

    1. Install the thrust washer and thrust needle roller bearing.

    2. Coat the No. 5 thrust race with petroleum jelly, and install it to the front planetary ring gear.

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      Bearing 43.4 to 43.6 mm (1.71 to 1.72 in.) 58.0 to 58.4 mm (2.28 to 2.30 in.)
      Race 38.0 to 38.2 mm (1.496 to 1.504 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
    3. A01DXVBE01

      Install the front planetary gear assembly and 1-way clutch inner race to the case.

  23. INSPECT PISTON STROKE OF NO. 1 BRAKE PISTON

    A01DYELE01

    1. Make sure the No. 1 brake piston moves smoothly when applying and releasing compressed air into the transmission case.

    2. A01DVWYE01

      Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.

      Standard piston stroke
      0.42 to 0.72 mm (0.0165 to 0.0283 in.)

      If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange.

      Tech Tips

      There are 4 different thicknesses for the flange.

      Flange Thickness
      Mark Thickness
      0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      1 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
      2 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      3 2.55 to 2.65 mm (0.100 to 0.104 in.)

  24. INSTALL 2ND BRAKE PISTON

    A01DWRHE11

    1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.

    2. Press the 2nd brake cylinder into the 2nd brake piston with both hands.

      Note

      Be careful not to damage the O-rings.

    3. A01DZPZE04

      Using SST and a press, compress the return spring and install the snap ring.

      SST
      09351-40010

      Note

      Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

  25. INSTALL 2ND BRAKE CYLINDER

    A01DZ84E01

    1. Install the 2nd brake cylinder to the case.

  26. INSTALL 1-WAY CLUTCH ASSEMBLY

    A01DZ6GE01

    1. Install the thrust washer and 1-way clutch to the case.

  27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

    A01E2IRE03

    1. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  28. INSTALL NO. 3 BRAKE DISC

    A01DXWKE05

    1. Install the cushion plate, 4 plates, 4 discs and flange to the case.

      Install in order
      C - P - D - P - D - P - D - P - D - F

      Tech Tips

      C = Cushion plate

      P = Plate

      D = Disc

      F = Flange

  29. INSTALL NO. 3 BRAKE SNAP RING

    A01DXCUE01

    1. Using a screwdriver, install the snap ring.

  30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A01E1ZEE02

    1. Coat 2 new O-rings with ATF, and install them to the direct clutch piston.

    2. A01E2GME01

      Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.

    3. Press the direct clutch piston into the clutch drum with both hands.

      Note

      Be careful not to damage the O-rings.

    4. A01E0YCE05

      Place SST on the direct clutch piston, and compress the return spring with a press.

      Note

      Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

      SST
      09320-89010
      09350-30020   ( 09350-07070 )

    5. Install the snap ring with a snap ring expander.

      Note

      Do not expand the snap ring excessively.

    6. A01E07ZE07

      Set the end gap of the snap ring in the piston as shown in the illustration

      Note

      Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

  31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. A01DVCQE02

      Coat a new O-ring with ATF, and install it to the clutch drum.

    2. A01E2PBE02

      Coat a new O-ring with ATF, and install it to the reverse clutch piston.

    3. A01DVDSE01

      Press the clutch drum into the reverse clutch piston with both hands.

      Note

      Be careful not to damage the O-ring.

  32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01DXI2E02

      Coat a new O-ring with ATF, and install it to the reverse clutch piston.

    2. Install the reverse clutch return spring to the reverse clutch piston.

  33. INSTALL NO. 3 CLUTCH BALANCER


    1. A01E0PUE04

      Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

      SST
      09387-00070
      09350-30020   ( 09350-07070 )

      Note

      Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

    2. Install the snap ring with a snap ring expander.

      Note

      Do not expand the snap ring excessively.

    3. A01DXBIE02

      Set the end gap of the snap ring in the piston as shown in the illustration.

      Note

      Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

  34. INSTALL DIRECT CLUTCH DISC

    A01DXGSE01

    1. for 1GR-FE:

      Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.

      Install in order
      P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A01E1X8E01

      for 1KD-FTV:

      Install the 6 plates, 6 discs and reverse clutch flange to the clutch drum.

      Install in order
      P - D - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    3. A01DZAZE01

      Using a screwdriver, install the 2 hole snap rings to the clutch drum.

  35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

    A01E0AIE02

    1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance for 1GR-FE
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)
      Standard pack clearance for 1KD-FTV
      0.6 to 0.9 mm (0.0236 to 0.0354 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Flange moving distance A = 0.26 to 1.14 mm (0.0102 to 0.0449 in.)

      Pack clearance = Flange moving distance A - 0.05 mm (0.00197 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)

  36. INSTALL REVERSE CLUTCH FLANGE

    A01DVZ2E01

    1. Install the reverse clutch flange to the clutch drum.

  37. INSTALL REVERSE CLUTCH REACTION SLEEVE

    A01DVZ7E02

    1. Install the 5 reverse clutch discs, 4 clutch plates, reverse clutch flange, clutch cushion plate and reverse clutch reaction sleeve to the reverse clutch hub.

      Install in order
      D - P - D - P - D - P - D - P - D - F - C - S

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

      S = Sleeve

    2. Using a screwdriver, install the hole snap ring.

  38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

    A01E1P9E02

    1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at both ends across a diameter while applying air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Piston stroke A = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

      Flange moving distance B = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

      Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.00236 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      0 2.75 to 2.85 mm (0.108 to 0.112 in.)
      1 2.85 to 2.95 mm (0.112 to 0.116 in.)
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)

  39. REMOVE REVERSE CLUTCH REACTION SLEEVE

    A01E16RE01

    1. Using a screwdriver, remove the snap ring from the clutch drum.

    2. A01DVIIE01

      Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub.

  40. INSTALL FORWARD CLUTCH PISTON

    A01E29SE02

    1. Coat 2 new O-rings with ATF, and install them to the forward clutch piston.

  41. INSTALL NO. 1 CLUTCH BALANCER

    A01DWQ6E02

    1. Coat a new O-ring with ATF and install it to the clutch balancer.

    2. A01DYK9E01

      Install the clutch balancer and forward clutch return spring.

      Note

      Be careful not to damage the O-ring.

    3. A01E00BE02

      Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07040, 09350-07070 )

      Note

      Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

    4. Install the snap ring with a snap ring expander.

      Note

      Do not expand the snap ring excessively.

    5. A01DV3EE02

      Set the end gap of the snap ring in the piston as shown in the illustration.

      Note

      Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

  42. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

    A01E0B6E02

    1. for 1GR-FE:

      Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

      Install in order
      F- D - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

    2. A01E160E01

      for 1KD-FTV:

      Install the 2 flanges, 7 discs and 6 plates to the input shaft assembly.

      Install in order
      F- D - P - D - P - D - P - D - P - D - P - D - P - D - F

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

    3. A01DXWCE01

      Using a screwdriver, install the hole snap ring.

  43. INSTALL INPUT SHAFT OIL SEAL RING


    1. A01E28UE01

      Coat 3 new oil seal rings with ATF.

    2. Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.

      Note

      Do not excessively widen the ring.

      Tech Tips

      After installing the oil seal rings, check that they rotate smoothly.

  44. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

    A01DXGBE02

    1. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance for 1GR-FE
      0.6 to 0.9 mm (0.0236 to 0.0354 in.)
      Standard pack clearance for 1KD-FTV
      0.8 to 1.0 mm (0.0315 to 0.0394 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Flange moving distance A = 0.26 to 1.36 mm (0.0102 to 0.0535 in.)

      Pack clearance = Flange moving distance A - 0.01 mm (0.000394 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      9 3.85 to 3.95 mm (0.148 to 0.152 in.)
      A 3.95 to 4.05 mm (0.152 to 0.159 in.)

  45. INSTALL INPUT SHAFT ASSEMBLY


    1. A01DWQVE01

      Install the input shaft to the clutch drum.

    2. A01DYY4E01

      Install the thrust needle roller bearing to the clutch drum.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing 21.4 to 21.6 mm (0.841 to 0.850 in.) 40.8 to 41.0 mm (1.606 to 1.614 in.)

  46. INSTALL MULTIPLE DISC CLUTCH HUB


    1. A01DZNNE06

      Coat the 2 thrust bearing races with petroleum jelly, and install them onto the multiple disc clutch hub.

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 3 Race 22.7 to 22.9 mm (0.892 to 0.902 in.) 60.0 to 60.4 mm (2.36 to 2.38 in.)
      No. 4 Race 33.3 to 33.5 mm (1.31 to 1.32 in.) 56.3 to 56.6 mm (2.22 to 2.23 in.)
    2. A01DVXHE01

      Install the multiple disc clutch hub to the clutch drum.

  47. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. A01DXKOE05

      Coat the 2 thrust needle roller bearings with petroleum jelly, and install them to the forward clutch hub.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing D 38.5 to 38.7 mm (1.515 to 1.524 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Bearing E 42.6 to 42.8 mm (1.68 to 1.69 in.) 60.8 to 61.1 mm (2.39 to 2.41 in.)
    2. A01DZVHE01

      Install the forward clutch hub to the clutch drum.

  48. INSTALL REAR CLUTCH DISC


    1. A01E11DE14

      Install the 5 discs, 4 plates, reverse clutch flange and clutch cushion plate to the reverse clutch hub.

      Install in order
      D - P - D - P - D - P - D - P - D - F - C

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

  49. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. A01DVNRE01

      Install the reverse clutch reaction sleeve to the reverse clutch hub.

  50. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A01DW8SE01

      Install the reverse clutch hub to the clutch drum.

    2. A01E1ZTE01

      Using a screwdriver, install the snap ring to the clutch drum and input shaft.

  51. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY


    1. A01E0VDE01

      Coat the No. 2 clutch drum thrust washer with petroleum jelly and install it to the clutch drum.

    2. Install the 1-way clutch to the clutch drum.

  52. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01DVE1E01

    1. Coat the 2 thrust needle roller bearings and clutch drum thrust washer with petroleum jelly and install them to the clutch drum and input shaft assembly.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing A 72.0 to 72.3 mm (2.83 to 2.85 in.) 85.3 to 85.6 mm (3.36 to 3.37 in.)
      Bearing A 34.7 to 34.9 mm (1366 to 1.374 in.) 51.6 to 51.9 mm (2.03 to 2.04 in.)
    2. A01DW8ZE01

      Install the clutch drum and input shaft assembly to the transmission case.

  53. INSTALL OIL PUMP ASSEMBLY

    A01E000E01

    1. Coat the No. 1 and No. 2 thrust bearing races with petroleum jelly, and install them to the front oil pump.

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 1 Race 74.3 to 74.6 mm (2.93 to 2.94 in.) 87.4 to 87.7 mm (3.44 to 3.45 in.)
      No. 2 Race 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.)
    2. A01DY2RE02

      Coat a new O-ring with ATF, and install it to the oil pump assembly.

    3. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.

    4. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

      Note

      Do not excessively push on the oil pump, as the oil seal ring will stick to the direct clutch drum.

    5. A01DVX5E01

      Install the 10 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  54. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A01DVD8E02

    1. Using SST and hammer, tap in 2 new oil seals.

      SST
      09350-30020   ( 09350-07110 )

    2. Coat the lip of the oil seals with MP grease.

  55. INSPECT INDIVIDUAL PISTON OPERATION


    1. A01DVJTE02

      Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

      Tech Tips

      When inspecting the O/D direct clutch, check with the accumulator piston holes indicated in the illustration.

      If there is no sound, disassemble and check the installation condition of the parts.


      1. No. 2 clutch (C2)

      2. No. 3 clutch (C3)

      3. No. 1 clutch (C1)

      4. No. 3 brake (B3)

      5. No. 1 brake (B1)

      6. No. 2 brake (B2)

      7. No. 4 brake (B4)

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    A01DW80E02

    1. Install a new spacer to the manual valve lever.

    2. Push the manual valve lever shaft through the transmission case, and install the manual valve lever to the manual valve lever shaft.

    3. A01DXBQE01

      Using a hammer, tap in a new spring pin.

    4. A01DYB0E01

      Align the manual valve lever indentation with the spacer hole, and stake them together with a punch.

    5. Check that the shaft rotates smoothly.

  57. INSTALL PARKING LOCK PAWL SHAFT

    A01DVBUE04

    1. Install the E-ring to the shaft.

    2. Install the parking lock pawl, shaft and spring.

  58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A01DYW5E01

    1. Connect the parking lock rod to the manual valve lever.

  59. INSTALL PARKING LOCK PAWL BRACKET

    A01DX17E01

    1. Place the parking lock pawl bracket onto the transmission case and install the 3 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A01E06ME03

      Move the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked up by the lock pawl.

  60. INSTALL C-1 ACCUMULATOR VALVE

    A01DZVJE06

    1. Coat a new O-ring with ATF, and install it to the accumulator valve.

    2. A01E0XPE01

      Install the spring and accumulator valve to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-1 Inner

      30.40 mm (1.20 in.)

      11.40 mm (0.449 in.)

      		 Pink
      C-1 Outer

      48.76 mm (1.92 in.)

      16.60 mm (0.654 in.)

      		 Light green

  61. INSTALL C-3 ACCUMULATOR PISTON

    A01DZVJE07

    1. Coat 2 new O-rings with ATF, and install them to the piston.

    2. A01DVVLE01

      Install the 2 springs and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3 Inner

      44.0 mm (1.73 in.)

      14.0 mm (0.551 in.)

      		 Yellow
      C-3 Outer

      73.35 mm (2.89 in.)

      19.90 mm (0.784 in.)

      		 Red

  62. INSTALL B-3 ACCUMULATOR PISTON

    A01DZVJE08

    1. Coat 2 new O-rings with ATF, and install them to the piston.

    2. A01E0N5E01

      Install the spring and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3

      70.5 mm (2.78 in.)

      19.7 mm (0.776 in.)

      		 Purple

  63. INSTALL C-2 ACCUMULATOR PISTON

    A01DZVJE09

    1. Coat 2 new O-rings with ATF, and install them to the piston.

    2. A01DW1JE01

      Install the spring and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-2

      62.0 mm (2.44 in.)

      15.9 mm (0.626 in.)

      		 White

  64. INSTALL CHECK BALL BODY

    A01DVXSE05

    1. Install the spring and check ball body.

  65. INSTALL BRAKE DRUM GASKET

    A01E0WAE01

    1. Install the 3 brake drum gaskets.

  66. INSTALL TRANSMISSION CASE GASKET

    A01E00ME08

    1. Install the 3 transmission case gaskets.

  67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A01DVW1E01

    1. Insert the pin of the manual valve into the hole of the manual valve lever.

    2. A01E2JRE01

      Install the transmission valve body assembly with the 19 bolts.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      36 mm (1.42 in.) for bolt A

      25 mm (0.984 in.) for bolt B

    3. Install the detent spring and detent spring cover with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  68. INSTALL TRANSMISSION WIRE

    A01DVV1E01

    1. Install a new O-ring to the transmission wire.

    2. Install the transmission wire harness.

    3. Install the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. A01DYKME02

      Connect the 7 solenoid connectors.

    5. Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

      Sensor Wire Harness:
      Wire Harness Color
      No. 1 temperature sensor Orange
      No. 2 temperature sensor Blue

  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A01DW6CE01

    1. Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.

    2. Install the oil strainer with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  70. INSTALL TRANSMISSION OIL CLEANER MAGNET

    A01DVSNE02

    1. Install the 4 magnets.

  71. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install a new gasket to the oil pan.

    2. Install the oil pan with the 20 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. Install the drain plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  72. INSTALL REAR TRANS CASE ADAPTOR OIL RECEIVER

    A01DVFF

    1. Install the trans case adaptor oil receiver to the rear adaptor transfer.

    2. Using snap ring pliers, install the snap ring.

  73. INSTALL TRANSMISSION CASE ADAPTER REAR OIL SEAL

    A01DVS7E01

    1. Coat the lip of a new oil seal with ATF.

    2. Using SST and a hammer, tap in the oil seal.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )
      Standard depth
      0 to 0.5 mm (0 to 0.0197 in.)

  74. INSTALL TRANSFER ADAPTER REAR


    1. Clean the threads of the bolts and case.

    2. A01DZ6IE01

      Apply seal packing or equivalent to the transmission case adapter and 8 bolts.

      Seal packing
      Toyota Genuine Seal Packing 1281,
      Three Bond 1281 or equivalent
      Seal diameter
      1.0 to 1.5 mm (0.0394 to 0.0591 in.)
    3. A01DVVCE07

      Install the transmission case adapter with the 8 bolts.

      Torque:
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      50 mm (1.97 in.) for bolt A

      40 mm (1.57 in.) for bolt B

  75. INSTALL AUTOMATIC TRANSMISSION HOUSING

    A01DZ1KE02

    1. Clean the threads of the bolts and case with non-residue solvent.

    2. Install the transmission housing with the 10 bolts.

      Torque:
      for 14 mm head bolt A
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }
      for 17 mm head bolt B
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      for 14 mm head bolt C
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

  76. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

    A01E31RE01

    1. Coat a new O-ring with ATF and install it to the breather tube.

    2. Install the breather tube with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  77. INSTALL SPEED SENSOR


    1. A01E1JJ

      Coat 2 new O-rings with ATF, and install them to the speed sensors.

    2. Install the 2 speed sensors.

    3. Install the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  78. INSTALL OIL COOLER TUBE UNION


    1. A01DX2YE02

      Coat a new O-ring with ATF, and install it to oil cooler tube union.

    2. Install the oil cooler tube union.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  79. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    Tech Tips

    Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch as the detent spring may become detached from the manual valve lever shaft.


    1. A01E2QYE01

      Install the park/neutral position switch to the manual valve lever shaft, and temporarily install the adjusting bolt.

    2. Install a new lock washer and the nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    3. A01DUXDE01

      Using the control shaft lever, turn the manual lever shaft clockwise until it stops, and then turn it counterclockwise 2 notches to set it to the N position.

    4. A01DXXTE10

      Align the neutral basic line with the switch groove, and tighten the adjusting bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    5. A01DWR0E01

      Using a screwdriver, bend the tabs of the lock washer.

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  80. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH

    A01E2V4E01

    1. Install the control shaft lever with the spring washer and nut.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }