AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A003CVQE02
    Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.)
    A 28.45 (1.120) / 47.3 (1.862) 29.2 (1.15) / 50.2 (1.976) -
    B 28.8 (1.134) / 46.4 (1.827) 28.9 (1.138) / 50.2 (1.976) -
    C 24.7 (0.972) / 41.8 (1.646) 24.2 (0.953) / 47.8 (1.882) -
    D 37.2 (1.465) / 58.8 (2.315) 33.8 (1.331) / 50.0 (1.969) -
    E 36.8 (1.449) / 50.9 (2.004) 33.7 (1.327) / 47.6 (1.874) -
    F 26.0 (1.024) / 48.9 (1.926) 26.0 (1.024) / 46.7 (1.839) 26.8 (1.055) / 47.0 (1.850)
    G - 35.2 (1.386) / 53.6 (2.110) 34.3 (1.350) / 47.8 (1.882)
    H 33.7 (1.327) / 47.6 (1.874) 35.5 (1.398) / 47.7 (1.878) -
    I 28.5 (1.122) / 44.2 (1.740) 27.7 (1.091) / 44.2 (1.740) -
    J - 39.38 (1.550) / 58.1 (2.287) -

  2. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A003FC1

      Install the transmission case in the overhaul attachment.

  3. INSTALL 1ST AND REVERSE BRAKE PISTON NO.1


    1. A003EU0E05

      Coat 3 new O-rings with ATF.

    2. Install the 2 O-rings on the 1st and reverse brake piston No.1.

    3. Install the O-ring on the reaction sleeve.

    4. Install the 1st and reverse brake piston No.1 to the reaction sleeve.

  4. INSTALL BRAKE REACTION SLEEVE


    1. A003G9F

      Coat new O-ring with ATF, and install it to the reaction sleeve.

    2. With the brake piston No.1 underneath (the rear side), install the brake reaction sleeve and the brake piston No.1 to the transmission case.

      Note

      Be careful not to damage the O-rings.

  5. INSTALL 1ST AND REVERSE BRAKE PISTON NO.2


    1. A003BJXE04

      Coat new O-ring with ATF.

    2. Install the O-ring on brake piston No.2.

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

      Note

      Be careful not to damage the O-ring.

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


    1. A003GRQ

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

    2. A003EBLE02

      Set SST as shown, and compress the return spring with SST.

      SST
      09350-30020   ( 09350-07050, 09350-07070 )

    3. Using a screwdriver, install the snap ring. Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

  7. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE

  8. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A003HDU

      Install the leaf spring.

    2. A003EYL

      Install the flange with the rounded edge facing forward. Reinstall the plates and discs.

      Install in order
      P = Plate D = Disc
      D - P - D - P - D - P - D - P - D - P - D - P

    3. Install the 2nd brake drum assembly.

    4. A003DDU

      Coat the bearing with petroleum jelly and install it onto the case.

      Bearing diameter:
      Inside Outside
      39.38 mm (1.5504 in.) 58.1 mm (2.2874 in.)
    5. A003GDP

      Align the teeth on the flange, the discs and the plates.

    6. A003D6I

      Align the splines of the transmission case with the assembled rear planetary gear, the 2nd brake drum, and the 1st and reverse brake pack with the output shaft,

    7. Hold the output shaft with wooden blocks or equivalents.

    8. A003C2JE01

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  9. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

  10. INSTALL 2ND BRAKE PISTON SLEEVE


    1. A003B2N

      Install the brake reaction sleeve.

  11. INSTALL BRAKE DRUM GASKET


    1. A003ANI

      Coat a new gasket with ATF.

    2. Install the brake drum gasket.

  12. INSTALL 1 WAY CLUTCH ASSEMBLY


    1. A003HUO

      Install the thrust washer.

    2. Install the 1 way clutch assembly.

  13. INSTALL 2ND BRAKE PACK


    1. A003AH9

      Install the 1.8 mm (0.071 in.) thick plate with the rounded edge side of the plate facing the disc.

    2. Install the plates and discs.

      Plate thickness
      2.5 mm (0.098 in.)
      Install in order
      P = Plate D = Disc
      D - P - D - P - D - P - D - P - D - P

    3. Install the flange with the rounded edge of the flange facing the disc.

    4. A003D5R

      Using a screwdriver, install the snap ring.

  14. INSPECT PACK CLEARANCE OF SECOND BRAKE

  15. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A003EOT

      While turning the planetary sun gear clockwise, install it into the 1 way clutch.

      Tech Tips

      Confirm the thrust washer is installed correctly.

  16. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A003BG0E01

      Coat the bearing and race with petroleum jelly and install them onto the front planetary gear.

      Bearing and race diameter:
      Inside Outside
      Bearing 35.5 mm (1.398 in.) 47.7 mm (1.878 in.)
      Race 33.7 mm (1.327 in.) 47.6 mm (1.874 in.)
    2. A003HTE

      Install the front planetary gear to the sun gear input drum.

    3. A003DGUE01

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

    4. Remove the wooden blocks or equivalent under the output shaft.

    5. A003E0CE01

      Coat the race with petroleum jelly, and install it onto the front planetary gear.

      Race diameter:
      Inside Outside
      34.3 mm (1.350 in.) 47.8 mm (1.882 in.)

  17. INSTALL 2ND COAST BRAKE BAND ASSEMBLY


    1. A003FR3

      Install the 2nd coast brake band to the case.

    2. Using needle-nose pliers, install the E-ring to the pin.

    3. A003H5L

      Install the pin through the brake band.

    4. A003ESI

      Using needle-nose pliers, install the E-ring to the pin.

  18. INSTALL DIRECT CLUTCH ASSEMBLY


    1. Install the bearing and thrust washer to the forward clutch.

    2. A003DISE01

      Install the direct clutch to the forward clutch.

    3. A003HYWE02

      Coat the bearing and the race with petroleum jelly, and install them onto the forward clutch.

      Bearing and race diameter:
      Inside Outside
      Race 26.0 mm (1.024 in.) 48.9 mm (1.926 in.)
      Bearing 26.0 mm (1.024 in.) 46.7 mm (1.839 in.)
    4. A003ASPE02

      Coat the race with the petroleum jelly, and install it onto the front planetary ring gear.

      Race diameter:
      Inside Outside
      Race 26.8 mm (1.055 in.) 47.0 mm (1.850 in.)
    5. A003DUT

      Align the flukes of the discs in the forward clutch.

    6. A003EAJE02

      Align the splines of the front planetary ring gear with the flukes of the discs and install the front planetary ring gear to the forward clutch.

  19. INSTALL FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003BCZE02

      Coat the bearing and the race with petroleum jelly, and install them onto the ring gear.

      Bearing and race diameter:
      Inside Outside
      Bearing 32.6 mm (1.283 in.) 47.7 mm (1.878 in.)
      Race 30.6 mm (1.205 in.) 53.6 mm (2.110 in.)
    2. A003H84

      Install the assembled direct clutch, the forward clutch and the front planetary ring gear into the transmission case.

    3. A003FF6

      Using vernier calipers, measure the distance between the sun gear input drum and the direct clutch drum as shown in the illustration.

      Height
      5.3 to 7.3 mm (0.209 to 0.287 in.)

      If the distance is outside standard, check for an improper installation.

    4. A003G3LE02

      Coat the bearing with petroleum jelly and install it onto the forward clutch.

      Bearing diameter:
      Inside Outside
      Bearing 33.7 mm (1.327 in.) 47.6 mm (1.874 in.)

  20. INSTALL 2ND COAST BRAKE PISTON


    1. A003G0T

      Coat 2 new O-rings with ATF and install them to the cover.

    2. Install the spring, the piston assembly and the cover to the case.

    3. A003H6CE02

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  21. INSPECT PISTON STROKE OF 2ND COAST BRAKE

  22. INSTALL OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. A003I64E04

      Coat the bearing and race with petroleum jelly, and install it onto the O/D support assembly.

      Bearing and race diameter:
      Inside Outside
      Bearing 36.8 mm (1.449 in.) 50.9 mm (2.004 in.)
      Race 36.8 mm (1.449 in.) 50.9 mm (2.004 in.)
    2. A003CSRE01

      Using 2 bolts of SST, aim the bolt and the oil holes of the O/D support toward the valve body side, and align them with the bolt holes of the transmission case, and insert.

      SST
      09350-30020   ( 09350-07020 )

    3. Temporarily tighten the 2 bolts.

    4. A003DGFE02

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

      Tech Tips

      Install the snap ring open end toward the valve body.

    5. A003AJ6

      Torque the 2 bolts.

      Torque:
      25 N*m  { 260 kgf*cm, 19 ft.*lbf }

  23. INSPECT OUTPUT SHAFT

  24. INSTALL OVERDRIVE BRAKE PACK


    1. A003C4W

      Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the discs.

    2. Install the plates and discs.

      Install in order
      P = Plate D = Disc
      P - D - P - D - P - D - P - D

    3. Install the flange (stepped ring) with the flat side of the flange facing the disc.

    4. A003AOU

      Using a screwdriver, install the snap ring.

  25. INSPECT OVERDRIVE BRAKE PISTON

  26. INSTALL OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. A003BEZ

      Coat the bearing and race with petroleum jelly, and install it onto the O/D support.

      Race diameter:
      Inside Outside
      Race 37.2 mm (1.465 in.) 58.8 mm (2.315 in.)
    2. A003GSV

      Install the O/D planetary ring gear.

    3. A003GE3

      Coat the bearing and the race with petroleum jelly, and install them onto the planetary ring gear.

      Bearing and race diameter:
      Inside Outside
      Bearing 26.0 mm (1.024 in.) 46.8 mm (1.843 in.)
      Race 24.2 mm (0.953 in.) 47.8 mm (1.882 in.)
    4. A003B6X

      Coat the race with petroleum jelly, and install it onto the planetary gear.

      Race diameter:
      Inside Outside
      24.7 mm (0.9724 in.) 41.8 mm (1.646 in.)
    5. A003E10

      Install the O/D planetary gear, O/D direct clutch and one- way clutch.

    6. A003G5BE02

      Place SST on the transmission case.

      SST
      09350-36010   ( 09350-06090 )

    7. Using vernier calipers, measure distance between the tops of SST and the clutch drum.

      Standard distance
      15.5 to 16.5 mm (0.610 to 0.650 in.)

      If the distance is outside the standard, check for an improper installation.

    8. A003GCIE02

      Coat the bearing with petroleum jelly and install it onto the O/D direct clutch.

      Bearing and race diameter:
      Inside Outside
      Bearing 29.2 mm (1.150 in.) 50.2 mm (1.976 in.)

  27. INSTALL OIL PUMP ASSEMBLY


    1. A003EZ4E02

      Coat the race with petroleum jelly, and install it onto the oil pump.

      Race diameter:
      Inside Outside
      Race 28.45 mm (1.120 in.) 47.3 mm (1.862 in.)

    2. Coat a new O-ring with ATF, and install it around the pump body.

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

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

      Note

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

    5. A003GWX

      Install the 7 bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }

  28. INSPECT INPUT SHAFT SUB-ASSEMBLY

  29. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION

  30. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A003I3XE02

      Using SST and a hammer, drive in 2 new manual valve lever shaft oil seals.

      SST
      09350-30020   ( 09350-07110 )

  31. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A003H2XE01

      Install a new spacer to the manual valve lever.

    2. Install the manual valve lever shaft to the transmission case through the manual valve lever.

    3. A003FD4

      Using a hammer, drive in a new pin.

    4. A003G8U

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

    5. Make sure the shaft rotates smoothly.

  32. INSTALL PARKING LOCK PAWL SHAFT


    1. A003ES3E02

      Install the E-ring to the shaft.

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

  33. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A003CHZ

      Connect the parking lock rod to the manual valve lever.

  34. INSTALL PARKING LOCK PAWL BRACKET


    1. A003AOB

      Install the parking lock pawl bracket with the 3 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A003GYNE02

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

  35. INSTALL C-0 ACCUMULATOR PISTON


    1. A003H77E02

      Coat new O-ring with ATF, and install them to the piston.

    2. A003DZO

      Install the 2 springs and the accumulator piston to the hole.

      Accumulator spring:
      Spring Free length outer diameter mm (in.) Color
      C0 Inner

      46.0 mm (1.811 in.)

      14.02 mm (0.552 in.)

      		 Yellow
      C0 Outer

      74.6 mm (2.937 in.)

      20.9 mm (0.823 in.)

      		 Orange

  36. INSTALL B-0 ACCUMULATOR PISTON


    1. A003H77E02

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

    2. A003IEW

      Install the spring and the accumulator piston to the hole.

      Accumulator spring:
      Spring Free length outer diameter mm (in.) Color
      B0

      62.0 mm (2.441 in.)

      16.0 mm (0.630 in.)

      		 Green

  37. INSTALL C-2 ACCUMULATOR PISTON


    1. A003H77E02

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

    2. A003CNA

      Install the 2 springs and the accumulator piston to the hole.

      Accumulator spring:
      Spring Free length outer diameter mm (in.) Color
      C2 Inner

      42.1 mm (1.657 in.)

      14.7 mm (0.579 in.)

      		 Pink
      C2 Outer

      68.53 mm (2.698 in.)

      20.2 mm (0.795 in.)

      		 Blue

  38. INSTALL B-2 ACCUMULATOR PISTON


    1. A003H77E02

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

    2. A003GM5

      Install the spring and the accumulator piston to the hole.

      Accumulator spring:
      Spring Free length outer diameter mm (in.) Color
      B2

      70.5 mm (2.776 in.)

      19.9 mm (0.783 in.)

      		 Light green

  39. INSTALL CHECK BALL BODY


    1. A003I3GE02

      Install the check ball body and spring.

  40. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A003HDHE02

      Align the groove of the manual valve with the pin of the lever.

    2. A003I22E02

      Install the 20 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt length
      Bolt A
      23 mm (0.91 in.)
      Bolt B
      28 mm (1.10 in.)
      Bolt C
      36 mm (1.42 in.)

  41. INSTALL TRANSMISSION WIRE


    1. A003GZS

      Coat a new O-ring with ATF, and install it to the transmission wire.

    2. Install the solenoid wiring to the case, and then install the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. A003F43

      Connect the connectors to each shift solenoid valve.

  42. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. Using a plastic hammer, install the pipe into the position.

      Note

      Be careful not to bend or damage the pipes.

    2. A003HOVE01

      Install the oil strainer with the 4 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Bolt length
      Bolt A
      16 mm (0.63 in.)
      Bolt B
      20 mm (0.79 in.)
      Bolt C
      28 mm (1.10 in.)

  43. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A003HRJ

      Install the 3 magnets on the oil pan.

  44. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A003BEHE03

      Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transmission case and the oil pan.

    2. Apply FIPG to the oil pan.

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Install the oil pan with the 19 bolts.

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

  45. INSTALL SENSOR ROTOR


    1. A003FC4

      Using a snap ring expander, install the front side snap ring.

    2. Install the key and sensor rotor.

    3. Using a snap ring expander, install the rear side snap ring.

  46. INSTALL EXTENSION HOUSING DUST DEFLECTOR


    1. A003CDC

      Using a screwdriver and hammer, install new extension housing dust deflector.

  47. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003GZ8E02

      Using SST and a hammer, install a new extension housing oil seal.

      SST
      09950-60020   ( 09951-00580 )
      09950-70010   ( 09951-07100 )
      Oil seal in depth
      5.8 to 6.2 mm (0.228 to 0.244 in.)

  48. INSTALL EXTENSION HOUSING BUSH APPLY TUBE


    1. A003CPCE04

      Install the extension housing bush apply tube.

  49. INSTALL EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. A003CPCE05

      Install the extension housing bush apply tube gasket.

  50. INSTALL EXTENSION HOUSING SUB-ASSEMBLY


    1. A003E1H

      Apply seal packing or equivalent to the 6 bolts.

      Seal packing
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the extension housing and a new gasket to the case with the 6 bolts.

      Torque:
      36 N*m  { 370 kgf*cm, 27 ft.*lbf }

      Tech Tips

      The 2 lower bolts are shorter.

  51. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. A003FUZ

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

    2. Install the revolution sensor with the bolt.

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

  52. INSTALL AUTOMATIC TRANSMISSION HOUSING


    1. A003CQS

      Install the transmission housing with the 6 bolts.

      Torque
      14 mm bolt
      34 N*m (345 kgf*cm, 25 ft.*lbf)
      17 mm bolt
      57 N*m (580 kgf*cm, 42 ft.*lbf)

  53. INSTALL SPEED SENSOR


    1. A003CLA

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

    2. Install the speed sensor.

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

  54. INSTALL TEMPERATURE SENSOR


    1. A003DCK

      Coat a new O-ring with ATF, and install it to the temperature sensor.

    2. Install the temperature sensor.

      Torque:
      15 N*m  { 160 kgf*cm, 11 ft.*lbf }

  55. INSTALL OIL COOLER TUBE UNION


    1. Coat a new O-rings with ATF, and install them to the unions.

    2. Install the oil cooler tube unions.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  56. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A003CCSE01

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

    2. Install the nut stopper and a new lock washer. Install the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    3. Using the control shaft lever, fully turn the manual lever shaft back, and then return 2 notches. It is now in neutral.

    4. A003GE4E01

      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. Bend the tabs of the lock washer.

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  57. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. A003BS3

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

    2. Install the cable to the case with the bolt.

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

  58. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH


    1. Install the transmission control shaft lever and the washer. Install the nut.

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

  59. INSTALL BREATHER PLUG HOSE


    1. Install the breather plug hose.

  60. INSTALL DRAIN (ATM) PLUG SUB-ASSEMBLY

    Torque:
    20 N*m  { 205 kgf*cm, 15 ft.*lbf }