AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A003BNAE01
    Mark

    Front Race Diameter

    Inside / Outside (mm (in.))

    Thrust Bearing Diameter

    Inside / Outside (mm (in.))

    Rear Race Diameter

    Inside / Outside (mm (in.))
    A 74.2 (2.921) / 87.74 (3.454) 71.9 (2.831) / 85.6 (3.370) -
    B 40.0 (1.575) / 52.8 (2.079) 34.6 (1.362) / 52.0 (2.047) -
    C 22.0 (0.890) / 44.8 (1.764) 21.3 (0.839) / 41.1 (1.618) -
    D 38.4 (1.512) / 56.5 (2.224) 33.3 (1.311) / 56.6 (2.228) -
    E - 40.83 (1.607) / 52.8 (2.079) 39.6 (1.559) / 52.8 (2.079)
    F - 37.1 (1.461) / 61.2 (2.409) 44.0 (1.732) / 62.8 (2.472)
    G 65.8 (2.591) / 86.3 (3.398) 63.3 (2.492) / 78.8 (3.102) -
    H 66.3 (2.610) / 78.9 (3.106) 63.3 (2.492) / 78.8 (3.102) -
    I - 55.7 (2.193) / 76.4 (3.008) 53.7 (2.114) / 74.0 (2.913)
    J 33.4 (1.315) / 49.0 (1.929) 32.1 (1.264) / 49.35 (1.943) 32.1 (1.264) / 49.0 (1.929)
    K - 21.0 (0.827) / 41.5 (1.634) 23.13 (0.911) / 41.5 (1.634)
    L - 43.55 (1.715) / 61.0 (2.402) 47.1 (1.854) / 67.1 (2.642)
    M 36.1 (1.421) / 52.5 (2.067) 37.0 (1.457) / 51.2 (2.016) 36.1 (1.421) / 51.0 (2.008)

  2. INSTALL BRAKE PLATE STOPPER SPRING


    1. A003HN2

      Install the 2 brake plate stopper springs to the automatic transmission case sub-assembly.

      Note

      The shapes of the parts are different. Refer to the illustration when installing the parts.

  3. INSTALL NO. 4 BRAKE PISTON


    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. A003FTRE07
      Text in Illustration
      *1 No. 4 Brake Piston
      *2 Brake Reaction Sleeve

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

      Note

      Be careful not to damage the O-rings.

  4. INSTALL BRAKE REACTION SLEEVE


    1. A003ER0E01
      Text in Illustration
      *1 Brake Reaction Sleeve
      *2 No. 4 Brake Piston

      With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and No. 4 brake piston to the automatic transmission case sub-assembly.

      Note

      Be careful not to damage the O-rings.

  5. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. A003CFF

      Coat a new O-ring with ATF, and install it to the 1st and reverse brake piston.

    2. Install the 1st and reverse brake piston to the automatic transmission case sub-assembly while making sure that the protrusion of the 1st and reverse brake piston is positioned as shown in the illustration.

      Note

      Be careful not to damage the O-ring.

    3. A003F9M

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

    4. Place the 1st and reverse brake return spring sub-assembly onto the 1st and reverse brake piston.

    5. A003EIOE01
      Text in Illustration
      *a Protective Tape

      Place SST on the 1st and reverse brake return spring sub-assembly, and compress the 1st and reverse brake return spring sub-assembly.

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080, 09381-06120, 09381-06130, 09381-05040, 09381-05050 )

    6. Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

      Note

      Be careful not to damage the 1st and reverse brake return spring sub-assembly and automatic transmission case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A003BCRE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing K
      *2 Thrust Bearing Race K
      *3 Thrust Needle Roller Bearing L
      *4 Thrust Bearing Race L

      Coat the thrust bearing race with ATF and install it to the automatic transmission case sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing K 21.0 (0.827) 41.5 (1.634)
      Thrust Bearing Race K 23.13 (0.911) 41.5 (1.634)
      Thrust Needle Roller Bearing L 43.55 (1.715) 61.0 (2.402)
      Thrust Bearing Race L 47.1 (1.854) 67.1 (2.642)

      Note

      Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

    2. Coat the 2 thrust needle roller bearings and thrust bearing race with ATF and install them to the rear planetary gear assembly.

    3. Install the rear planetary gear assembly to the automatic transmission case sub-assembly.

    4. A003E1ME01
      Text in Illustration
      *1

      Thrust Bearing Race M

      (Front Race)
      *2 Thrust Needle Roller Bearing M
      *3

      Thrust Bearing Race M

      (Rear Race)

      Coat the thrust needle roller bearing and 2 thrust bearing races with ATF and install it to the output shaft of the rear planetary gear assembly.

      Bearing and Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))

      Thrust Bearing Race M

      (Front Race)

      		 36.1 (1.421) 52.5 (2.067)
      Thrust Needle Roller Bearing M 37.0 (1.457) 51.2 (2.016)

      Thrust Bearing Race M

      (Rear Race)

      		 36.1 (1.421) 51.0 (2.008)

      Note

      Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

    5. A003DUL

      Using a snap ring expander, install the snap ring.

    6. A003EGGE01
      Text in Illustration
      *1

      Thrust Bearing Race M

      (Rear Race)
      *a Mark Area

      Using a feeler gauge, measure the clearance between the snap ring and thrust bearing race.

      Standard clearance
      0.02 to 0.12 mm (0.000787 to 0.00472 in.)

      If the clearance is outside the standard range, select another thrust bearing race that brings the clearance within the standard range.

      Tech Tips

      There are 12 different thicknesses for the thrust bearing race.

      Thrust Bearing Race Thickness
      Part No. Mark Thickness (mm (in.))
      35789-35060 A003AXV 3.80 (0.150)
      35789-50070 A003DEV 3.85 (0.152)
      35789-35070 A003HDF 3.90 (0.154)
      35789-50080 A003CRI 3.95 (0.156)
      35789-35080 A003GXW 4.00 (0.157)
      35789-50090 A003BT6 4.05 (0.159)
      35789-35090 A003HFG 4.10 (0.161)
      35789-50100 A003CDW 4.15 (0.163)
      35789-35100 A003E33 4.20 (0.165)
      35789-50110 A003HAD 4.25 (0.167)
      35789-50120 A003BQZ 4.30 (0.169)
      35789-50130 A003CBN 4.35 (0.171)

  7. INSTALL NO. 4 BRAKE DISC


    1. A003D1UE01
      Text in Illustration
      *1 No. 4 Brake Flange
      *2 No. 4 Brake Disc
      *3 No. 4 Brake Plate

      Install the 2 No. 4 brake flanges, 5 No. 4 brake discs and 4 No. 4 brake plates to the automatic transmission case sub-assembly.

      Note


      • Make sure that the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are installed in the correct order.

      • Install the thicker No. 4 brake flange first, and then install the thinner one.

  8. INSTALL INTERMEDIATE SHAFT


    1. A003B5QE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing J
      *2 Thrust Bearing Race J

      Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the intermediate shaft.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing J 32.1 (1.264) 49.35 (1.943)

      Thrust Bearing Race J

      (Rear Race)

      		 32.1 (1.264) 49.0 (1.929)

    2. Install the intermediate shaft to the automatic transmission case sub-assembly.

  9. INSTALL REAR PLANETARY RING GEAR


    1. A003E89E01
      Text in Illustration
      *1 Rear Planetary Ring Gear Flange Sub-assembly
      *2 Rear Planetary Ring Gear

      Install the rear planetary ring gear to the rear planetary ring gear flange sub-assembly.

    2. A003I87E01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, install the snap ring to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

      Note

      Be careful not to damage the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

      Tech Tips

      Tape the screwdriver tip before use.

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY WITH REAR PLANETARY RING GEAR


    1. A003BRWE01
      Text in Illustration
      *1 Thrust Bearing Race J

      Coat the thrust bearing race with ATF and install it to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

      Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))

      Thrust Bearing Race J

      (Front Race)

      		 33.4 (1.315.) 49.0 (1.929)

      Note

      Be sure to install the thrust bearing race in the correct direction.

    2. Install the rear planetary ring gear flange sub-assembly with rear planetary ring gear to the automatic transmission case sub-assembly.

  11. INSTALL ONE-WAY CLUTCH INNER RACE


    1. A003DR3E01
      Text in Illustration
      *1 One-way Clutch Inner Race
      *2 No. 3 One-way Clutch Assembly

      Install the one-way clutch inner race to the No. 3 one-way clutch assembly.

      Tech Tips

      Rotate the one-way clutch inner race clockwise to install it.

  12. INSTALL NO. 3 ONE-WAY CLUTCH ASSEMBLY WITH ONE-WAY CLUTCH INNER RACE


    1. A003BP9

      Install the No. 3 one-way clutch assembly with one-way clutch inner race to the automatic transmission case sub-assembly.

    2. A003HW0E01
      Text in Illustration
      *1 Snap Ring
      *a 19°
      *b 49°
      A003DCD Front Side

      Using SST, install the snap ring to the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07060 )

      Note


      • Install the snap ring so that the tapered side is facing out.

      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

  13. INSPECT CLEARANCE OF NO. 4 BRAKE


    1. A003C5O

      Make sure that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. A003FJ7E01
      Text in Illustration
      *1 Selected No. 4 Brake Flange

      Using a feeler gauge, measure the No. 4 brake pack clearance between the No. 4 brake disc and No. 4 brake flange.

      Standard clearance
      0.5 to 0.8 mm (0.0197 to 0.0314 in.)

      If the clearance is not as specified, select and install an appropriate No. 4 brake flange that will bring the clearance within the specified range.

      No. 4 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 1.80 (0.0709)
      1 1.97 (0.0776)
      3 2.11 (0.0831)
      4 2.25 (0.0886)
      5 2.39 (0.0941)
      7 2.53 (0.0996)
      8 2.67 (0.105)
      10 2.81 (0.111)
      11 2.95 (0.116)
      12 3.09 (0.122)
      14 3.23 (0.127)

  14. INSTALL NO. 1 BRAKE PISTON


    1. Coat 2 new O-rings with ATF and install them to the No. 1 brake piston.

    2. A003ENT

      With the No. 1 brake piston return spring sub-assembly installed to the No. 1 brake piston, align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston to the No. 1 brake cylinder.

  15. INSTALL NO. 1 BRAKE CYLINDER WITH NO. 1 BRAKE PISTON


    1. A003EMV

      Install the No. 1 brake cylinder with No. 1 brake piston to the automatic transmission case sub-assembly while making sure that the 2 claws of the No. 1 brake cylinder with No. 1 brake piston are positioned as shown in the illustration.

  16. INSTALL NO. 1 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A003BV9

      Align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston return spring sub-assembly to the No. 1 brake piston.

    2. A003BL2E01
      Text in Illustration
      *a Turn

      Place SST on the No. 1 brake piston return spring sub-assembly, and compress the No. 1 brake piston return spring sub-assembly with a press.

      SST
      09380-60010   ( 09381-06010, 09381-06040, 09381-06050, 09381-06070, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )
    3. A003AX3E01
      Text in Illustration
      *a 22.5°
      *b 37.5°

      Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

      Note


      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

      • Be careful not to damage the automatic transmission case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  17. INSTALL NO. 1 BRAKE DISC


    1. A003I15E01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate

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

      Note

      Make sure that the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are installed in the correct order.

    2. A003G6SE01
      Text in Illustration
      *a 22.5°
      *b 37.5°

      Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

      Note


      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

      • Be careful not to damage the automatic transmission case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  18. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A003F4I

      Make sure that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. A003BHIE01
      Text in Illustration
      *1 Selected No. 1 Brake Flange

      Using a feeler gauge, measure the No. 1 brake pack clearance between the No. 1 brake disc and No. 1 brake flange.

      Standard clearance
      0.3 to 0.6 mm (0.0119 to 0.0236 in.)

      If the clearance is not as specified, select and install an appropriate No. 1 brake flange that will bring the clearance within the specified range.

      No. 1 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 4.9 (0.193)
      1 5.0 (0.197)
      2 5.1 (0.201)
      3 5.2 (0.205)
      4 5.3 (0.209)
      5 5.4 (0.213)
      6 5.5 (0.217)
      7 5.6 (0.220)
      8 5.7 (0.224)
      A 5.8 (0.228)

  19. INSTALL PLANETARY SUN GEAR


    1. A003DZZ

      Install the planetary sun gear to the automatic transmission case sub-assembly.

  20. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. A003GBCE01
      Text in Illustration
      *1 Thrust Bearing Race I

      Coat the thrust bearing race with ATF and install it to the center planetary gear assembly.

      Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing Race I 53.7 (2.114) 74.0 (2.913)

    2. Install the center planetary gear assembly to the automatic transmission case sub-assembly.

  21. INSTALL CENTER PLANETARY RING GEAR


    1. A003FH9E01
      Text in Illustration
      *1 Center Planetary Ring Gear Flange
      *2 Center Planetary Ring Gear

      Install the center planetary ring gear to the center planetary ring gear flange

    2. A003EBYE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, install the snap ring to the center planetary ring gear flange with center planetary ring gear.

      Note

      Be careful not to damage the center planetary ring gear flange with center planetary ring gear.

      Tech Tips

      Tape the screwdriver tip before use.

  22. INSTALL CENTER PLANETARY RING GEAR FLANGE WITH CENTER PLANETARY RING GEAR


    1. A003H7RE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing H
      *2 Thrust Needle Roller Bearing I

      Coat the 2 thrust needle roller bearings with ATF and install them to the center planetary ring gear flange with center planetary ring gear.

      Thrust Needle Roller Bearing Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing H 63.3 (2.492) 78.8 (3.102)
      Thrust Needle Roller Bearing I 55.7 (2.193) 76.4 (3.008)

      Note

      Be sure to install the thrust needle roller bearing in the correct direction.

    2. Install the center planetary ring gear flange with center planetary ring gear to the automatic transmission case sub-assembly.

  23. INSTALL NO. 2 BRAKE DISC


    1. A003ACYE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate

      Install the 2 No. 2 brake flanges, 4 No. 2 brake discs and 3 No. 2 brake plates to the automatic transmission case sub-assembly.

      Note

      Make sure that the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are installed in the correct order.

  24. INSTALL NO. 2 BRAKE PISTON


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

    2. A003CP4

      With the No. 2 brake piston return spring sub-assembly installed to the No. 2 brake piston, align the claw of the No. 2 brake piston return spring sub-assembly with the claw of the No. 2 brake cylinder, and then install the No. 2 brake piston to the No. 2 brake cylinder.

      Note

      Be careful not to damage the O-rings.

  25. INSTALL NO. 2 BRAKE CYLINDER WITH NO. 2 BRAKE PISTON


    1. A003DN3

      Install the No. 2 brake piston return spring sub-assembly to the automatic transmission case sub-assembly while making sure that the claw of the No. 2 brake piston return spring sub-assembly is positioned as shown in the illustration.

    2. A003H79

      Install the No. 2 brake cylinder with No. 2 brake piston to the automatic transmission case sub-assembly while making sure that the claw of the No. 1 brake cylinder with No. 1 brake piston is positioned as shown in the illustration.

    3. A003BLSE01
      Text in Illustration
      *a Turn

      Place SST on the No. 2 brake cylinder, and compress the No. 2 brake piston return spring sub-assembly with a press.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06040, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )
    4. A003FAAE01
      Text in Illustration
      *a 30°

      Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

      Note


      • Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

      • Be careful not to damage the automatic transmission case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  26. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A003E7W

      Make sure that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. A003D83E01
      Text in Illustration
      *1 Selected No. 2 Brake Flange

      Using a feeler gauge, measure the No. 2 brake pack clearance between the No. 2 brake disc and No. 2 brake flange.

      Standard clearance
      0.4 to 0.7 mm (0.0158 to 0.0275 in.)

      If the clearance is not as specified, select and install an appropriate No. 2 brake flange that will bring the clearance within the specified range.

      No. 2 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 2.0 (0.0787)
      1 2.1 (0.0827)
      2 2.2 (0.0866)
      3 2.3 (0.0906)
      4 2.4 (0.0945)
      5 2.5 (0.0984)
      6 2.6 (0.102)
      7 2.7 (0.106)
      8 2.8 (0.110)

  27. INSTALL FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. A003AKYE01
      Text in Illustration
      *1 Front Planetary Ring Gear
      *2 Snap Ring
      *3 Front Planetary Ring Gear Flange Sub-assembly

      Set the snap ring onto the front planetary ring gear flange sub-assembly. Using needle-nose pliers, insert the snap ring into the front planetary ring gear while squeezing it, and then expand the snap ring to install it.

      Note

      Make sure the snap ring is securely inserted into the groove of the front planetary ring gear.

  28. INSTALL FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. A003ADRE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing G
      *2 Thrust Bearing Race H

      Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the front planetary ring gear with front planetary ring gear flange sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing G 63.3 (2.492) 78.8 (3.102)
      Thrust Bearing Race H 66.3 (2.610) 78.9 (3.106)

      Note

      Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

    2. Install the front planetary ring gear with front planetary ring gear flange sub-assembly to the automatic transmission case sub-assembly.

  29. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A003BM6E01
      Text in Illustration
      *1 Thrust Bearing Race F
      *2 Thrust Bearing Race G

      Coat the 2 thrust bearing races with ATF and install them to the front planetary gear assembly.

      Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing Race F 44.0 (1.732) 62.8 (2.472)
      Thrust Bearing Race G 65.8 (2.591) 86.3 (3.398)

      Note

      Be sure to install the thrust bearing race in the correct direction.

    2. Install the front planetary gear assembly to the automatic transmission case sub-assembly.

  30. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. A003AZ5E01
      Text in Illustration
      *1 Thrust Bearing Race E
      *2 Thrust Needle Roller Bearing F

      Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the sun gear input drum sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing Race E 40.83 (1.607) 52.8 (2.079)
      Thrust Needle Roller Bearing F 37.1 (1.461) 61.2 (2.409)

      Note

      Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

    2. Install the sun gear input drum sub-assembly to the automatic transmission case sub-assembly.

  31. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. A003E4BE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing D
      *2 Thrust Needle Roller Bearing E

      Coat the 2 thrust needle roller bearings with ATF and install them to the forward clutch hub sub-assembly.

      Thrust Needle Roller Bearing Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing D 33.3 (1.311) 56.6 (2.228)
      Thrust Needle Roller Bearing E 39.6 (1.559) 52.8 (2.079)

      Note

      Be sure to install the thrust needle roller bearing in the correct direction.

    2. Install the forward clutch hub sub-assembly to the automatic transmission case sub-assembly.

  32. INSTALL MULTIPLE DISC CLUTCH HUB


    1. A003CJQE01
      Text in Illustration
      *1 Thrust bearing race C
      *2 Thrust bearing race D

      Coat the 2 thrust bearing races with ATF and install them to the multiple disc clutch hub.

      Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust bearing race C 22.6 (0.890) 44.8 (1.764)
      Thrust bearing race D 38.4 (1.512) 56.5 (2.224)

      Note

      Be sure to install the thrust bearing race in the correct direction.

    2. Install the multiple disc clutch hub to the automatic transmission case sub-assembly.

  33. INSTALL DIRECT CLUTCH PISTON


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

    2. A003FOW

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

      Note

      Be careful not to damage the O-rings.

  34. INSTALL NO. 2 CLUTCH BALANCER


    1. A003DQVE01
      Text in Illustration
      *1 No. 2 Clutch Balancer
      *2 Direct Clutch Return Spring Sub-assembly

      Install the direct clutch return spring sub-assembly to the direct clutch piston.

    2. Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.

    3. Install the No. 2 clutch balancer to the direct clutch drum sub-assembly.

      Note

      Be careful not to damage the O-ring.

    4. A003I7ZE01

      Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080, 09381-06100, 09381-06110 )

      Note

      Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

  35. INSTALL NO. 2 CLUTCH DISC (DIRECT CLUTCH DISC)


    1. A003ASFE01
      Text in Illustration
      *1 Direct Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate

      Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.

      Note

      Make sure that the No. 2 clutch discs, No. 2 clutch plates and direct clutch flange are installed in the correct order.

    2. A003HTQE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, install the snap ring to the direct clutch drum sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  36. INSPECT CLEARANCE OF NO. 2 CLUTCH (DIRECT CLUTCH)


    1. A003H58E01
      Text in Illustration
      *1 Selected Direct Clutch Flange
      *a Oil Hole

      Using a dial indicator, measure the clearance of the No. 2 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) to the oil hole as shown in the illustration, and calculate the average.

      Standard clearance
      0.4 to 0.7 mm (0.0157 to 0.0275 in.)

      If the clearance is not as specified, select and install an appropriate direct clutch flange that will bring the clearance within the specified range.

      Tech Tips

      There are direct clutch flanges of different thicknesses.

      Direct Clutch Flange Thickness
      Part No. Thickness (mm (in.))
      35675-71010 3.0 (0.118)
      35675-71020 3.1 (0.122)
      35675-71030 3.2 (0.126)
      35675-71040 3.3 (0.130)
      35675-71050 3.4 (0.134)
      35675-71060 3.5 (0.138)
      35675-71070 3.6 (0.142)
      35675-71080 3.7 (0.146)
      35675-71090 3.8 (0.150)

  37. INSTALL FORWARD CLUTCH PISTON


    1. Coat a new O-ring with ATF, and install it to the input shaft sub-assembly.

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

    3. A003GAG

      Install the forward clutch piston to the input shaft sub-assembly.

      Note

      Be careful not to damage the O-rings.

  38. INSTALL NO. 1 CLUTCH BALANCER


    1. Coat a new O-ring with ATF, and install it to the No. 1 clutch balancer.

    2. A003EMRE01
      Text in Illustration
      *1 No. 1 Clutch Balancer
      *2 Forward Clutch Return Spring Sub-assembly

      Install the forward clutch return spring sub-assembly and No. 1 clutch balancer to the input shaft sub-assembly.

      Note

      Be careful not to damage the O-ring.

    3. A003FOFE01

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

      SST
      09387-00110

      Note

      Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

    4. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

  39. INSTALL NO. 1 CLUTCH DISC (FORWARD CLUTCH DISC)


    1. A003FQQE01
      Text in Illustration
      *1 Forward Clutch Flange
      *2 No. 1 Clutch Disc
      *3 No. 1 Clutch Plate

      Install the 5 No. 1 clutch plates, 5 No. 1 clutch discs and forward clutch flange to the input shaft sub-assembly.

      Note

      Make sure that the No. 1 clutch discs, No. 1 clutch plates and forward clutch flange are installed in the correct order.

    2. A003EDIE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the input shaft sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  40. INSPECT CLEARANCE OF NO. 1 CLUTCH (FORWARD CLUTCH DISC)


    1. A003C0KE01
      Text in Illustration
      *1 Selected Forward Clutch Flange
      *a Oil Hole

      Using a dial indicator, measure the clearance of the No. 1 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) to the oil hole as shown in the illustration, and calculate the average.

      Standard clearance
      0.75 to 1.05 mm (0.0295 to 0.0413 in.)

      If the clearance is not as specified, select and install an appropriate forward clutch flange that will bring the clearance within the specified range.

      Tech Tips

      There are forward clutch flanges of different thicknesses.

      Forward Clutch Flange Thickness
      Part No. Thickness (mm (in.))
      35635-71010 3.0 (0.118)
      35635-71020 3.1 (0.122)
      35635-71030 3.2 (0.126)
      35635-71040 3.3 (0.130)
      35635-71050 3.4 (0.134)
      35635-71060 3.5 (0.138)
      35635-71070 3.6 (0.142)
      35635-71080 3.7 (0.146)
      35635-71090 3.8 (0.150)
      35635-71100 3.9 (0.154)
      35635-71110 4.0 (0.157)
      35635-71120 4.1 (0.161)
      35635-71130 4.2 (0.165)

  41. INSTALL CLUTCH DRUM OIL SEAL RING


    1. A003DDT

      Coat 3 new clutch drum oil seal rings with ATF and install them to the input shaft sub-assembly.

      Note

      Do not expand the clutch drum oil seal ring ends excessively.

      Tech Tips

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

  42. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. A003AXFE01
      Text in Illustration
      *1 Direct Clutch Drum Sub-assembly
      *2 Input Shaft Sub-assembly

      Install the direct clutch drum sub-assembly to the input shaft sub-assembly.

  43. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY


    1. A003BIAE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing A
      *2 Thrust Needle Roller Bearing B
      *3 Thrust Needle Roller Bearing C

      Coat the 3 thrust needle roller bearings with ATF and install them to the clutch drum and input shaft assembly.

      Thrust Needle Roller Bearing Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Needle Roller Bearing A 71.9 (2.831) 85.6 (3.370)
      Thrust Needle Roller Bearing B 34.6 (1.362) 52.0 (2.047)
      Thrust Needle Roller Bearing C 21.3 (0.839) 41.1 (1.618)

      Note

      Be sure to install the thrust needle roller bearing in the correct direction.

    2. Install the clutch drum and input shaft assembly to the automatic transmission case sub-assembly.

  44. INSTALL OIL PUMP ASSEMBLY


    1. A003BSOE01
      Text in Illustration
      *1 Thrust Bearing Race B
      *2 Thrust Bearing Race A
      *3 Oil Pump O-ring

      Coat the 2 thrust bearing races with ATF and install them to the oil pump assembly.

      Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust Bearing Race B 40.0 (1.575) 52.8 (2.079)
      Thrust Bearing Race A 74.2 (2.921) 87.74 (3.454)

      Note

      Be sure to install the thrust bearing race in the correct direction.

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

    3. Set the oil pump assembly on the input shaft, and align the bolt holes of the oil pump assembly with the automatic transmission case sub-assembly.

      Note

      Be careful not to damage the oil pump O-ring.

    4. Temporarily install the oil pump assembly to the automatic transmission case sub-assembly.

    5. A003GYZ

      Install the oil pump assembly with the 10 bolts.

      Torque:
      21 N*m  { 215 kgf*cm, 16 ft.*lbf }

  45. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A003CBQE01

      Using SST and a hammer, drive in 2 new manual valve lever shaft oil seals to the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07110 )
      Standard depth
      -0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

    2. Coat the lip of the manual valve lever shaft oil seal with MP grease.

  46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A003DH0E01
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Spacer

      Install a new spacer to the manual valve lever sub-assembly.

    2. Install the manual valve lever shaft to the automatic transmission case sub-assembly through the manual valve lever sub-assembly.

    3. A003G82

      Using a hammer, drive in a new spring pin.

    4. Turn the spacer and manual valve lever shaft to align the smaller hole on the spacer with the indent on the manual valve lever sub-assembly.

    5. A003G4K

      Using a 3 mm pin punch and a hammer, stake the spacer.

    6. Check that the spacer does not turn.

    7. Make sure that the shaft rotates smoothly.

  47. INSTALL PARKING LOCK PAWL SHAFT


    1. Install the E-ring to the parking lock pawl shaft.

    2. A003E2XE01
      Text in Illustration
      *1 Parking Lock Pawl
      *2 E-ring
      *3 Parking Lock Pawl Shaft
      *4 Spring

      Install the parking lock pawl, parking lock pawl shaft and spring to the automatic transmission case sub-assembly.

  48. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A003I1R

      Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.

  49. INSTALL PARKING LOCK PAWL BRACKET


    1. A003BR9

      Install the parking lock pawl bracket to the automatic transmission case sub-assembly with the 3 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Move the manual valve lever sub-assembly to P, and check the output shaft is locked by the parking lock pawl.

  50. INSTALL BRAKE DRUM GASKET


    1. A003GAF

      Install 2 new brake drum gaskets to the automatic transmission case sub-assembly.

  51. INSTALL TRANSMISSION CASE GASKET


    1. A003G22

      Install 2 new transmission case gaskets to the automatic transmission case sub-assembly.

  52. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A003CW1E01
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Manual Valve

      Insert the manual valve lever sub-assembly into the groove on the end of the manual valve and install the transmission valve body assembly to the automatic transmission case sub-assembly with the 12 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      Bolt A
      25 mm (0.984 in.)
      Bolt B
      36 mm (1.42 in.)
      Bolt C
      50 mm (1.97 in.)
    2. A003BM7

      Install the detent spring and detent spring cover to the transmission valve body assembly with the bolt.

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

  53. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


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

    2. A003FSH

      Install the valve body oil strainer assembly to the transmission valve body assembly with the 3 bolts.

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

  54. INSTALL TRANSMISSION WIRE


    1. A003B1C

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

    2. A003HGP

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

    3. A003GNY

      Install the transmission wire to the automatic transmission case sub-assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. A003GESE02
      Text in Illustration
      *1 Temperature Sensor Clamp
      *2 Temperature Sensor

      Connect the 7 solenoid valve connectors.

    5. Install the 2 temperature sensors and 2 temperature sensor clamps to the transmission valve body assembly with the bolt.

      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 }

  55. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A003HW2E01

      Install the 4 transmission oil cleaner magnets to the automatic transmission oil pan sub-assembly as shown in the illustration.

    2. Install a new automatic transmission oil pan gasket to the automatic transmission oil pan sub-assembly.

    3. A003HUX
      A003AGTE06

      Install the automatic transmission oil pan sub-assembly with automatic transmission oil pan gasket to the automatic transmission case sub-assembly with the 10 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      Text in Illustration
      *1 Sleeve
      *2 Automatic Transmission Case Sub-assembly
      *a Correct
      *b Incorrect
      *c Protrusion

      Note


      • Make sure that automatic transmission oil pan gasket seal surface and automatic transmission oil pan sub-assembly contact surface are free of oil and foreign matter.

      • Install the automatic transmission oil pan gasket so that there is no slack in the automatic transmission oil pan gasket, and the entire seal surface is level.

      • Make sure that the 8 protrusions are properly engaged to the automatic transmission oil pan sub-assembly.

      • When installing the automatic transmission oil pan sub-assembly, make sure that the automatic transmission oil pan gasket is not pinched between the sleeve and the seal surface of the automatic transmission case sub-assembly.

    4. Install the drain plug and a new gasket to the automatic transmission oil pan sub-assembly.

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

    5. Using a 5 mm hexagon socket wrench, install a new gasket and overflow plug to the automatic transmission oil pan sub-assembly.

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

  56. INSTALL AUTOMATIC TRANSMISSION HOUSING


    1. Clean and degrease the bolts and bolt holes with non-residue solvent.

    2. A003EQF

      Install the automatic transmission housing to the automatic transmission case sub-assembly with the 8 bolts.

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

    3. Apply adhesive to 2 or 3 threads on the end of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A003GBAE01

      Install 4 bolts to the automatic transmission housing.

      Torque:
      for Bolt A (M10 bolt)
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }
      for Bolt B (M12 bolt)
      57 N*m  { 579 kgf*cm, 42 ft.*lbf }

  57. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003DMVE01

      Using SST and a hammer, drive in the automatic transmission extension housing oil seal to the extension housing sub-assembly.

      SST
      09309-37010
      Standard depth
      5.4 to 5.8 mm (0.213 to 0.228 in.)

    2. Coat the lip of a new automatic transmission extension housing oil seal with MP grease.

  58. INSTALL EXTENSION HOUSING DUST DEFLECTOR


    1. A003F11E01

      Using SST and a press, install a new extension housing dust deflector to the extension housing sub-assembly.

      SST
      09950-60020   ( 09951-01030 )

  59. INSTALL EXTENSION HOUSING SUB-ASSEMBLY


    1. Clean and degrease the threads of the 8 bolts, bolt holes and the contact surfaces of the automatic transmission case sub-assembly and extension housing sub-assembly with non-residue solvent.

    2. A003GWJE01
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the extension housing sub-assembly as shown in the illustration.

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

      Note


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

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

    3. Apply adhesive to 2 or 3 threads on the end of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    4. A003D41E01

      Install the extension housing sub-assembly to the automatic transmission case sub-assembly with the 8 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      for Bolt A
      40 mm (1.57 in.)
      for Bolt B
      45 mm (1.77 in.)

  60. INSTALL OIL COOLER TUBE UNION


    1. Coat 2 new O-rings with ATF and install them to the 2 oil cooler tube unions.

    2. A003HM0E01
      Text in Illustration
      *a Torque Wrench Fulcrum Length
      *b 18° to 22°
      *c -2° to 2°

      Using SST, install the 2 oil cooler tube unions to the automatic transmission case sub-assembly.

      SST
      09268-78010
      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using SST (fulcrum length of 34.5 mm (1.3583 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 25 N*m (252 kgf*cm, 18 ft.*lbf)

  61. INSTALL AUTOMATIC TRANSMISSION CASE PLUG


    1. Coat 6 new O-rings with ATF, and install them to the 6 automatic transmission case plugs.

    2. A003B90

      Install the 6 automatic transmission case plugs to the automatic transmission case sub-assembly.

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

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

    4. A003E0I

      Using a T55 "TORX" socket wrench, install the automatic transmission case plug to the automatic transmission case sub-assembly.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  62. INSTALL REFILL PLUG


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

    2. A003DZQ

      Install the refill plug to the extension housing sub-assembly.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  63. 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 assembly as the detent spring may become detached from the manual valve lever shaft.


    1. Clean the bolt and bolt hole.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    3. A003FZ5

      Temporarily install the park/neutral position switch assembly to the automatic transmission case sub-assembly with the bolt.

    4. Install a lock washer and nut to the park/neutral position switch assembly.

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

    5. Temporarily install the transmission control shaft lever LH to the manual valve lever shaft with the spring washer and nut.

    6. A003G72E01

      Turn the transmission control shaft lever clockwise until it stops, and then return the transmission control shaft lever counterclockwise 2 notches to N.

    7. A003F5GE28
      Text in Illustration
      *a Neutral Basic Line
      *b Groove

      Align the neutral basic line with the groove as shown in the illustration, and tighten the bolt.

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

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

      Note


      • Be careful not to damage the park/neutral position switch assembly.

      • Bend at least 2 of the lock washer tabs.

      Tech Tips

      Tape the screwdriver tip before use.

  64. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH


    1. A003G7BE01

      Install the transmission control shaft lever LH to the manual valve lever shaft with the spring washer and nut.

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

  65. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. A003G7J

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

    2. Install the transmission revolution sensor NT to the automatic transmission case sub-assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. A003D9S

      Coat a new O-ring with ATF, and install it to the transmission revolution sensor SP2.

    4. Install the transmission revolution sensor SP2 to the automatic transmission case sub-assembly with the bolt.

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

  66. INSTALL BREATHER PLUG HOSE


    1. A003HLDE01
      Text in Illustration
      *1 Breather Plug Sub-assembly
      *2 Clamp
      *3 Breather Plug Hose
      *4 Breather Plug
      *5 O-ring

      Install the breather plug sub-assembly, clamp and breather plug to the breather plug hose.

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

    3. A003C0I

      Install the breather plug hose to the automatic transmission case sub-assembly with the bolt.

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

      Note

      Be careful not to damage the O-rings.