AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    A001D6PE01
    Bearing Position
    Position

    Front Race Diameter

    Inside/Outside

    Thrust Bearing Diameter

    Inside/Outside

    Rear Race Diameter

    Inside/Outside
    A - 36.2 mm (1.425 in.) / 58.2 mm (2.291 in.) 44.0 mm (1.732 in.) / 62.0 mm (2.441 in.)
    B - 34.5 mm (1.358 in.) / 49.4 mm (1.945 in.) 36.6 mm (1.441 in.) / 51.9 mm (2.043 in.)
    C 46.5 mm (1.831 in.) / 60.1 mm (2.366 in.) 47.0 mm (1.850 in.) / 61.9 mm (2.437 in.) -
    D - 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) 72.7 mm (2.858 in.) / 89.2 mm (3.512 in.)
    E 30.0 mm (1.181 in.) / 49.9 mm (1.965 in.) 31.0 mm (1.221 in.) / 53.1 mm (2.091 in.) -
    F 31.5 mm (1.240 in.) / 53.0 mm (2.0866 in.) 28.7 mm (1.130 in.) / 52.3 mm (2.059 in.) 28.7 mm (1.130 in.) / 50.4 mm (1.984 in.)
    G - 30.5 mm (1.201 in.) / 55.7 mm (2.189 in.) 33.5 mm (1.319 in.) / 59.0 mm (2.323 in.)
    H - 58.9 mm (2.319 in.) / 77.3 mm (3.043 in.) 62.0 mm (2.441 in.) / 82.5 mm (3.248 in.)

  2. INSTALL NO. 2 BRAKE PISTON


    1. Coat 3 new O-rings with ATF and install them to the No. 2 brake piston.

    2. A001DG8E02
      Text in Illustration
      *1 Spline
      *2 Parking Hole

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

      Tech Tips

      Make sure that the parking hole of the No. 2 brake piston is on the bottom side by engaging the brake piston's 2 protrusions with the transmission case's spline grooves (one groove is 3 places clockwise from the top, and the other is 2 places clockwise from the bottom).

    3. Install the No. 2 brake piston return spring sub-assembly to the transmission case.

    4. A0019DFE02
      Text in Illustration
      *1 No. 2 Brake Piston Return Spring Sub-assembly
      *2 Snap Ring

      Set SST against the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.

      SST
      09380-50010

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  3. INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING

    A0019SQE01

    1. Using SST, tap in a new output shaft rear radial ball bearing to the transmission case.

      SST
      09316-60011   ( 09316-00011, 09316-00021 )

    2. Using needle-nose pliers, install the snap ring.

  4. INSTALL TRANSFER CASE ADAPTER REAR OIL SEAL


    1. Coat the lip of a new transfer case adapter rear oil seal with MP grease.

    2. A001EPKE01

      Using SST and a hammer, tap the transfer case adapter rear oil seal into the transmission case.

      SST
      09502-12010
      09513-36040
      Standard oil seal depth
      3.3 to 3.7 mm (0.13 to 0.15 in.)

  5. SELECT NO. 2 BRAKE FLANGE

    A001C4YE01
    Standard
    14.11 to 14.69 mm (0.5555 to 0.5783 in.)
    Text in Illustration
    *1 No. 2 Brake Flange
    *2 No. 2 Brake Plate
    *3 No. 1 Brake Disc
    *4 Weight

    1. Measure length A (from the tip of the No. 2 brake piston to the step in the transmission case) in the illustration. *1

      Standard
      14.77 to 15.37 mm (0.5815 to 0.6051 in.)
    2. A0019OEE03
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 1 Brake Disc
      *4 Weight

      Assemble the 4 No. 2 brakes discs, 3 No. 2 brake plates, and No. 2 brake flange as shown in the illustration. Then with a weight of 500 g (17.64 oz) or less placed on the flange, measure length B. *2

      Standard
      14.11 to 14.69 mm (0.5555 to 0.5783 in.)
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 1 Brake Disc
      *4 Weight

    3. Choose a No. 2 brake flange so that the value of measured length A minus length B (from steps *1 and *2) is 0.52 to 0.82 mm (0.0204 to 0.0323 in.).

      Flange Thickness
      Mark Thickness
      0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      1 2.05 to 2.15 mm (0.0807 to 0.0846 in.)
      2 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
      3 2.25 to 2.35 mm (0.0886 to 0.0925 in.)
      4 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      5 2.45 to 2.55 mm (0.0965 to 0.1004 in.)
      6 2.55 to 2.65 mm (0.1004 to 0.1043 in.)
      7 2.65 to 2.75 mm (0.1043 to 0.1083 in.)
      8 2.75 to 2.85 mm (0.1083 to 0.1122 in.)

  6. INSTALL DIRECT CLUTCH PISTON


    1. Coat a new O-ring with ATF and install it to the direct clutch drum sub-assembly.

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

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

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

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

    6. A001B0HE01

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

      SST
      09387-00020

    7. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  7. INSTALL NO. 2 CLUTCH DISC SET

    A001EWJE01

    1. Install the 6 No. 2 clutch plates, 6 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

      Note

      Before assembling new No. 2 clutch discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.

    3. A001EWPE02
      Text in Illustration
      *1 Oil Hole
      *a Distance A

      Using a dial indicator, measure the moving distance (distance A) of the direct clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.

      Standard
      0.90 to 1.20 mm (0.0354 to 0.0472 in.)
      Flange Thickness
      Mark Thickness
      40 3.95 to 4.05 mm (0.1555 to 0.1594 in.)
      41 4.05 to 4.15 mm (0.1594 to 0.1634 in.)
      42 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      43 4.25 to 4.35 mm (0.1673 to 0.1713 in.)
      44 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      45 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      46 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      47 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      48 4.75 to 4.85 mm (0.1870 to 0.1909 in.)

    4. Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

  8. CONNECT DIRECT CLUTCH ASSEMBLY


    1. A0019AVE02
      Text in Illustration
      *1 New Oil Seal Ring

      Coat 2 new oil seal rings with ATF and install them to the direct clutch drum.

      Note

      Do not excessively widen the rings.

    2. A0019AQE02
      Text in Illustration
      *1 New Oil Seal Ring

      Coat 3 new oil seal rings with ATF and install them to the output shaft.

      Note

      Do not excessively widen the rings.

    3. A001ERTE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust needle roller bearing and thrust bearing race.

      Standard bearing and race diameter
      Item Inside Outside
      Bearing 30.5 mm (1.201 in.) 55.7 mm (2.189 in.)
      Race 33.5 mm (1.319 in.) 59.0 mm (2.323 in.)

      Note

      Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

    4. Connect the direct clutch drum sub-assembly to the output shaft sub-assembly.

  9. INSTALL REAR PLANETARY RING GEAR


    1. Install the snap ring to the groove of the output shaft sub-assembly.

    2. Using needle-nose pliers, attach the snap ring to install the rear planetary ring gear to the output shaft sub-assembly.

  10. INSTALL DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY


    1. A001AFGE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the 2 thrust needle roller bearings, the 2 thrust bearing races and the direct clutch drum sub-assembly with rear planetary ring gear and output shaft sub-assembly to the transmission case.

      Standard bearing and race diameter
      Item Inside Outside
      Race A 62.0 mm (2.441 in.) 82.5 mm (3.248 in.)
      Bearing A 58.9 mm (2.319 in.) 77.3 mm (3.043 in.)
      Race B 28.7 mm (1.130 in.) 50.4 mm (1.984 in.)
      Bearing B 28.7 mm (1.130 in.) 52.3 mm (2.059 in.)

      Note

      Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

  11. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A001FO6E01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust bearing race, rear planetary gear assembly and thrust needle roller bearing to the transmission case.

      Standard bearing and race diameter
      Item Inside Outside
      Race 31.5 mm (1.240 in.) 53.0 mm (2.0866 in.)
      Bearing 31.0 mm (1.221 in.) 53.1 mm (2.091 in.)

      Note


      • Before installing the rear planetary gear, apply ATF to the sliding surfaces of the rear planetary gear bush. After installation, check that the rear planetary gear rotates smoothly.

      • Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

  12. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

    A0019SV

    1. Install the thrust bearing race and rear planetary sun gear assembly to the transmission case.

      Standard bearing race diameter
      Item Inside Outside
      Race 30.0 mm (1.181 in.) 49.9 mm (1.965 in.)

      Note


      • Before installing the rear planetary sun gear, apply ATF to the sliding surfaces of the sun gear bush. After installation, check that the rear planetary sun gear assembly rotates smoothly.

      • Use a small amount of MP grease to make the thrust bearing race stay securely in place.

  13. INSTALL NO. 2 BRAKE DISC SET

    A001FE1E04
    Text in Illustration
    *1 No. 2 Brake Flange *3 No. 2 Brake Plate
    *2 Brake plate *4 Groove

    1. Install the selected No. 2 brake flange, 4 No. 2 brake discs, 3 No. 2 brake plates and brake plate.

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

      Tech Tips

      F = No. 2 Brake Flange

      D = No. 2 Brake Disc

      P = No. 2 Brake Plate

      B = Brake Plate

      Tech Tips

      Assemble the transmission case, No. 2 brake flanges and No. 2 brake plates by aligning their grooves as shown in the illustration.

      A001C8SE02

      Note

      Before assembling new No. 2 brake discs, soak them in ATF for at least 2 hours.

  14. INSTALL NO. 1 1-WAY CLUTCH


    1. Install the No. 1 1-way clutch to the 1-way clutch outer race with the 2 snap rings.

      Note

      Make sure that the No. 1 1-way clutch is facing in the correct direction.

  15. INSPECT NO. 1 1-WAY CLUTCH

    Click here

  16. INSTALL 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH


    1. Install the 1-way clutch outer race with No. 1 1-way clutch to the transmission case.

    2. Using SST, install the snap ring to the transmission case.

      SST
      09350-30020   ( 09350-07060 )

      Note


      • A001DUSE01

      • Install the snap ring so that its tapered face is facing the front side of the transmission case.

      • Install the snap ring so that its gap is within the range shown in the illustration.

      Text in Illustration
      *1 Snap Ring
      *a Front Side

  17. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. A001CANE01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust bearing race, thrust needle roller bearing and sun gear input drum sub-assembly.

      Standard bearing and race diameter
      Item Inside Outside
      Race 72.7 mm (2.858 in.) 89.2 mm (3.512 in.)
      Bearing 71.9 mm (2.831 in.) 85.6 mm (3.370 in.)

      Note


      • Before installing the sun gear input drum sub-assembly, apply ATF to the sliding surfaces of the sun gear input drum bush. After installation, check that the sun gear input drum sub-assembly rotates smoothly.

      • Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

  18. INSTALL FORWARD CLUTCH PISTON


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

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

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

    4. Install the forward clutch return spring sub-assembly and No. 1 clutch balancer to the forward clutch drum sub-assembly.

    5. Place SST on the No. 1 clutch balancer and compress the No. 1 clutch balancer with a press.

      SST
      09380-50010

    6. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


      • Make sure that the end gap of the snap ring is not aligned with the spring retainer claw.

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

      • Do not expand the snap ring excessively.

  19. INSTALL FORWARD MULTIPLE CLUTCH CLUTCH DISC SET

    A001DQAE01

    1. Install the clutch cushion plate, 6 forward multiple disc clutch clutch plates, 6 forward multiple disc clutch clutch discs and forward clutch flange to the forward clutch drum sub-assembly.

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

      Tech Tips

      C = Clutch Cushion Plate

      P = Forward Multiple Disc Clutch Clutch Plate

      D = Forward Multiple Disc Clutch Clutch Disc

      F = Forward Clutch Flange

      Note


      • Install the clutch cushion plate with its marked side facing towards the plates.

      • Before assembling new forward multiple disc clutch clutch discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.

    3. Temporarily install the front planetary ring gear to the forward clutch drum assembly.

    4. A001C7PE02
      Text in Illustration
      *1 Oil Hole
      *a Distance A

      Using a dial indicator, measure the moving distance (distance A) of the forward clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm, 28 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.

      Standard
      0.90 to 1.20 mm (0.0354 to 0.0472 in.)
      Flange Thickness
      Mark Thickness
      0 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      1 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      2 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      3 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      4 4.75 to 4.85 mm (0.1870 to 0.1909 in.)
      5 4.85 to 4.95 mm (0.1909 to 0.1949 in.)
      6 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      7 5.05 to 5.15 mm (0.1988 to 0.2029 in.)
      8 5.15 to 5.25 mm (0.2029 to 0.2067 in.)

    5. Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

    6. Remove the front planetary gear assembly.

  20. INSTALL FRONT PLANETARY RING GEAR


    1. Install the snap ring to the groove of the forward clutch drum sub-assembly.

    2. A001A77

      Using needle-nose pliers, attach the snap ring to install the forward planetary ring gear to the forward disc clutch drum sub-assembly.

      Note

      Check that the snap ring is securely inserted into the groove by looking through the ring gear slots on both sides.

  21. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB


    1. A0019KIE01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust needle roller bearing, thrust bearing race and multiple disc clutch clutch hub to the forward clutch drum sub-assembly.

      Standard bearing and race diameter
      Item Inside Outside
      Bearing 34.5 mm (1.358 in.) 49.4 mm (1.945 in.)
      Race 36.6 mm (1.441 in.) 51.9 mm (2.043 in.)

      Note

      Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

  22. INSTALL FORWARD CLUTCH DRUM SUB-ASSEMBLY WITH FRONT PLANETARY RING GEAR AND MULTIPLE DISC CLUTCH CLUTCH HUB


    1. A001DWQE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust bearing race, the thrust needle roller bearing and the forward clutch drum sub-assembly with front planetary ring gear and multiple disc clutch clutch hub to the transmission case.

      Standard bearing and race diameter
      Item Inside Outside
      Bearing 47.0 mm (1.850 in.) 61.9 mm (2.437 in.)
      Race 46.5 mm (1.831 in.) 60.1 mm (2.366 in.)

      Note


      • Before installing the forward clutch drum, apply ATF to the sliding surfaces of the forward clutch drum bush. After installation, check that the forward clutch drum rotates smoothly.

      • Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

  23. INSTALL OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. Coat a new O-ring with ATF and install it to the overdrive direct clutch drum sub-assembly.

    2. Coat a new O-ring with ATF and install it to the overdrive direct clutch piston sub-assembly.

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

    4. Coat a new O-ring with ATF and install it to the No. 3 clutch balancer.

    5. Install the overdrive clutch return spring sub-assembly and No. 3 clutch balancer to the overdrive direct clutch drum sub-assembly.

    6. A001ACCE01

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

      SST
      09380-50010

    7. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


      • Make sure that the end gap of the snap ring is not aligned with the spring retainer claw.

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

      • Do not expand the snap ring excessively.

  24. INSTALL REVERSE CLUTCH DRUM SUB-ASSEMBLY


    1. Coat 3 new O-rings with ATF and install them to the reverse clutch drum sub-assembly.

    2. Install the reverse clutch drum sub-assembly to the overdrive direct clutch drum sub-assembly.

  25. INSTALL REVERSE CLUTCH PISTON


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

    2. Install the reverse clutch piston, reverse clutch return spring sub-assembly and reverse clutch balancer.

    3. A001E29E01

      Place SST on the reverse clutch balancer and compress the reverse clutch balancer with a press.

      SST
      09380-50010

    4. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


      • Make sure that the end gap of the snap ring is not aligned with the spring retainer claw.

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

      • Do not expand the snap ring excessively.

  26. INSTALL REVERSE CLUTCH DISC SET

    A001ASIE01

    1. Install the cushion plate, 5 reverse clutch plates, 5 reverse clutch discs and reverse clutch flange to the reverse clutch drum sub-assembly.

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

      Tech Tips

      C = Cushion Plate

      P = Reverse Clutch Plate

      D = Reverse Clutch Disc

      F = Reverse Clutch Flange

      Note


      • Install the cushion plate with its marked side facing towards the plates.

      • Before assembling new discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.

    3. Place the oil pump assembly onto the torque converter, and then place the overdrive direct clutch drum sub-assembly and front planetary gear assembly onto the oil pump assembly.

      A001C5ZE01
      Text in Illustration
      *1 Oil Hole *2 Speed Sensor Hole
      *a Distance A - -

    4. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.

      Standard
      0.75 to 1.05 mm (0.0295 to 0.0354 in.)
      Flange Thickness
      Mark Thickness
      0 2.95 to 3.05 mm (0.1161 to 0.1201 in.)
      1 3.05 to 3.15 mm (0.1201 to 0.1240 in.)
      2 3.15 to 3.25 mm (0.1240 to 0.1280 in.)
      3 3.25 to 3.35 mm (0.1280 to 0.1319 in.)
      4 3.35 to 3.45 mm (0.1319 to 0.1358 in.)
      5 3.45 to 3.55 mm (0.1358 to 0.1398 in.)
      6 3.55 to 3.65 mm (0.1398 to 0.1437 in.)
      7 3.65 to 3.75 mm (0.1437 to 0.1476 in.)
      8 3.75 to 3.85 mm (0.1476 to 0.1516 in.)

    5. Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

  27. INSTALL OVERDRIVE CLUTCH DISC SET

    A001E43E01
    Text in Illustration
    *1 Oil Hole *2 Speed Sensor Hole
    *a Distance A - -

    1. Install the 4 overdrive brake clutch plates, 4 overdrive clutch discs and overdrive clutch flange to the overdrive direct clutch drum sub-assembly.

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

      Tech Tips

      P = Overdrive Brake Clutch Plate

      D = Overdrive Clutch Disc

      F = Overdrive Clutch Flange

      Note

      Before assembling new overdrive clutch discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.

    3. Using a dial indicator, measure the moving distance (distance A) of the overdrive clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 7 flange thicknesses in the table so that the measured value is within the standard range.

      A001EBWE01
      Standard
      0.6 to 0.9 mm (0.0236 to 0.0354 in.)
      Flange Thickness
      Mark Thickness
      0 3.95 to 4.05 mm (0.1555 to 0.1594 in.)
      1 4.05 to 4.15 mm (0.1594 to 0.1634 in.)
      2 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      3 4.25 to 4.35 mm (0.1673 to 0.1713 in.)
      4 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      5 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      6 4.55 to 4.65 mm (0.1791 to 0.1831 in.)

    4. Temporarily remove the snap ring, install the selected overdrive clutch flange and reinstall the snap ring.

  28. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. Install the planetary sun gear.

    2. Coat 2 new clutch drum oil seal rings with ATF and install them to the front planetary gear assembly.

      Note

      Do not excessively widen the rings.

    3. Coat 3 new clutch drum oil seal rings with ATF and install them to the front planetary gear assembly.

      Note

      Do not excessively widen the rings.

    4. Install the planetary carrier thrust washer to the front planetary gear assembly.

      Note

      Use a small amount of MP grease to make the thrust washer stay securely in place.

    5. Install the front planetary gear assembly together with the front planetary sun gear to the overdrive direct clutch drum sub-assembly.

  29. SELECT NO. 1 BRAKE FLANGE

    A001ET7E01

    1. Measure length A (from the step of the oil pump installation surface of the transmission case to the step of the No. 1 brake flange installation surface) shown in the illustration. *1

      Standard
      59.77 to 60.03 mm (2.3531 to 2.3634 in.)
    2. A001DWBE01

      Measure length B (from the flange face of the oil pump assembly to the tip of the stator shaft piston) shown in the illustration. *2

      Standard
      34.636 to 34.964 mm (1.3636 to 1.3765 in.)
    3. A001AHGE02
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 brake Plate

      Assemble the 5 No. 1 brake plates, 5 No. 1 brake discs, and No. 1 brake flange, and measure length C shown in the illustration. *3

      Standard
      23.84 to 24.36 mm (0.9386 to 0.9591 in.)

    4. Choose a No. 1 brake flange so that the value of measured length A minus lengths B and C (from steps *1, *2 and *3) is 0.75 to 1.05 mm (0.0295 to 0.0413 in.).

      Flange thickness
      Mark Thickness
      0 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      1 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      2 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      3 4.75 to 4.85 mm (0.1870 to 0.1909 in.)
      4 4.85 to 4.95 mm (0.1909 to 0.1949 in.)
      5 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      6 5.05 to 5.15 mm (0.1988 to 0.2028 in.)
      7 5.15 to 5.25 mm (0.2028 to 0.2067 in.)
      8 5.25 to 5.35 mm (0.2067 to 0.2106 in.)

  30. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY WITH FRONT PLANETARY GEAR ASSEMBLY


    1. A001AEEE01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Install the thrust bearing race, the thrust needle roller bearing and the overdrive clutch drum sub-assembly with front planetary gear assembly to the transmission case.

      Standard bearing and race diameter
      Item Inside Outside
      Race 44.0 mm (1.732 in.) 62.0 mm (2.441 in.)
      Bearing 36.2 mm (1.425 in.) 58.2 mm (2.291 in.)

      Note


      • Before installing the overdrive and reverse clutch, apply ATF to the sliding surfaces of the overdrive direct clutch drum bush. After installation, check that the overdrive direct clutch drum rotates smoothly.

      • Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.

  31. INSTALL NO. 1 BRAKE DISC SET

    A0019TBE02

    1. Install the selected No. 1 brake flange, 5 No. 1 brake discs and 5 No. 1 brake plates to the transmission case.

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

      Tech Tips

      F = No. 1 Brake Flange

      D = No. 1 Brake Disc

      P = No. 1 Brake Plate

      Note

      Before assembling new No. 1 brake discs, soak them in ATF for at least 2 hours.

  32. INSTALL OIL PUMP ASSEMBLY


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

    2. Place the oil pump assembly over the input shaft and align the bolt holes of the oil pump assembly with the transmission case.

    3. Hold the input shaft and lightly press the oil pump assembly to slide the oil seal rings into the overdrive direct clutch drum sub-assembly.

    4. Install the 11 bolts.

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

      Note


      • Make sure to apply seal packing to the flanges of the bolts.

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

      • Do not allow seal packing to contact the threads of the bolts.

      • During installation, do not allow oil to contact the bolts or the surface of the oil pump body.

  33. INSPECT INDIVIDUAL PISTON OPERATION

    A001DI2E02

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

      Tech Tips

      C1 = Forward multiple clutch clutch disc

      C2 = No. 2 clutch

      C3 = Overdrive direct clutch

      C4 = Reverse clutch

      B1 = No. 1 brake

      B2 = No. 2 brake

      Text in Illustration
      *a IN
      *b OUT

  34. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A001ACAE02

    1. Using SST and a hammer, tap in a new manual valve lever shaft oil seal.

      SST
      09350-30020   ( 09350-07110 )
      Standard depth
      0 +/-0.3 mm (0 +/-0.012 in.)

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

  35. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A001C58E02
      Text in Illustration
      *1 Spacer

      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. A001DHE

      Using a hammer, tap in a new spring pin.

    4. A001CJ9

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

    5. Make sure that the shaft rotates smoothly.

  36. INSTALL PARKING LOCK PAWL SHAFT


    1. A001B8ME01
      Text in Illustration
      *1 Parking Lock Pawl
      *2 E-Ring

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

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

  37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A001FFV

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

  38. INSTALL PARKING LOCK PAWL BRACKET

    A001BB7E02

    1. Place the parking lock pawl bracket onto the transmission case. Loosely install the 3 bolts, and then tighten them in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    2. A001BVR

      Shift the manual valve lever sub-assembly to the P position and confirm that the output shaft is correctly locked by the parking lock pawl.

  39. INSTALL AUTOMATIC TRANSMISSION CASE PLUG


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

    2. Install the automatic transmission case plug to the transmission case.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  40. INSTALL SPEED SENSOR


    1. Coat the O-ring with ATF and install it to speed sensor NT.

    2. Using a T30 ''TORX'' wrench, install speed sensor NT with the bolt.

      Torque:
      6.8 N*m  { 69 kgf*cm, 60 in.*lbf }

    3. Install speed sensors SP2 and NC3 with the 2 bolts.

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

  41. INSTALL TRANSMISSION WIRE


    1. Coat the O-ring of the transmission wire connector with ATF.

    2. Install the transmission wire.

    3. Install the bolt.

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

    4. Connect the 3 speed sensor connectors.

  42. INSTALL CHECK BALL BODY


    1. Install the spring and check ball body.

  43. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A001EJK

    1. Align the groove of the manual valve lever sub-assembly with the pin of the manual valve and install the pin.

    2. A001AVIE02

      Install the 17 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      21 mm (0.83 in.) for bolt A
      31 mm (1.22 in.) for bolt B
      64 mm (2.52 in.) for bolt C
    3. A001CIBE01
      Text in Illustration
      *1 Detent Spring
      *2 Manual Valve Lever Sub-assembly

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

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

      Note

      Make sure that the roller at the end of the detent spring is perpendicular to the manual valve lever, and that the manual valve lever sub-assembly is positioned at the center of the roller.

    4. A001F6S

      Connect the 9 connectors to the solenoid valves.

    5. Connect the oil pressure switch connector.

    6. Coat the O-ring of the ATF temperature sensor with ATF.

    7. Install the ATF temperature sensor and lock plate with the bolt.

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

  44. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


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

      Note

      Ensure that the O-ring is not twisted or pinched.

    2. Install the valve body oil strainer assembly to the transmission valve body assembly with the 4 bolts.

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

  45. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A0019ES

    1. Install the 3 magnets to the automatic transmission oil pan.

    2. A0019UDE04
      Text in Illustration
      *1 Sleeve
      *2 Protrusion
      *a Correct
      *b Incorrect

      Install a new gasket and the automatic transmission oil pan to the transmission case with the 9 bolts.

      Torque:
      7.3 N*m  { 74 kgf*cm, 64 in.*lbf }

      Note


      • Make sure that there is no oil or foreign matter on the gasket seal surface or automatic transmission oil pan contact surface.

      • Install the gasket so that there is no slack in the gasket, and that the entire circumference of the seal surface is level.

      • Make sure that the 9 gasket drop prevention protrusions are set in place on the oil pan.

      • When tightening the bolts of the oil pan, make sure that the gasket is not pinched between the sleeve and the seal surface of the transmission.

  46. INSTALL NO. 1 BREATHER PLUG

  47. INSTALL OIL COOLER TUBE ELBOW


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

    2. A001FRCE01
      Text in Illustration
      *a 3 to 7°
      *b 63 to 67°

      Install the oil cooler tube elbows as shown in the illustration.

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

  48. 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. Install the park/neutral position switch assembly to the manual valve lever shaft sub-assembly and temporarily install the bolt.

    2. Install a new lock washer with the nut.

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

    3. Temporarily install the transmission control shaft lever RH.

    4. A001949E02

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

    5. Remove the transmission control shaft lever RH.

    6. A001BONE02
      Text in Illustration
      *1 Neutral Basic Line
      *2 Groove

      Align the groove with the neutral basic line.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    7. Hold the switch in position and tighten the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

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

      Tech Tips

      Bend at least 2 washer tabs.

  49. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH


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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }