AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    A01X62UE01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A 74.3 to 74.6 mm (2.93 to 2.94 in.)/87.4 to 87.7 mm (3.44 to 3.45 in.) 72.0 to 72.3 mm (2.83 to 2.85 in.)/85.3 to 85.6 mm (3.36 to 3.37 in.) -
    B 37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.) 34.7 to 34.9 mm (1.366 to 1.374 in.)/51.6 to 51.9 mm (2.03 to 2.04 in.) -
    C - 21.4 to 21.6 mm (0.841 to 0.850 in.)/40.8 to 41.0 mm (1.606 to 1.614 in.) 22.7 to 22.9 mm (0.892 to 0.902 in.)/60.0 to 60.4 mm (2.36 to 2.38 in.)
    D 33.3 to 33.5 mm (1.31 to 1.32 in.)/56.3 to 56.6 mm (2.22 to 2.23 in.) 38.5 to 38.7 mm (1.515 to 1.524 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) -
    E - 42.6 to 42.8 mm (1.68 to 1.69 in.)/60.8 to 61.1 mm (2.39 to 2.41 in.) -
    F 38.0 to 38.2 mm (1.496 to 1.504 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) 43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.4 mm (2.28 to 2.30 in.) -
    G - 55.8 to 56.0 mm (2.197 to 2.204 in.)/76.1 to 76.4 mm (2.996 to 3.008 in.) 53.8 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.)
    H 33.4 to 33.6 mm (1.31 to 1.32 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.) 32.2 to 32.3 mm (1.268 to 1.272 in.)/49.0 to 49.2 mm (1.93 to 1.94 in.) 32.2 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)
    I - 21.5 to 21.8 mm (0.846 to 0.858 in.)/40.5 to 40.8 mm (1.59 to 1.61 in.) -
    J - 43.6 to 43.9 mm (1.72 to 1.73 in.)/60.6 to 60.9 mm (2.39 to 2.40 in.) 47.2 to 47.4 mm (1.86 to 1.87 in.)/66.9 to 67.1 mm (2.63 to 2.64 in.)

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

    A01X44RE16
    *1 New O-Ring

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

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

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

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

    A01XBA5

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

      Note


      • Do not damage the O-rings.

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

  4. INSTALL 1ST AND REVERSE BRAKE PISTON

    A01X4PL

    1. Coat a new O-ring with ATF.

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

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

      Note

      Be careful not to damage the O-ring.

    4. A01X4PN

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

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


    1. A01X8QAE05
      *1 Snap Ring

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

      SST
      09350-30020   ( 09350-07050 )

    2. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A01X2N7

      Install the No. 9 thrust bearing race.

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 9 Race 47.2 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.)
    2. A01X6UME09
      *1 Bearing I
      *2 Bearing J

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing J 43.6 to 43.9 mm (1.72 to 1.73 in.) 60.6 to 60.9 mm (2.39 to 2.40 in.)
      Bearing I 21.5 to 21.8 mm (0.846 to 0.858 in.) 40.5 to 40.8 mm (1.59 to 1.61 in.)
    3. A01X2LR

      Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. A01X3TY

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

    2. A01X88CE01

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

      Note

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

      Tech Tips

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

    3. A01X65SE03

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

      Tech Tips

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

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

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

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

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

  8. INSTALL NO. 4 BRAKE DISC


    1. A01X0D8

      Install the 2 flanges, 8 discs and 7 plates.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

  9. INSTALL BRAKE PLATE STOPPER SPRING

    A01X8TZ

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. A01X3AFE25
      *1 No. 7 Race
      *2 No. 8 Race

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

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

  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY


    1. A01X1Z8

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

  12. INSTALL INTERMEDIATE SHAFT


    1. A01X7FC

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

    2. A01X6VJE17

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. A01WZLY

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

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

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

  14. INSTALL NO. 2 BRAKE PISTON


    1. A01X0CFE18
      *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

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

  15. INSTALL NO. 2 BRAKE DISC

    A01X6VH

    1. Install the brake piston return spring.

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

    3. A01X5DGE15

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

      SST
      09351-40010

  16. INSTALL NO. 1 BRAKE PISTON


    1. A01X92WE03
      *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

  17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A01X763

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

  18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING


    1. A01X6HGE10

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

      SST
      09351-40010

  19. INSTALL NO. 1 BRAKE DISC

    A01X1RZ

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

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

  20. INSTALL CENTER PLANETARY RING GEAR


    1. A01X9FR

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

    2. A01X30Y

      Using a screwdriver, install the snap ring.

  21. INSTALL FRONT PLANETARY RING GEAR


    1. A01X9Z0

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

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

  22. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01X5PQE26
      *1 Race
      *2 Bearing

      Install the thrust washer and thrust needle roller bearing.

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

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      Bearing 43.4 to 43.6 mm (1.71 to 1.72 in.) 58.0 to 58.4 mm (2.28 to 2.30 in.)
      Race 38.0 to 38.2 mm (1.496 to 1.504 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
    3. A01WZQ3

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

  23. INSPECT PISTON STROKE OF NO. 1 BRAKE PISTON


    1. A01WZUX

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

    2. A01X2AHE01

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

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

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

      Tech Tips

      There are 4 different thicknesses for the flange.

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

  24. INSTALL 2ND BRAKE PISTON


    1. A01X46LE22
      *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

    3. A01X85FE13

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

      SST
      09351-40010

      Note

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

  25. INSTALL 2ND BRAKE CYLINDER


    1. A01X9WO

      Install the 2nd brake cylinder to the case.

  26. INSTALL 1-WAY CLUTCH ASSEMBLY


    1. A01X1QZ

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

  27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING


    1. A01X6VJE17

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  28. INSTALL NO. 3 BRAKE DISC


    1. A01X0XF

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

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

      Tech Tips

      C = Cushion plate

      P = Plate

      D = Disc

      F = Flange

  29. INSTALL NO. 3 BRAKE SNAP RING


    1. A01X1AF

      Using a screwdriver, install the snap ring.

  30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A01WZY7E12
      *1 New O-Ring

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

    2. A01X3NV

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

    3. A01X9MEE04
      *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

    5. A01X71VE13

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

      Note

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

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

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

      Note

      Do not expand the snap ring excessively.

    7. A01X413E19
      *1 Stopper

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

      Note

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

  31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. A01X6LPE11
      *1 New O-Ring

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

    2. A01X2B3E11
      *1 New O-Ring

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

    3. A01X8FF

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

      Note

      Be careful not to damage the O-ring.

  32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01X3HAE17
      *1 New O-Ring

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

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

  33. INSTALL NO. 3 CLUTCH BALANCER


    1. A01X0VBE12

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

      Note

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

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

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

      Note

      Do not expand the snap ring excessively.

    3. A01X6DOE07
      *1 Gap

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

      Note

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

  34. INSTALL DIRECT CLUTCH DISC

    A01X7E0E01

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

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A01X56O

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

  35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

    Click here

  36. INSTALL REVERSE CLUTCH FLANGE


    1. A01X8QQ

      Install the reverse clutch flange to the clutch drum.

  37. INSTALL REVERSE CLUTCH REACTION SLEEVE

    A01X4U4E01

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

      S = Sleeve

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

  38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

    Click here

  39. REMOVE REVERSE CLUTCH REACTION SLEEVE


    1. A01WYYR

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

    2. A01XAXO

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

  40. INSTALL FORWARD CLUTCH PISTON


    1. A01X1WLE05
      *1 New O-Ring

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

  41. INSTALL NO. 1 CLUTCH BALANCER


    1. A01X9LFE07
      *1 New O-Ring

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

    2. A01WZW5

      Install the clutch balancer and forward clutch return spring.

      Note

      Be careful not to damage the O-ring.

    3. A01X96VE04

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

      Note

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

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

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

      Note

      Do not expand the snap ring excessively.

    5. A01X89BE05
      *1 Gap

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

      Note

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

  42. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

    A01XBOQE01

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

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

    2. A01X0OH

      Using a screwdriver, install the hole snap ring.

  43. INSTALL INPUT SHAFT OIL SEAL RING


    1. A01X5V6

      Coat 3 new oil seal rings with ATF.

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

      Note

      Do not excessively widen the ring.

      Tech Tips

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

  44. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

    Click here

  45. INSTALL INPUT SHAFT ASSEMBLY


    1. A01WZOD

      Install the input shaft to the clutch drum.

    2. A01X369

      Install the thrust needle roller bearing to the clutch drum.

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

  46. INSTALL MULTIPLE DISC CLUTCH HUB


    1. A01XBMKE11
      *1 No. 3 Race
      *2 No. 4 Race

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

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 3 Race 22.7 to 22.9 mm (0.892 to 0.902 in.) 60.0 to 60.4 mm (2.36 to 2.38 in.)
      No. 4 Race 33.3 to 33.5 mm (1.31 to 1.32 in.) 56.3 to 56.6 mm (2.22 to 2.23 in.)
    2. A01X24O

      Install the multiple disc clutch hub to the clutch drum.

  47. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. A01X6PEE09
      *1 Bearing E
      *2 Bearing D

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing D 38.5 to 38.7 mm (1.515 to 1.524 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Bearing E 42.6 to 42.8 mm (1.68 to 1.69 in.) 60.8 to 61.1 mm (2.39 to 2.41 in.)
    2. A01XAH0

      Install the forward clutch hub to the clutch drum.

  48. INSTALL REAR CLUTCH DISC


    1. A01WZNDE23

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

  49. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. A01X21M

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

  50. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A01X7TQ

      Install the reverse clutch hub to the clutch drum.

    2. A01X92M

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

  51. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY


    1. A01XA7V

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

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

  52. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY


    1. A01X3NEE05
      *1 Bearing A
      *2 Bearing B

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing A 72.0 to 72.3 mm (2.83 to 2.85 in.) 85.3 to 85.6 mm (3.36 to 3.37 in.)
      Bearing A 34.7 to 34.9 mm (1366 to 1.374 in.) 51.6 to 51.9 mm (2.03 to 2.04 in.)
    2. A01X58B

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

  53. INSTALL OIL PUMP ASSEMBLY


    1. A01WZZ9E01
      *1 No. 1 Race
      *2 No. 2 Race

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

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 1 Race 74.3 to 74.6 mm (2.93 to 2.94 in.) 87.4 to 87.7 mm (3.44 to 3.45 in.)
      No. 2 Race 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.)
    2. A01X38IE07
      *1 New O-Ring

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

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

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

      Note

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

    5. A01X1QB

      Install the 10 bolts.

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

  54. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01XB50E07

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

      SST
      09350-30020   ( 09350-07110 )

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

  55. INSPECT INDIVIDUAL PISTON OPERATION

    Click here

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A01XAKHE07
      *1 Spacer
      *2 Manual Valve Lever

      Install a new spacer to the manual valve lever.

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

    3. A01X5RA

      Using a hammer, tap in a new spring pin.

    4. A01XB08

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

    5. Check that the shaft rotates smoothly.

  57. INSTALL PARKING LOCK PAWL SHAFT


    1. A01X4UBE10
      *1 Parking Lock Pawl
      *2 E-Ring
      *3 Spring

      Install the E-ring to the shaft.

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

  58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01X6JW

      Connect the parking lock rod to the manual valve lever.

  59. INSTALL PARKING LOCK PAWL BRACKET


    1. A01XBQ4

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

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A01XBVFE03
      *1 Planetary Ring Gear
      *2 Manual Valve Lever
      *3 Lock Pawl

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

  60. INSTALL C-1 ACCUMULATOR VALVE


    1. A01X4XRE14
      *1 New O-Ring

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

    2. A01X4OE

      Install the spring and accumulator valve to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-1 Inner

      30.40 mm (1.20 in.)

      11.40 mm (0.449 in.)

      		 Pink
      C-1 Outer

      48.76 mm (1.92 in.)

      16.60 mm (0.654 in.)

      		 Light green

  61. INSTALL C-3 ACCUMULATOR PISTON


    1. A01X4XRE15
      *1 New O-Ring

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

    2. A01X0YW

      Install the 2 springs and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3 Inner

      44.0 mm (1.73 in.)

      14.0 mm (0.551 in.)

      		 Yellow
      C-3 Outer

      73.35 mm (2.89 in.)

      19.90 mm (0.784 in.)

      		 Red

  62. INSTALL B-3 ACCUMULATOR PISTON


    1. A01X4XRE16
      *a New O-Ring

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

    2. A01X4D1

      Install the spring and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3

      70.5 mm (2.78 in.)

      19.7 mm (0.776 in.)

      		 Purple

  63. INSTALL C-2 ACCUMULATOR PISTON


    1. A01X4XRE17
      *1 New O-Ring

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

    2. A01X5XL

      Install the spring and accumulator piston to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-2

      62.0 mm (2.44 in.)

      15.9 mm (0.626 in.)

      		 White

  64. INSTALL CHECK BALL BODY


    1. A01X827E01
      *1 Check Ball Body
      *2 Spring

      Install the spring and check ball body.

  65. INSTALL BRAKE DRUM GASKET


    1. A01X42X

      Install the 3 brake drum gaskets.

  66. INSTALL TRANSMISSION CASE GASKET


    1. A01X1SQE15
      *1 Gasket

      Install the 3 transmission case gaskets.

  67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01X23PE09
      *1 Pin

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

    2. A01X4OLE08

      Install the transmission valve body assembly with the 19 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      36 mm (1.42 in.) for bolt A

      25 mm (0.984 in.) for bolt B

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

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

  68. INSTALL TRANSMISSION WIRE


    1. A01WZHQE01

      Install a new O-ring to the transmission wire.

    2. Install the transmission wire harness.

    3. Install the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. A01X5AGE09
      *1 Orange
      *2 Blue

      Connect the 7 solenoid connectors.

    5. Install the 2 ATF temperature sensors.

    6. Install the 2 clamps and 2 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

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

  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01X674

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

    2. Install the oil strainer with the 4 bolts.

      Torque:
      10 N*m  { 100 kgf*cm, 7 ft.*lbf }

  70. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A01X9YUE06
      *1 Magnet

      Install the 4 magnets.

  71. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install a new gasket to the oil pan.

    2. Install the oil pan with the 20 bolts.

      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    3. Install the drain plug.

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

  72. INSTALL TRANSFER CASE ADAPTER RADIAL BALL BEARING

    A01X6L6E01

    1. Using SST and a press, press in the bearing until it stops.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )

    2. Using a screwdriver, install the snap ring.

  73. INSTALL TRANSMISSION CASE ADAPTER REAR OIL SEAL

    A01X6MHE07
    *1 0 to 0.5 mm

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

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

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

  74. INSTALL TRANSFER ADAPTER REAR


    1. Clean the threads of the bolts and case.

    2. A01X40QE08
      *1 Seal Packing
      *2 Seal Diameter: 1 to 1.5 mm

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

      Seal packing
      Toyota Genuine Seal Packing 1281,
      Three Bond 1281 or equivalent
      Seal diameter
      1.0 to 1.5 mm (0.0394 to 0.0591 in.)
    3. A01X9REE03

      Install the transmission case adapter with the 8 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      50 mm (1.97 in.) for bolt A

      45 mm (1.77 in.) for bolt B

  75. INSTALL AUTOMATIC TRANSMISSION HOUSING

    A01X0ARE03

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

    2. Install the transmission housing with the 10 bolts.

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

  76. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

    A01WZJW

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

    2. Install the breather tube with the 2 bolts.

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

  77. INSTALL SPEED SENSOR


    1. A01X4UK

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

    2. Install the 2 speed sensors.

    3. Install the 2 bolts.

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

  78. INSTALL OIL COOLER TUBE UNION


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

    2. A01X6QQ

      Using a union nut wrench, install the 2 oil cooler tube unions.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  79. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01WYYA

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

    2. Install a new lock washer and the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    3. A01X7EHE03

      Push the control shaft rearward as much as possible.

    4. Return the control shaft lever 2 notches to the N position.

    5. A01X2QRE03
      *1 Neutral Basic Line
      *2 Groove

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

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    6. A01X5X2

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  80. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH


    1. A01WZIV

      Install the control shaft lever with the washer and nut.

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