AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    B00201TE01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside / Outside Thrust Bearing Diameter Inside / Outside Rear Race Diameter Inside / Outside
    A 74.26 to 74.56 mm (2.92 to 2.94 in.) / 87.39 to 87.74 mm (3.44 to 3.45 in.) 71.96 to 72.26 mm (2.83 to 2.84 in.) / 85.25 to 85.6 mm (3.36 to 3.37 in.) -
    B 38.0 to 38.3 mm (1.50 to 1.51 in.) / 53.9 to 54.1 mm (2.12 to 2.13 in.) 36.45 to 36.7 mm (1.44 to 1.45 in.) / 52.96 to 53.26 mm (2.09 to 2.10 in.) -
    C - 21.05 to 21.3 mm (0.829 to 0.839 in.) / 39.63 to 39.88 mm (1.56 to 1.57 in.) 22.8 to 23.1 mm (0.898 to 0.909 in.) / 44.5 to 44.75 mm (1.75 to 1.76 in.)
    D - 39.45 to 39.7 mm (1.55 to 1.56 in.) / 60.5 to 60.75 mm (2.38 to 2.39 in.) -
    E - 46.45 to 46.7 mm (1.83 to 1.84 in.) / 64.3 to 64.55 mm (2.53 to 2.54 in.) -
    F 55.0 to 55.2 mm (2.165 to 2.173 in.) / 68.8 to 69.3 mm (2.71 to 2.73 in.) 54.55 to 54.8 mm (2.15 to 2.16 in.) / 70.0 to 70.5 mm (2.76 to 2.78 in.) -
    G - 65.35 to 65.6 mm (2.57 to 2.58 in.) / 85.6 to 85.95 mm (3.37 to 3.38 in.) 62.85 to 63.1 mm (2.47 to 2.48 in.) / 82.3 to 82.6 mm (3.24 to 3.25 in.)
    H 39.67 to 39.87 mm (1.56 to 1.57 in.) / 56.5 to 57.0 mm (2.22 to 2.24 in.) 36.45 to 36.61 mm (1.437 to 1.441 in.) / 56.62 to 56.92 mm (2.23 to 2.24 in.) 36.45 to 36.7 mm (1.435 to 1.445 in.) / 56.5 to 57.0 mm (2.22 to 2.24 in.)
    I 21.05 to 21.3 mm (0.829 to 0.839 in.) / 39.5 to 39.8 mm (1.56 to 1.57 in.) 23.2 to 23.4 mm (0.913 to 0.921 in.) / 43.9 to 44.15 mm (1.73 to 1.74 in.) -
    J - 43.6 to 43.85 mm (1.72 to 1.73 in.) / 62.3 to 62.8 mm (2.45 to 2.47 in.) 47.15 to 47.4 mm (1.86 to 1.87 in.) / 66.9 to 67.1 mm (2.63 to 2.64 in.)

  2. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. B002058E02
      Text in Illustration
      *1 New O-Ring

      Coat 3 new O-rings with ATF and install them to the 1st and reverse brake piston.

    2. B001XH0E02
      Text in Illustration
      *1 Protrusion
      *2 Parking Hole

      Install the 1st and reverse brake piston to the transmission case.

      Note


      • Be careful not to damage the O-ring.

      • Make sure that the parking hole of the brake piston is on the bottom by engaging the brake piston protrusion and the transmission case spline grooves.

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


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

    2. Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring.

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

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  4. SELECT NO. 4 BRAKE FLANGE


    1. B00205QE01
      Text in Illustration
      *1 Brake Piston

      Measure distance A (from the tip of the 1st and reverse brake piston to the step in the transmission case) in the illustration.*1

      Tech Tips

      Standard distance A: 27.82 to 28.42 mm (1.09 to 1.12 in.)

    2. B001VMCE02
      Text in Illustration
      *1 Disc
      *2 Plate
      *3 Flange
      *a Selected No. 4 brake flange

      Assemble the flange, No. 4 brake flange, 7 No. 4 brake discs and 6 plates, and measure distance B in the illustration.*2

      Tech Tips

      Standard distance B: 25.98 to 27.01 mm (1.02 to 1.06 in.)

    3. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 4 brake flange indicated by the graph point.

    4. Measure length H of the selected No. 4 brake flange as shown in the illustration.

      Tech Tips

      Make sure that when the B measurement and the H dimension of the selected No. 4 brake flange are subtracted from the A measurement, the value is 0.961 to 1.261 mm (0.0378 to 0.0495 in.).

      B001ZGLE01
      Text in Illustration
      *1 Mark 0 *2 Mark 2
      *3 Mark 4 *4 Mark 6
      *5 Mark 8 *6 Mark 10
      *a Distance A mm (in.) *b Distance B mm (in.)
      Selected No. 4 Brake Flange Length H
      Mark Length H
      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.)

  5. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. B001X6KE04
      Text in Illustration
      *1 Race J

      Install the thrust bearing race.

      Tech Tips

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

      Bearing Race Diameter
      Item Inside Outside
      Race J 47.15 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.)
    2. B001XH3E04
      Text in Illustration
      *1 Bearing I
      *2 Bearing J

      Install the 2 thrust needle roller bearings to the rear planetary gear assembly.

      Bearing Diameter
      Item Inside Outside
      Bearing I 23.2 to 23.4 mm (0.913 to 0.921 in.) 43.9 to 44.15 mm (1.73 to 1.74 in.)
      Bearing J 43.6 to 43.85 mm (1.72 to 1.73 in.) 62.3 to 62.8 mm (2.45 to 2.47 in.)

      Tech Tips

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

    3. Install the rear planetary gear assembly.

  6. INSTALL BRAKE PLATE STOPPER SPRING

  7. INSTALL REAR PLANETARY RING GEAR


    1. Install the rear planetary ring gear flange to the rear planetary ring gear.

    2. Using a screwdriver, install the snap ring.

    3. B001WLAE03
      Text in Illustration
      *1 Front Race H
      *2 Bearing H
      *3 Rear Race H
      *4 Race I

      Install the 3 thrust bearing races, thrust needle roller bearing and rear planetary ring gear together with the rear planetary ring gear flange to the intermediate shaft.

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Front race H 39.67 to 39.87 mm (1.56 to 1.57 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Bearing H 36.45 to 36.61 mm (1.437 to 1.441 in.) 56.62 to 56.92 mm (2.23 to 2.24 in.)
      Rear race H 36.45 to 36.7 mm (1.435 to 1.445 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Race I 21.05 to 21.3 mm (0.829 to 0.839 in.) 39.5 to 39.8 mm (1.56 to 1.57 in.)

  8. INSTALL INTERMEDIATE SHAFT WITH REAR PLANETARY RING GEAR FLANGE AND REAR PLANETARY RING GEAR

    A01X1HJ

    1. Install the intermediate shaft together with the rear planetary ring gear flange and rear planetary ring gear to the transmission case.

  9. INSTALL NO. 4 BRAKE DISC

    B001WXJE01
    *1 S/F

    1. Install the flange, 7 discs, 6 plates and selected No. 4 brake flange.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected No. 4 brake flange

      Note

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

  10. INSTALL 1-WAY CLUTCH INNER RACE

    B001ZIJE01
    Text in Illustration
    *a Front

    1. Install the No. 3 1-way clutch inner race to the No. 3 1-way clutch assembly.

      Note

      Be sure to install the 1-way clutch inner race so that it is facing in the proper direction.

  11. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

    Click here

  12. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

    A01X8A6

    1. Install the No. 3 1-way clutch assembly to the transmission case.

    2. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL NO. 2 BRAKE PISTON


    1. B001WNXE03
      Text in Illustration
      *1 New O-ring

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

    2. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.

      Note

      Be careful not to damage the O-rings.

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


    1. Install the No. 2 brake cylinder with No. 2 brake piston to the transmission case.

      Note


      • A01XBJH

      • When installing the No. 2 brake cylinder with No. 2 brake piston to the transmission case, align the cylinder claw with the groove in the top of the case.

      • Make sure the No. 2 brake cylinder with No. 2 brake piston is securely inserted into the transmission case.

  15. SELECT NO. 2 BRAKE FLANGE


    1. Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.

    2. Place SST on the No. 2 brake flange and compress the No. 2 brake piston return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06070, 09381-06090, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

    4. B001XMPE04
      Text in Illustration
      *1 No. 2 Brake Piston Return Spring

      Measure distance A (from the top surface of the snap ring to the top surface of the No. 2 brake piston return spring) in the illustration.*1

      Tech Tips

      Standard distance A: 21.00 to 21.76 mm (0.834 to 0.857 in.)

    5. B00205OE05
      Text in Illustration
      *1 Flange
      *2 Plate
      *3 Disc
      *a Fixture
      *b 165.2 mm or less

      Assemble the 4 discs, 3 plates and flange as shown in the illustration. Then, with a fixture of 165.2 mm (6.50 in.) or less placed on the flange, measure distance B.*2

      Tech Tips

      Standard distance B: 16.54 to 17.15 mm (0.651 to 0.675 in.)

    6. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 2 brake flange indicated by the graph point.

      B001W4LE01
      Text in Illustration
      *1 Mark 0 *2 Mark 1
      *3 Mark 2 *4 Mark 3
      *5 Mark 4 *6 Mark 5
      *7 Mark 6 *8 Mark 7
      *a Distance A mm (in.) *b Distance B mm (in.)

      Tech Tips

      Make sure that when the B measurement and selected No. 2 brake flange thickness are subtracted from the A measurement, the value is 2.20 to 2.50 mm (0.0866 to 0.0984 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 0.100 in.)
      6 2.55 to 2.65 mm (0.100 to 0.104 in.)
      7 2.65 to 2.75 mm (0.104 to 0.108 in.)

    7. Remove the snap ring, flange and No. 2 brake piston return spring from the transmission case.

  16. INSTALL NO. 2 BRAKE DISC SET

    B001VX2E11
    *1 S/F

    1. Install the No. 2 brake piston return spring, selected No. 2 brake flange, 4 No. 2 brake discs, 3 plates and flange.

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

      Tech Tips

      S/F = Selected flange

      D = No. 2 brake disc

      P = Plate

      F = Flange

      Note

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

    2. Place SST on the flange and compress the No. 2 brake piston return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06070, 09381-06090, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

  17. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. B001Y2YE01
      Text in Illustration
      *1 Return Spring Retainer

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

      Note

      Make sure to install the center planetary sun gear with the groove facing the transmission case.

  18. INSTALL NO. 1 BRAKE PISTON


    1. B001ZX4E03
      Text in Illustration
      *1 New O-Ring

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

    2. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.

      Note

      Be careful not to damage the O-rings.

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


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

      Note


      • B001Y4FE01

      • When installing the No. 1 brake cylinder with No. 1 brake piston to the transmission case, align the cylinder claw with the groove in the top of the case

      • Make sure the No. 1 brake cylinder with No. 1 brake piston is securely inserted into the transmission case.

    2. Place SST on the brake piston return spring and compress the brake piston return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

  20. SELECT NO. 1 BRAKE FLANGE

    B001XVVE02

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

      Tech Tips

      Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)

    2. B001ZB4E04
      Text in Illustration
      *1 Disc
      *2 Plate

      Assemble the 4 plates and 4 discs and measure distance B in the illustration.*2

      Tech Tips

      Standard distance B: 16.72 to 17.19 mm (0.658 to 0.677 in.)

    3. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 1 brake flange indicated by the graph point.

      B001YTPE01
      Text in Illustration
      *1 Mark 0 *2 Mark 1
      *3 Mark 2 *4 Mark 3
      *a Distance A mm (in.) *b Distance B mm (in.)

      Tech Tips

      Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 0.56 to 0.86 mm (0.0220 to 0.0339 in.).

      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.)

  21. INSTALL CENTER PLANETARY RING GEAR


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

    2. Using a screwdriver, install the snap ring.

  22. INSTALL FRONT PLANETARY RING GEAR


    1. Install the front planetary ring gear to the center planetary ring gear.

  23. INSTALL FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY AND CENTER PLANETARY RING GEAR


    1. B001XZ6E04
      Text in Illustration
      *1 Bearing
      *2 Race

      Install the thrust bearing race and thrust needle roller bearing.

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Race 62.85 to 63.1 mm (2.47 to 2.48 in.) 82.3 to 82.6 mm (3.24 to 3.25 in.)
      Bearing 65.35 to 65.6 mm (2.57 to 2.58 in.) 85.6 to 85.95 mm (3.37 to 3.38 in.)

    2. Install the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear to the transmission case.

  24. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    A01X9Y7

    1. Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.

      Tech Tips

      Use a small amount of MP grease to make the No. 2 planetary carrier thrust washer stay securely in place.

    2. B001ZHIE04
      Text in Illustration
      *1 Bearing
      *2 Race

      Install the thrust needle roller bearing, thrust bearing race, front planetary sun gear and front planetary gear assembly.

      Tech Tips

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

      Bearing Diameter
      Item Inside Outside
      Bearing 54.55 to 54.8 mm (2.15 to 2.16 in.) 70.0 to 70.5 mm (2.76 to 2.78 in.)
      Race 55.0 to 55.2 mm (2.165 to 2.173 in.) 68.8 to 69.3 mm (2.71 to 2.73 in.)

  25. INSTALL 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY


    1. Install the No. 1 planetary carrier thrust washer to the 1-way clutch inner race, and then install them to the 1-way clutch assembly.

      Tech Tips

      Use a small amount of MP grease to make the No. 1 planetary carrier thrust washer stay securely in place.

  26. INSPECT 1-WAY CLUTCH ASSEMBLY

    Click here

  27. INSTALL 1-WAY CLUTCH ASSEMBLY WITH 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY


    1. Install the 1-way clutch assembly with the 1-way clutch inner race to the transmission case.

  28. INSTALL NO. 1 BRAKE DISC SET

    B001XOOE03

    1. Install the 4 plates, 4 discs and No. 1 brake flange.

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

      Tech Tips

      P = Plate

      D = Disc

      F = No. 1 brake flange

      Note

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

  29. INSTALL NO. 3 BRAKE PISTON

    B001YDME03
    Text in Illustration
    *1 New O-Ring

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

    2. Press the No. 3 brake piston into the No. 3 brake cylinder with both hands.

      Note

      Be careful not to damage the O-rings.

    3. Using SST and a press, compress the No. 3 brake piston return spring and install the snap ring with a screwdriver.

      SST
      09380-60010   ( 09381-06020, 09381-06040, 09381-06060, 09381-06100, 09381-06110 )

      Note

      Be sure the end gap of the snap ring is not aligned with the No. 3 brake piston return spring claw.

  30. INSTALL NO. 3 BRAKE CYLINDER WITH NO. 3 BRAKE PISTON AND NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. Install the No. 3 brake cylinder together with the No. 3 brake piston and No. 3 brake piston return spring to the transmission case.

      Note


      • B001XJIE02

        Align the oil holes of the No. 3 brake cylinder and transmission case as shown in the illustration.

      • Make sure the No. 3 brake piston and cylinder are securely inserted into the transmission case.

      Text in Illustration
      *1 Oil Hole

  31. INSTALL NO. 3 BRAKE PISTON HOLE SNAP RING


    1. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  32. INSTALL NO. 3 BRAKE DISC SET

    B001W8XE03
    *1 OF

    1. Install the ''O'' mark flange, 4 discs, 3 plates and ''A'' mark flange to the transmission case.

      Install in order
      OF - D - P - D - P - D - P - D - AF

      Tech Tips

      OF = ''O'' mark flange

      P = Plate

      D = Disc

      AF = ''A'' mark flange

      Note

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

  33. INSTALL NO. 3 BRAKE SNAP RING


    1. Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

  34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. B001ZHZE02
      Text in Illustration
      *1 New O-ring

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

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

    3. A01X7ET

      Press the direct clutch piston together with the direct clutch return spring and No. 2 clutch balancer into the clutch drum with both hands.

      Note

      Be careful not to damage the O-ring.

    4. B001ZROE01

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

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

      Note

      Stop pressing when the spring sheet is lowered to a position 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.

    6. B001XSME21
      Text in Illustration
      *1 Stopper

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

      Note

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

  35. INSTALL DIRECT CLUTCH DISC SET


    1. Place the oil pump assembly onto the torque converter, and then place the clutch drum onto the oil pump assembly.

    2. B001XPTE01

      for 1VD-FTV:

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

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

      Tech Tips

      P = Plate

      D = Disc

      F = Direct clutch flange

      Note

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

    3. B001ZCPE01

      for 1UR-FE, 3UR-FE:

      Install the 5 plates, 5 discs and direct 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 = Direct clutch flange

      Note

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

    4. Using a screwdriver, install the snap ring to the clutch drum.

      Note

      Be careful not to damage the clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

    5. Using a dial indicator, measure the moving distance (A) of the direct clutch flange at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 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 moving distance (A)
      0.58 to 0.88 mm (0.0228 to 0.0346 in.)
      B001VM1E01
      Text in Illustration
      *1 Oil Hole
      *a Distance (A)
      Flange Thickness (for 1VD-FTV)
      Mark Thickness
      0 3.45 to 3.55 mm (0.136 to 0.140 in.)
      1 3.55 to 3.65 mm (0.140 to 0.144 in.)
      2 3.65 to 3.75 mm (0.144 to 0.148 in.)
      3 3.75 to 3.85 mm (0.148 to 0.152 in.)
      4 3.85 to 3.95 mm (0.152 to 0.156 in.)
      5 3.95 to 4.05 mm (0.156 to 0.159 in.)
      6 4.05 to 4.15 mm (0.159 to 0.163 in.)
      7 4.15 to 4.25 mm (0.163 to 0.167 in.)
      8 4.25 to 4.35 mm (0.167 to 0.171 in.)
      A 4.35 to 4.45 mm (0.171 to 0.175 in.)
      Flange Thickness (for 1UR-FE, 3UR-FE)
      Mark Thickness
      0 3.45 to 3.55 mm (0.136 to 0.140 in.)
      1 3.55 to 3.65 mm (0.140 to 0.144 in.)
      2 3.65 to 3.75 mm (0.144 to 0.148 in.)
      3 3.75 to 3.85 mm (0.148 to 0.152 in.)
      4 3.85 to 3.95 mm (0.152 to 0.156 in.)
      5 3.95 to 4.05 mm (0.156 to 0.159 in.)
      6 4.05 to 4.15 mm (0.159 to 0.163 in.)
      7 4.15 to 4.25 mm (0.163 to 0.167 in.)
      8 4.25 to 4.35 mm (0.167 to 0.171 in.)

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

  36. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

    B001VLPE02
    Text in Illustration
    *1 New O-Ring

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

    2. B001X7WE02
      Text in Illustration
      *1 New O-Ring

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

    3. A01X0L7

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

      Note


      • Be careful not to damage the O-ring.

      • Make sure to align the holes of the reverse clutch piston with those of the clutch drum as shown in the illustration.

      • Make sure to align the protrusions of the reverse clutch piston with the cutout of the clutch drum.

  37. INSTALL NO. 3 CLUTCH BALANCER

    B001XM3E02
    Text in Illustration
    *1 New O-ring

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

    2. Install the reverse clutch return spring and No. 3 balancer to the reverse clutch piston.

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

      SST
      09380-60010   ( 09381-06020, 09381-06030, 09381-06040, 09381-06050, 09381-06070, 09381-06080 )

      Note

      Stop pressing when the spring sheet is lowered to a position 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.

    5. A01X0J7

      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.

  38. SELECT REVERSE CLUTCH FLANGE


    1. B001XTJE01
      Text in Illustration
      *1 Protective Tape

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

      Note


      • Be careful not to damage the clutch drum.

      • Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

    2. B001Z1RE01
      *1 S/F

      for 1VD-FTV:

      Install the flange, 4 discs, 3 plates, selected reverse clutch flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected reverse clutch flange

      C = Cushion plate

    3. B001WE7E01
      *1 S/F

      for 1UR-FE, 3UR-FE:

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

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected reverse clutch flange

      C = Cushion plate

    4. A01X8JY

      Using a screwdriver, install the snap ring.

    5. Using a dial indicator, measure the moving distance (A minus B) of the top surface of the reverse clutch piston (A) and cushion plate (B) at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard range.

      B001XRGE01
      Standard moving distance (A minus B)
      for 1VD-FTV
      0.46 to 0.76 mm (0.0181 to 0.0299 in.)
      for 1UR-FE, 3UR-FE
      0.59 to 0.89 mm (0.0232 to 0.0350 in.)
      Text in Illustration
      *1 Oil Hole - -
      *a Distance (A) *b Distance (B)
      Flange Thickness
      Mark Thickness
      0 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      1 2.45 to 2.55 mm (0.0965 to 0.100 in.)
      2 2.55 to 2.65 mm (0.100 to 0.104 in.)
      3 2.65 to 2.75 mm (0.104 to 0.108 in.)
      4 2.75 to 2.85 mm (0.108 to 0.112 in.)
      5 2.85 to 2.95 mm (0.112 to 0.116 in.)
      6 2.95 to 3.05 mm (0.116 to 0.120 in.)
      7 3.05 to 3.15 mm (0.120 to 0.124 in.)
      8 3.15 to 3.25 mm (0.124 to 0.128 in.)
      A 3.25 to 3.35 mm (0.128 to 0.132 in.)
      B 3.35 to 3.45 mm (0.132 to 0.136 in.)
      C 3.45 to 3.55 mm (0.136 to 0.140 in.)
    6. A01XAXO

      Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.

  39. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

    B001XTDE03
    Text in Illustration
    *1 New O-Ring

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

    2. A01XBC5

      Install the forward clutch piston to the input shaft.

  40. INSTALL COAST CLUTCH PISTON


    1. A01X94E
      Text in Illustration
      *1 New O-Ring

      Install the coast clutch piston to the input shaft.

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

    3. Install the forward clutch return spring and No. 1 clutch balancer to the input shaft.

      Note

      Be careful not to damage the O-rings.

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

      SST
      09350-30020   ( 09350-07040 )

      Note

      Stop pressing when the spring sheet is lowered to a position 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.

    6. B001ZXOE07
      Text in Illustration
      *a Correct
      *b Incorrect

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

      Note

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

  41. INSTALL COAST CLUTCH DISC SET


    1. B001Z76E01

      for 1VD-FTV:

      Install the 5 plates, 5 discs and coast clutch flange.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

      Note

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

    2. B001XEWE01

      for 1UR-FE, 3UR-FE:

      Install the 4 plates, 4 discs and coast clutch flange.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

      Note

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

    3. B001YTRE01
      Text in Illustration
      *1 Protective Tape

      Temporarily install the snap ring.

      Note

      Be careful not to damage the forward clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

    4. B001W3WE01
      Text in Illustration
      *1 Oil Hole
      *a Distance (A)

      Using a dial indicator, measure the moving distance (A) of the coast 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 11 flange thicknesses in the table so that the measured value is within the standard range.

      Standard moving distance (A)
      for 1VD-FTV
      0.51 to 0.81 mm (0.0201 to 0.0319 in.)
      for UR Engine Series
      0.41 to 0.71 mm (0.0161 to 0.0280 in.)
      Flange Thickness
      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      A 3.85 to 3.95 mm (0.152 to 0.156 in.)
      B 3.95 to 4.05 mm (0.156 to 0.159 in.)

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

      Note

      Be careful not to damage the forward clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

  42. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC SET


    1. B001X91E01

      Install the cushion plate, 6 plates, 6 discs and flange to the input shaft.

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

      Tech Tips

      C = Cushion plate

      P = Plate

      D = Disc

      F = Flange

      Note

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

    2. B001XQYE01
      Text in Illustration
      *1 Protective Tape

      Temporarily install the snap ring.

      Note

      Be careful not to damage the forward clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

    3. B001XN5E01
      Text in Illustration
      *1 Oil Hole
      *a Distance (A)

      Using a dial indicator, measure the moving 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 12 flange thicknesses in the table so that the measured value is within the standard range.

      Standard moving distance (A)
      0.85 to 1.15 mm (0.0335 to 0.0453 in.)
      Flange Thickness
      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      A 3.85 to 3.95 mm (0.152 to 0.156 in.)
      B 3.95 to 4.05 mm (0.156 to 0.159 in.)
      C 4.05 to 4.15 mm (0.159 to 0.163 in.)

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

      Note

      Be careful not to damage the forward clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

  43. INSTALL NO. 4 1-WAY CLUTCH ASSEMBLY


    1. Install the No. 2 clutch hub thrust washer to the coast clutch hub.

      Tech Tips

      Use a small amount of MP grease to make the No. 2 clutch hub thrust washer stay securely in place.

    2. Install the No. 4 1-way clutch assembly to the coast clutch hub.

  44. INSPECT NO. 4 1-WAY CLUTCH ASSEMBLY

    Click here

  45. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY WITH NO. 4 1-WAY CLUTCH ASSEMBLY


    1. B001XJXE07
      Text in Illustration
      *1 Bearing C
      *2 Race
      *3 Bearing D

      Install the 2 thrust needle roller bearings, thrust bearing race and coast clutch hub with the No. 4 1-way clutch assembly to the input shaft.

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Bearing C 21.05 to 21.3 mm (0.829 to 0.839 in.) 39.63 to 39.88 mm (1.56 to 1.57 in.)
      Race 22.8 to 23.1 mm (0.898 to 0.909 in.) 44.5 to 44.75 mm (1.75 to 1.76 in.)
      Bearing D 39.45 to 39.7 mm (1.55 to 1.56 in.) 60.5 to 60.75 mm (2.38 to 2.39 in.)

  46. INSTALL INPUT SHAFT OIL SEAL RING


    1. B001WEDE02
      Text in Illustration
      *a Correct
      *b Incorrect

      Overlap the seal ring edges in the axial direction.

      Note


      • Overlapping the seal ring edges in the axial direction prevents damage to the seal ring.

      • Do not overlap the seal ring edges in the radial direction, as this may damage the seal ring.

    2. B001YB6E02
      Text in Illustration
      *1 New O-Ring

      Coat 4 new oil seal rings with ATF.

    3. Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.

      Note

      Do not excessively widen the rings.

      Tech Tips

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

  47. INSTALL INPUT SHAFT ASSEMBLY


    1. Install the input shaft to the clutch drum.

  48. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. Install the No. 3 clutch hub thrust washer, forward clutch hub and thrust needle roller bearing to the clutch drum.

      Note

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

      Tech Tips

      Use a small amount of MP grease to make the thrust needle roller bearing and No. 3 clutch hub thrust washer stay securely in place.

      Bearing Diameter
      Item Inside Outside
      Bearing 46.45 to 46.7 mm (1.83 to 1.84 in.) 64.3 to 64.55 mm (2.53 to 2.54 in.)

  49. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


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

      Note

      Before installing of the reverse clutch hub, apply ATF to the sliding surfaces of the reverse clutch hub bush. After the installation, check that the reverse clutch rotates smoothly.

  50. INSTALL REAR CLUTCH DISC SET


    1. Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape before use.

    2. B001XV4E01
      *1 S/F

      for 1VD-FTV:

      Install the flange, 4 discs, 3 plates, selected reverse clutch flange and reverse clutch reaction sleeve to the clutch drum.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected reverse clutch flange

      C = Cushion plate

    3. B001X61E01
      *1 S/F

      for 1UR-FE, 3UR-FE:

      Install the flange, 5 discs, 4 plates, selected reverse clutch flange and reverse clutch reaction sleeve to the clutch drum.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected reverse clutch flange

      C = Cushion plate

    4. Using a screwdriver, install the snap ring to the clutch drum.

  51. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY


    1. Install the clutch drum thrust washer to the clutch drum.

      Tech Tips

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

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

  52. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY

    Click here

  53. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    B001YSBE07
    Text in Illustration
    *1 Bearing A
    *2 Bearing B

    1. Install the 2 thrust needle roller bearings.

      Tech Tips

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

      Bearing Diameter
      Item Inside Outside
      Bearing A 71.96 to 72.26 mm (2.83 to 2.84 in.) 85.25 to 85.6 mm (3.36 to 3.37 in.)
      Bearing B 36.45 to 36.7 mm (1.44 to 1.45 in.) 52.96 to 53.26 mm (2.09 to 2.10 in.)

    2. Coat the clutch drum thrust washer with petroleum jelly and install it to the clutch drum and input shaft assembly.

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

  54. INSTALL OIL PUMP ASSEMBLY

    B001VVXE02
    Text in Illustration
    *1 Race A
    *2 Race B
    *3 New O-Ring

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

    2. Install the 2 thrust bearing races to the front oil pump assembly.

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race A 74.26 to 74.56 mm (2.92 to 2.94 in.) 87.39 to 87.74 mm (3.44 to 3.45 in.)
      Race B 38.0 to 38.3 mm (1.50 to 1.51 in.) 53.9 to 54.1 mm (2.12 to 2.13 in.)

    3. Pass the input shaft through the center hole of the oil pump assembly, 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.

    5. Apply seal packing to the flanges of the bolts.

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

      Note

      Do not allow seal packing to contact the bolt threads.

    6. Install the 10 bolts.

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

      Note

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

  55. INSPECT INDIVIDUAL PISTON OPERATION

    Click here

  56. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    B001YAIE03

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

      SST
      09350-30020   ( 09350-07110 )

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

  57. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    B001WCBE02
    Text in Illustration
    *1 New Spacer

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

    2. Push the manual valve lever shaft through the transmission case and install the manual valve lever sub-assembly to the manual valve lever shaft.

    3. A01XARV

      Using a hammer, tap in a new spring pin.

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

    5. Check that the shaft rotates smoothly.

  58. INSTALL PARKING LOCK PAWL


    1. Install a new E-ring to the shaft.

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

  59. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


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

  60. INSTALL PARKING LOCK PAWL BRACKET


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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    2. B001YXGE04
      Text in Illustration
      *1 Lock Pawl
      *2 Rear Planetary Gear

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

  61. INSTALL B-1 ACCUMULATOR VALVE

    A01WZTJ

    1. Install the 2 springs and accumulator valve to the hole.

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-1 Inner

      44.98 mm (1.77 in.)

      11.30 mm (0.445 in.)

      		 Natural
      B-1 Outer

      46.36 mm (1.83 in.)

      17.10 mm (0.673 in.)

      		 Natural

  62. INSTALL C-3 ACCUMULATOR PISTON

    B001XIOE04
    Text in Illustration
    *1 New O-Ring

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3

      76.65 mm (3.02 in.)

      20.1 mm (0.791 in.)

      for 1VD-FTV:

      White

      for 1UR-FE, 3UR-FE:

      Natural

  63. INSTALL B-3 ACCUMULATOR PISTON

    B001XFJE04
    Text in Illustration
    *1 New O-Ring

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3

      64.50 mm (2.54 in.)

      19.5 mm (0.768 in.)

      		 Orange

  64. INSTALL C-2 ACCUMULATOR PISTON

    B001ZQ9E04
    Text in Illustration
    *1 New O-Ring

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-2

      68.0 mm (2.68 in.)

      16.1 mm (0.634 in.)

      for 1VD-FTV:

      Blue

      for 1UR-FE, 3UR-FE:

      Light green

  65. INSTALL CHECK BALL BODY


    1. Install the spring and check ball body.

  66. INSTALL BRAKE DRUM GASKET

    B001YLEE04
    Text in Illustration
    *1 New O-Ring

    1. Install 3 new brake drum gaskets.

  67. INSTALL TRANSMISSION CASE GASKET

    B001Z4HE04
    Text in Illustration
    *1 New O-Ring

    1. Install 3 new transmission case gaskets.

  68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    B001VOXE04
    Text in Illustration
    *1 Pin

    1. Align the hole of the manual valve with the pin of the lever.

    2. B00203OE05

      Install the 19 bolts.

      Torque:
      11 N*m  { 112 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

      45 mm (1.77 in.) for bolt C

      50 mm (1.97 in.) for bolt D

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

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

  69. INSTALL NO. 1 TRANSMISSION WIRE AND NO. 2 TRANSMISSION WIRE

    B001XTHE02
    Text in Illustration
    *1 New O-Ring

    1. Install 2 new O-rings to the transmission wires.

    2. Install the transmission wire harnesses.

    3. Install the No. 1 transmission wire and No. 2 transmission wire with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. B001WDNE02
      Text in Illustration
      *a Orange
      *b Blue

      Connect the 9 connectors to the solenoid valves.

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

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

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

  70. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    B001Z0S

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

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

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

  71. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    B001Z7YE04
    Text in Illustration
    *1 Magnet

    1. Install the 4 magnets.

    2. Install a new gasket to the oil pan.

    3. Install the oil pan with the 12 bolts.

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

      Note


      • B001WPEE02

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

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

      • Make sure that the 9 gasket drop prevention protrusions are attached to the oil pan.

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

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

    4. Install the drain plug.

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

  72. INSTALL TRANSFER CASE ADAPTER RADIAL BALL BEARING


    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 OIL SEAL

    B001X59E04
    Text in Illustration
    *a 0 to 1 mm

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

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

      Standard depth
      0 to 1 mm (0 to 0.0394 in.)
      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )

  74. INSTALL REAR TRANSFER ADAPTER

    B001W84E02
    Text in Illustration
    *1 Seal Packing
    *a Seal Diameter: 1 to 1.5 mm

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

    2. Apply seal packing to the rear transfer adapter.

      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. Install the rear transfer adapter with the 10 bolts.

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

  75. INSTALL AUTOMATIC TRANSMISSION HOUSING


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

    2. Install the transmission housing with the 14 bolts.

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

  76. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE


    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. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/ ATF Warmer)

    Click here

  78. INSTALL OIL COOLER TUBE UNION (w/o ATF Warmer)


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

    2. B001Z6JE01
      Text in Illustration
      *a -2 to 2°

      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 SPEED SENSOR


    1. 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 }

  80. 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. Clean the bolt and the 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

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

    4. Install a new lock washer and the 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 RH.

    6. B001Z4VE01

      Using the transmission control shaft lever RH, turn the manual lever shaft all the way back and then forward 2 notches to select the N position.

    7. Remove the control shaft lever RH.

    8. B001Y2ME02
      Text in Illustration
      *1 Neutral Basic Line
      *2 Groove

      Align the groove with the neutral basic line.

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    10. A01X5X2

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

  81. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH


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

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