AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    B001XYNE01
    Mark

    Front Race Diameter

    Inside / Outside (mm (in.))

    Thrust Bearing Diameter

    Inside / Outside (mm (in.))

    Rear Race Diameter

    Inside / Outside (mm (in.))
    A 74.2 (2.921) / 87.74 (3.454) 71.9 (2.831) / 85.6 (3.370) -
    B 40.0 (1.575) / 52.8 (2.079) 34.6 (1.362) / 52.0 (2.047) -
    C 22.0 (0.866) / 44.8 (1.764) 21.3 (0.839) / 41.1 (1.618) -
    D 38.4 (1.512) / 56.5 (2.224) 33.3 (1.311) / 56.6 (2.228) -
    E - 40.83 (1.607) / 52.8 (2.079) 39.6 (1.559) / 52.8 (2.079)
    F - 37.1 (1.461) / 61.2 (2.409) 44.0 (1.732) / 62.8 (2.472)
    G 65.8 (2.591) / 86.3 (3.398) 63.3 (2.492) / 78.8 (3.102) -
    H 66.3 (2.610) / 78.9 (3.106) 63.3 (2.492) / 78.8 (3.102) -
    I - 55.7 (2.193) / 76.4 (3.008) 53.7 (2.114) / 74.0 (2.913)
    J 33.4 (1.315) / 49.0 (1.929) 32.1 (1.264) / 49.35 (1.943) 32.1 (1.264) / 49.0 (1.929)
    K - 21.0 (0.827) / 41.5 (1.634) 23.13 (0.911) / 41.5 (1.634)
    L - 43.55 (1.715) / 61.0 (2.402) 47.1 (1.854) / 67.1 (2.642)

  2. INSTALL BRAKE PLATE STOPPER SPRING


    1. B001WO0

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

      Note

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

  3. INSTALL NO. 4 BRAKE PISTON


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

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

    3. B001XE3E07
      Text in Illustration
      *1 No. 4 Brake Piston
      *2 Brake Reaction Sleeve

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

      Note

      Be careful not to damage the O-rings.

  4. INSTALL BRAKE REACTION SLEEVE


    1. B001WDVE02
      Text in Illustration
      *1 Brake Reaction Sleeve
      *2 No. 4 Brake Piston

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

      Note

      Be careful not to damage the O-rings.

  5. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. B001Y2T

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

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

      Note

      Be careful not to damage the O-ring.

    3. B001WHM

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

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

    5. B001XAVE02
      Text in Illustration
      *a Protective Tape

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

      SST
      09380-60011   ( 09381-06030, 09381-06040, 09381-06080, 09381-06120, 09381-06130, 09381-05040, 09381-05050 )

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. B001ZU9E01
      Text in Illustration
      *1 Thrust Needle Roller Bearing K
      *2 Thrust Bearing Race K
      *3 Thrust Needle Roller Bearing L
      *4 Thrust Bearing Race L

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

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

      Note

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

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

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

  7. INSTALL NO. 4 BRAKE DISC


    1. B001ZH2E01
      Text in Illustration
      *1 No. 4 Brake Flange
      *2 No. 4 Brake Disc
      *3 No. 4 Brake Plate

      Install the 2 No. 4 brake flanges, 7 No. 4 brake discs and 6 No. 4 brake plates to the automatic transmission case sub-assembly.

      Note


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

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

  8. INSTALL INTERMEDIATE SHAFT


    1. B001WUFE04
      Text in Illustration
      *1 Thrust Needle Roller Bearing J
      *2 Thrust Bearing Race J (Rear Race)

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

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

      Thrust Bearing Race J

      (Rear Race)

      		 32.1 (1.264) 49.0 (1.929)

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

  9. INSTALL REAR PLANETARY RING GEAR


    1. B001W9SE01
      Text in Illustration
      *1 Rear Planetary Ring Gear Flange Sub-assembly
      *2 Rear Planetary Ring Gear

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

    2. B001XPEE03
      Text in Illustration
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. B001ZUDE05
      Text in Illustration
      *1 Thrust Bearing Race J (Front Race)

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

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

      Thrust Bearing Race J

      (Front Race)

      		 33.4 (1.315.) 49.0 (1.929)

      Note

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

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

  11. INSTALL ONE-WAY CLUTCH INNER RACE


    1. B001WBYE05
      Text in Illustration
      *1 One-way Clutch Inner Race
      *2 No. 3 One-way Clutch Assembly

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

      Tech Tips

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

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


    1. B001Z7E

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

    2. B001ZK6E02
      Text in Illustration
      *1 Snap Ring
      *a 19°
      *b 49°
      B001XPG Front Side

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

      SST
      09350-30020   ( 09350-07060 )

      Note


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

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

  13. INSPECT CLEARANCE OF NO. 4 BRAKE

    Click here

  14. INSTALL NO. 1 BRAKE PISTON


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

    2. B001WFD

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

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


    1. B001YNO

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

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


    1. B001WVD

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

    2. B001WN5E01
      Text in Illustration
      *a Turn

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

      SST
      09380-60011   ( 09381-06010, 09381-06040, 09381-06050, 09381-06070, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )
    3. B001VP4E01
      Text in Illustration
      *a 22.5°
      *b 37.5°

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

      Note


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

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

      Tech Tips

      Tape the screwdriver tip before use.

  17. INSTALL NO. 1 BRAKE DISC


    1. B001VZ1E02
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate

      Install the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates to the automatic transmission case sub-assembly.

      Note

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

    2. B001YSDE01
      Text in Illustration
      *a 22.5°
      *b 37.5°

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

      Note


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

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

      Tech Tips

      Tape the screwdriver tip before use.

  18. INSPECT CLEARANCE OF NO. 1 BRAKE

    Click here

  19. INSTALL PLANETARY SUN GEAR


    1. B001W23

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

  20. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. B001YFBE04
      Text in Illustration
      *1 Thrust Bearing Race I

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

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

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

  21. INSTALL CENTER PLANETARY RING GEAR


    1. B001WXIE01
      Text in Illustration
      *1 Center Planetary Ring Gear Flange
      *2 Center Planetary Ring Gear

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

    2. B001WEGE01
      Text in Illustration
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. B001XZJE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing H
      *2 Thrust Needle Roller Bearing I

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

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

      Note

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

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

  23. INSTALL NO. 2 BRAKE DISC


    1. B001XGTE01
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate

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

      Note


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

      • Install the thicker No. 2 brake flange first, and then install the thinner one.

  24. INSTALL NO. 2 BRAKE PISTON


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

    2. B001ZTN

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

      Note

      Be careful not to damage the O-rings.

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


    1. B001WD0

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

    2. B001W82

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

    3. B001Z28E01
      Text in Illustration
      *a Turn

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

      SST
      09380-60011   ( 09381-06010, 09381-06020, 09381-06040, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )
    4. B001YYRE01
      Text in Illustration
      *a 30°

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

      Note


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

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

      Tech Tips

      Tape the screwdriver tip before use.

  26. INSPECT CLEARANCE OF NO. 2 BRAKE

    Click here

  27. INSTALL FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. B001ZYLE01
      Text in Illustration
      *1 Front Planetary Ring Gear
      *2 Snap Ring
      *3 Front Planetary Ring Gear Flange Sub-assembly

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

      Note

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

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


    1. B001W4VE03
      Text in Illustration
      *1 Thrust Needle Roller Bearing G
      *2 Thrust Bearing Race H

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

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

      Note

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

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

  29. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B001XJRE04
      Text in Illustration
      *1 Thrust Bearing Race F
      *2 Thrust Bearing Race G

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

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

      Note

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

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

  30. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. B001ZC7E04
      Text in Illustration
      *1 Thrust Bearing Race E
      *2 Thrust Needle Roller Bearing F

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

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

      Note

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

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

  31. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. B001XQBE04
      Text in Illustration
      *1 Thrust Needle Roller Bearing D
      *2 Thrust Needle Roller Bearing E

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

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

      Note

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

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

  32. INSTALL MULTIPLE DISC CLUTCH HUB


    1. B001WMHE05
      Text in Illustration
      *1 Thrust bearing race C
      *2 Thrust bearing race D

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

      Thrust Bearing Race Diameter
      Item Inside (mm (in.)) Outside (mm (in.))
      Thrust bearing race C 22.0 (0.866) 44.8 (1.764)
      Thrust bearing race D 38.4 (1.512) 56.5 (2.224)

      Note

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

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

  33. INSTALL DIRECT CLUTCH PISTON


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

    2. B001WY9

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

      Note

      Be careful not to damage the O-rings.

  34. INSTALL NO. 2 CLUTCH BALANCER


    1. B001XHCE01
      Text in Illustration
      *1 No. 2 Clutch Balancer
      *2 Direct Clutch Return Spring Sub-assembly

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

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

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

      Note

      Be careful not to damage the O-ring.

    4. B00201BE03

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

      SST
      09380-60011   ( 09381-06030, 09381-06040, 09381-06080, 09381-06100, 09381-06110 )

      Note

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

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

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


    1. B001XQ0E01
      Text in Illustration
      *1 Direct Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate

      Install the 5 No. 2 clutch plates, 5 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.

      Note

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

    2. B001XLDE01
      Text in Illustration
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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

    Click here

  37. INSTALL FORWARD CLUTCH PISTON


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

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

    3. B001WRD

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

      Note

      Be careful not to damage the O-rings.

  38. INSTALL NO. 1 CLUTCH BALANCER


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

    2. B001ZPME01
      Text in Illustration
      *1 No. 1 Clutch Balancer
      *2 Forward Clutch Return Spring Sub-assembly

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

      Note

      Be careful not to damage the O-ring.

    3. B001WX7E04

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

      SST
      09387-00110

      Note

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

    4. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

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


    1. B001YICE01
      Text in Illustration
      *1 Forward Clutch Flange
      *2 No. 1 Clutch Disc
      *3 No. 1 Clutch Plate

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

      Note

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

    2. B001XXBE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, install the snap ring.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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

    Click here

  41. INSTALL CLUTCH DRUM OIL SEAL RING


    1. B001WS8

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

      Note

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

      Tech Tips

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

  42. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. B001YGYE01
      Text in Illustration
      *1 Direct Clutch Drum Sub-assembly
      *2 Input Shaft Sub-assembly

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

  43. INSTALL DIRECT CLUTCH DRUM SUB-ASSEMBLY AND INPUT SHAFT ASSEMBLY


    1. B001VQ8E01
      Text in Illustration
      *1 Thrust Needle Roller Bearing A
      *2 Thrust Needle Roller Bearing B
      *3 Thrust Needle Roller Bearing C

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

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

      Note

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

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

  44. INSTALL OIL PUMP ASSEMBLY


    1. B001ZK9E04
      Text in Illustration
      *1 Thrust Bearing Race B
      *2 Thrust Bearing Race A
      *3 Oil Pump O-ring

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

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

      Note

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

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

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

      Note

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

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

    5. B001XAB

      Install the oil pump assembly with the 10 bolts.

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

  45. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B001WZDE02

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

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

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

  46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B001XAPE01
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Spacer

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

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

    3. B001YJV

      Using a hammer, drive in a new spring pin.

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

    5. B001Y57

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

    6. Check that the spacer does not turn.

    7. Make sure that the shaft rotates smoothly.

  47. INSTALL PARKING LOCK PAWL SHAFT


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

    2. B001WDJE06
      Text in Illustration
      *1 Parking Lock Pawl
      *2 E-ring
      *3 Parking Lock Pawl Shaft
      *4 Spring

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

  48. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B001ZQQ

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

  49. INSTALL PARKING LOCK PAWL BRACKET


    1. B001W7F

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

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

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

  50. INSTALL BRAKE DRUM GASKET


    1. B001YGB

      Coat 2 new brake drum gaskets with ATF and install them to the automatic transmission case sub-assembly.

  51. INSTALL TRANSMISSION CASE GASKET

    Click here

  52. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    Click here

  53. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    Click here

  54. INSTALL TRANSMISSION WIRE


    1. B001ZA0

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

    2. B001XRS

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

    3. B001ZZN

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. B001Z6YE03
      Text in Illustration
      *1 Temperature Sensor Clamp
      *2 Temperature Sensor

      Connect the 7 solenoid valve connectors.

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

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

  55. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Click here

  56. INSTALL DRAIN PLUG


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

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

  57. INSTALL OVERFLOW PLUG


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

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

      Tech Tips

      After adjusting the automatic transmission oil level, replace the gasket with a new one.

  58. INSTALL AUTOMATIC TRANSMISSION HOUSING


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

    2. B001YSZ

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

      Torque:
      34 N*m  { 346 kgf*cm, 25 ft.*lbf }
    3. B001YT6E03

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    4. Install 4 bolts to the automatic transmission housing.

      Torque:
      for bolt A (M10 bolt)
      34 N*m  { 346 kgf*cm, 25 ft.*lbf }
      for bolt B (M12 bolt)
      57 N*m  { 579 kgf*cm, 42 ft.*lbf }

  59. INSTALL REAR TRANSFER CASE ADAPTER OIL RECEIVER


    1. B001ZOS

      Install the rear transfer case adapter oil receiver to the transfer adapter sub-assembly.

    2. Using snap ring pliers, install the snap ring to the transfer adapter sub-assembly.

  60. INSTALL TRANSFER ADAPTER OIL SEAL


    1. B001Z6UE02

      Using SST and a hammer, drive in a new transfer adapter oil seal to the transfer adapter sub-assembly.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      0 to 0.5 mm (0 to 0.0196 in.)

    2. Coat the lip of the transfer adapter oil seal with MP grease.

  61. INSTALL TRANSFER ADAPTER SUB-ASSEMBLY


    1. B001VPO

      Using a plastic-faced hammer, tap 2 new straight pins into the transfer adapter sub-assembly.

      Standard Protrusion Height
      5.7 to 6.3 mm (0.225 to 0.248 in.)

      Tech Tips

      It is not necessary to remove the straight pins they are being replaced.

    2. Clean and degrease the threads of the 10 bolts, bolt holes and the contact surfaces of the automatic transmission case sub-assembly and transfer adapter sub-assembly with non-residue solvent.

    3. B001ZO0E02
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the transfer adapter sub-assembly as shown in the illustration.

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

      Note


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

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

    4. Apply adhesive to 2 or 3 threads on the end of the 10 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    5. B001WDXE03

      Install the transfer adapter sub-assembly to the automatic transmission case sub-assembly with the 10 bolts.

      Torque:
      34 N*m  { 346 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt Length
      for bolt A
      40 mm (1.57 in.)
      for bolt B
      50 mm (1.97 in.)

  62. INSTALL OIL COOLER TUBE UNION


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

    2. B001ZOCE04
      Text in Illustration
      *a Torque Wrench Fulcrum Length
      *b -2° to 2°
      *c Turn
      *d Hold

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

      SST
      09268-78010
      Torque:
      31 N*m  { 317 kgf*cm, 23 ft.*lbf }

      Tech Tips


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

        Click here

      • When using SST (fulcrum length of 34.5 mm (1.3583 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 26 N*m (266 kgf*cm, 19 ft.*lbf)

  63. INSTALL AUTOMATIC TRANSMISSION CASE PLUG


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

    2. B001W11

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

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

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

    4. B001XTR

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

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

  64. INSTALL REFILL PLUG


    1. Install the O-ring and refill plug to the transfer adapter sub-assembly.

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

      Tech Tips

      After adjusting the automatic transmission oil level, replace the O-ring with a new one.

  65. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    Tech Tips

    Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch assembly as the detent spring may become detached from the manual valve lever shaft.


    1. Clean the bolt and bolt hole.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Install the bolt within 3 minutes of applying adhesive.

    3. B001WPT

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

      Tech Tips

      Tighten the bolt to the specified torque when adjusting the park/neutral position switch assembly.

    4. B001Z05

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

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    5. B001Y46

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

      Tech Tips

      Tighten the nut to the specified torque when adjusting the park/neutral position switch assembly.

    6. B00204XC01
      *1 Transmission Control Shaft Lever RH

      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.

    7. Remove the nut, spring washer and transmission control shaft lever RH from the manual valve lever shaft.

    8. B001ZF1C01
      *a Neutral Basic Line
      *b Groove

      Align the groove with the neutral basic line.

    9. Hold the park/neutral position switch assembly in the position described above and tighten the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    10. B001XMD

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

      Note


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

      • Bend at least 2 of the lock washer tabs.

      Tech Tips

      Tape the screwdriver tip before use.

  66. INSTALL TRANSMISSION REVOLUTION SENSOR (SP2)

    Click here

  67. INSTALL TRANSMISSION REVOLUTION SENSOR (NT)

    Click here

  68. INSTALL BREATHER PLUG HOSE


    1. B001ZBCC01
      *1 Breather Plug Sub-assembly
      *2 Breather Plug Hose
      *3 Breather Plug
      *4 O-ring

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

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

    3. B001ZFX

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

      Note

      Be careful not to damage the O-rings.