AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION


    1. Check each bearing position and installation direction.

      B001ZP8E01
      Bearing Position
      Position

      Front Race Diameter

      Inside/Outside

      Thrust Bearing Diameter

      Inside/Outside

      Rear Race Diameter

      Inside/Outside
      A - 36.2 mm (1.425 in.) / 58.2 mm (2.291 in.) 44.0 mm (1.732 in.) / 62.0 mm (2.441 in.)
      B - 34.5 mm (1.358 in.) / 49.9 mm (1.965 in.) 36.6 mm (1.441 in.) / 51.9 mm (2.043 in.)
      C 46.5 mm (1.831 in.) / 60.1 mm (2.366 in.) 47.0 mm (1.850 in.) / 61.9 mm (2.437 in.) -
      D - 71.2 mm (2.803 in.) / 84.5 mm (3.327 in.) 71.9 mm (2.831 in.) / 87.8 mm (3.457 in.)
      E 30.0 mm (1.181 in.) / 49.9 mm (1.965 in.) 31.0 mm (1.221 in.) / 53.7 mm (2.112 in.) -
      F 31.5 mm (1.240 in.) / 57.3 mm (2.256 in.) 28.7 mm (1.130 in.) / 53.8 mm (2.118 in.) 28.7 mm (1.130 in.) / 53.5 mm (2.106 in.)
      G 26.2 mm (1.031 in.) / 52.7 mm (2.075 in.) 29.3 mm (1.154 in.) / 51.2 mm (2.016 in.) 29.3 mm (1.154 in.) / 54.0 mm (2.126 in.)
      H - 58.9 mm (2.319 in.) / 76.7 mm (3.020 in.) 62.0 mm (2.441 in.) / 82.5 mm (3.248 in.)

  2. INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING


    1. B001X4JE01

      Using SST, tap in a new output shaft rear radial ball bearing to the automatic transmission case sub-assembly.

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

      Tech Tips

      Install the output shaft rear radial ball bearing so that there is no clearance between the output shaft rear radial ball bearing and the automatic transmission case sub-assembly.

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

  3. INSTALL 1ST AND REVERSE BRAKE PLATE STOPPER SPRING


    1. B001Y8U

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

      Note

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

  4. INSTALL NO. 2 BRAKE PISTON


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

    2. B001YIZE01
      Text in Illustration
      *a Spline
      *b Protrusion
      *c Spline and Protrusion

      Install the No. 2 brake piston to the automatic transmission case sub-assembly.

      Tech Tips

      Make sure that the parking hole of the No. 2 brake piston is on the bottom side by engaging the 2 protrusions of the brake piston to the spline grooves of the transmission case.

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

    4. B001Y2LE05
      Text in Illustration
      *1 No. 2 Brake Piston Return Spring Sub-assembly
      *2 Snap Ring

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

      SST
      09380-50010   ( 09381-05010, 09381-05020, 09381-05030, 09381-05040, 09381-05050 )

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  5. INSPECT PACK CLEARANCE OF NO. 2 BRAKE

    Click here

  6. INSTALL DIRECT CLUTCH PISTON


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

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

    3. B001Z13E01
      Text in Illustration
      *1 Direct Clutch Piston

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

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

    5. B001VKPE01
      Text in Illustration
      *1 No. 2 Clutch Balancer
      *2 Direct Clutch Return Spring Sub-assembly

      Install the direct clutch return spring sub-assembly and No. 2 clutch balancer to the direct clutch drum sub-assembly.

    6. B001YDGE01

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

      SST
      09387-00020

    7. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  7. INSTALL NO. 2 CLUTCH DISC SET


    1. B001YKWE01
      Text in Illustration
      *1 No. 2 Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate

      Install the 7 No. 2 clutch plates, 7 No. 2 clutch discs and the No. 2 clutch flange to the direct clutch drum sub-assembly.

      Install in order
      *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      Note

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

    2. B001Y6HE01
      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.

  8. INSPECT PACK CLEARANCE OF NO. 2 CLUTCH

    Click here

  9. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B001Z4DE01
      Text in Illustration
      *1 Oil Seal Ring

      Coat a new oil seal ring with ATF, and install them to the direct multiple disc clutch assembly.

      Note

      Do not expand the gap of the oil seal rings excessively.

    2. B002019E01
      Text in Illustration
      *1 Oil Seal Ring

      Coat 2 new oil seal ring with ATF, and install them to the output shaft sub-assembly.

      Note

      Do not expand the gap of the oil seal rings excessively.

    3. B001X7BE01
      Text in Illustration
      *1 Direct Multiple Disc Clutch Assembly
      *2 Thrust Needle Roller Bearing (G)
      *3 Thrust Bearing Race (G)
      *4 Output Shaft Sub-assembly

      Install the thrust needle roller bearing and 2 thrust bearing races to the direct multiple disc clutch assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside

      for Front Side:

      Thrust bearing race (G)

      		 26.2 mm (1.031 in.) 52.7 mm (2.075 in.)
      Thrust needle roller bearing (G) 29.3 mm (1.154 in.) 51.2 mm (2.016 in.)

      for Rear Side:

      Thrust bearing race (G)

      		 29.3 mm (1.154 in.) 54.0 mm (2.126 in.)

      Note

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

    4. Install the direct multiple disc clutch assembly to the output shaft sub-assembly.

  10. INSTALL REAR PLANETARY RING GEAR


    1. B001VRAE02
      Text in Illustration
      *1 Rear Planetary Ring Gear
      *2 Snap Ring
      *3 Output Shaft Sub-assembly

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

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

  11. INSTALL DIRECT MULTIPLE DISC CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY


    1. B001ZUME04
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust bearing race (H) 62.0 mm (2.441 in.) 82.5 mm (3.248 in.)
      Thrust needle roller bearing (H) 58.9 mm (2.319 in.) 76.7 mm (3.020 in.)

      for Rear Side:

      Thrust bearing race (F)

      		 28.7 mm (1.130 in.) 53.5 mm (2.106 in.)
      Thrust needle roller bearing (F) 28.7 mm (1.130 in.) 53.8 mm (2.118 in.)

      Note

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

  12. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. B001XBFE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Planetary Gear Assembly
      *3 Thrust Bearing Race

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside

      for Front Side

      Thrust bearing race (F)

      		 31.5 mm (1.240 in.) 57.3 mm (2.256 in.)
      Thrust needle roller bearing (E) 31.0 mm (1.221 in.) 53.7 mm (2.114 in.)

      Note


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

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

  13. INSTALL REAR PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B001ZL6E01
      Text in Illustration
      *1 Rear Planetary Sun Gear Sub-assembly
      *2 Thrust Bearing Race (E)

      Install the thrust bearing race and rear planetary sun gear sub-assembly to the automatic transmission case sub-assembly.

      Standard Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust bearing race (E) 30.0 mm (1.181 in.) 49.9 mm (1.965 in.)

      Note


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

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

  14. INSTALL NO. 2 BRAKE DISC SET


    1. B001XFZE01
      Text in Illustration
      *1 Brake Plate
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate
      *4 No. 2 Brake Flange

      Install the No. 2 brake flange, 6 No. 2 brake discs, 5 No. 2 brake plates and brake plate to the automatic transmission case sub-assembly.

      Install in order
      *4 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      Note

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

      Tech Tips

      Assemble the automatic transmission case sub-assembly, No. 2 brake flange, No. 2 brake plate and brake plate by aligning their grooves as shown in the illustration.

      B001YZVE04
      Text in Illustration
      *1 Brake Plate, No. 2 Brake Plate and No. 2 Brake Flange - -
      *a Groove - -

    2. Install the snap ring to the automatic transmission case sub-assembly.

  15. INSTALL NO. 1 ONE-WAY CLUTCH


    1. B001ZQ3E01
      Text in Illustration
      *1 Snap Ring
      *2 No. 1 One-way Clutch
      *3 One-way Clutch Outer Race

      Install the No. 1 one-way clutch to the one-way clutch outer race with the snap ring.

      Note

      Make sure that the No. 1 one-way clutch is oriented correctly.

  16. INSPECT NO. 1 ONE-WAY CLUTCH

    Click here

  17. INSTALL ONE-WAY CLUTCH OUTER RACE WITH NO. 1 ONE-WAY CLUTCH


    1. B001ZE7

      Install the one-way clutch outer race with No. 1 one-way clutch to the automatic transmission case sub-assembly.

    2. B001XYSE05

      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 its end gap will be within the range shown in the illustration.

      B001XCB

  18. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. B001X9EE01
      Text in Illustration
      *1 Sun Gear Input Drum Sub-assembly
      *2 Thrust Needle Roller Bearing (D)
      *3 Thrust Bearing Race (D)

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust bearing race (D) 71.9 mm (2.831 in.) 87.8 mm (3.457 in.)
      Thrust needle roller bearing (D) 71.2 mm (2.803 in.) 84.5 mm (3.327 in.)

      Note


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

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

  19. INSTALL FORWARD CLUTCH PISTON


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

    2. B001ZJ9E01
      Text in Illustration
      *1 Forward Clutch Piston

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

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

    4. B001YPNE01
      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 forward clutch drum sub-assembly.

    5. B001X6JE01

      Set SST on the No. 1 clutch balancer, tighten SST and compress the No. 1 clutch balancer.

      SST
      09380-50010   ( 09381-05010, 09381-05020, 09381-05030, 09381-05040, 09381-05050 )

      Note

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

    6. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


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

      • Do not expand the snap ring excessively.

  20. INSTALL FORWARD MULTIPLE CLUTCH DISC SET


    1. B002018E01
      Text in Illustration
      *1 Forward Clutch Flange
      *2 Forward Multiple Clutch Disc
      *3 Forward Multiple Clutch Plate

      Install the 7 forward multiple clutch plates, 7 forward multiple clutch discs and forward clutch flange to the forward clutch drum sub-assembly.

      Install in order
      *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      Note

      Make sure that the forward multiple clutch discs, forward multiple clutch plates and the forward clutch flange are installed in the correct order.

    2. B001VVZE01
      Text in Illustration
      *1 Snap Ring

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

  21. INSPECT PACK CLEARANCE OF FORWARD MULTIPLE CLUTCH

    Click here

  22. INSTALL FRONT PLANETARY RING GEAR


    1. B001YRME01
      Text in Illustration
      *1 Front Planetary Ring Gear
      *2 Snap Ring
      *3 Forward Multiple Disc Clutch Assembly

      Using needle-nose pliers, install the snap ring to the groove of forward multiple disc clutch assembly.

    2. B001XZA

      Using needle-nose pliers, contract the snap ring and install the front planetary ring gear to the forward multiple disc clutch assembly.

      Note

      Confirm that the snap ring is correctly located in the groove of the forward multiple disc clutch assembly as shown in the illustration.

  23. INSTALL FORWARD MULTIPLE DISC CLUTCH HUB


    1. B001WJUE02
      Text in Illustration
      *1 Forward Multiple Disc Clutch Assembly with Front Planetary Ring Gear
      *2 Thrust Needle Roller Bearing (B)
      *3 Thrust Bearing Race (B)
      *4 Forward Multiple Disc Clutch Hub

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust needle roller bearing (B) 34.5 mm (1.358 in.) 49.9 mm (1.965 in.)
      Thrust bearing race (B) 36.6 mm (1.441 in.) 51.9 mm (2.043 in.)

      Note

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

  24. INSTALL FORWARD MULTIPLE DISC CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR AND FORWARD MULTIPLE DISC CLUTCH HUB


    1. B001Z0WE01
      Text in Illustration
      *1 Forward Multiple Disc Clutch Assembly with Front Planetary Ring Gear
      *2 Thrust Bearing Race (C)
      *3 Thrust Needle Roller Bearing (C)

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

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust needle race (C) 47.0 mm (1.850 in.) 61.9 mm (2.437 in.)
      Thrust bearing roller bearing (C) 46.5 mm (1.831 in.) 60.1 mm (2.366 in.)

      Note


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

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

  25. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


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

    2. B001XIPE01
      Text in Illustration
      *1 Reverse Clutch Piston Sub-assembly

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

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

    4. B001XSAE01
      Text in Illustration
      *1 No. 3 Clutch Balancer
      *2 Reverse Clutch Return Spring Sub-assembly (Front)

      Install the reverse clutch return spring sub-assembly (front) and No. 3 clutch balancer to the reverse clutch drum sub-assembly.

    5. B001X0NE01

      Set SST on the No. 3 clutch balancer, tighten SST and compress the No. 3 clutch balancer.

      SST
      09380-50010   ( 09381-05010, 09381-05020, 09381-05030, 09381-05040, 09381-05050 )

      Note

      Stop pressing when the balancer is lowered to the place 1.0 to 2.0 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent spring sheet deformation.

    6. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


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

      • Do not expand the snap ring excessively.

  26. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY


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

    2. B001XEUE01
      Text in Illustration
      *1 Overdrive Direct Clutch Drum Sub-assembly

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

  27. INSTALL NO. 4 CLUTCH PISTON


    1. Coat a new O-ring with ATF, and install it to the No. 4 clutch piston.

    2. B001ZW6E01
      Text in Illustration
      *1 No. 4 Clutch Piston

      Install the No. 4 clutch piston to the overdrive direct clutch drum sub-assembly.

    3. B001WTRE01
      Text in Illustration
      *1 Reverse Clutch Balancer
      *2 Reverse Clutch Return Spring Sub-assembly (Rear)

      Install the reverse clutch return spring sub-assembly (rear) and reverse clutch balancer to the overdrive direct clutch drum sub-assembly.

    4. B001Z1DE01

      Set SST on the reverse clutch balancer, tighten SST and compress the reverse clutch balancer.

      SST
      09380-50010   ( 09381-05010, 09381-05020, 09381-05030, 09381-05040, 09381-05050 )

      Note

      Stop pressing when the balancer is lowered to the place 1.0 to 2.0 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent spring sheet deformation.

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note


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

      • Do not expand the snap ring excessively.

  28. INSTALL OVERDRIVE DIRECT CLUTCH DISC


    1. B001VVEE01
      Text in Illustration
      *1 Overdrive Clutch Flange
      *2 Overdrive Direct Clutch Disc
      *3 Overdrive Direct Clutch Plate

      Install the 6 overdrive direct clutch plates, 6 overdrive direct clutch discs and overdrive clutch flange to the overdrive direct clutch drum sub-assembly.

      Install in order
      *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      Note

      Make sure that the overdrive direct clutch discs, overdrive direct clutch plates and the overdrive clutch flange are installed in the correct order.

    2. B001WEIE01
      Text in Illustration
      *1 Snap Ring

      Install the snap ring to the overdrive direct clutch drum sub-assembly.

  29. INSPECT PACK CLEARANCE OF OVERDRIVE DIRECT CLUTCH

    Click here

  30. INSTALL NO. 3 CLUTCH DISC SET


    1. B001X42E01
      Text in Illustration
      *1 No. 3 Clutch Flange
      *2 No. 3 Clutch Discs
      *3 No. 3 Clutch Plate (A)
      *4 No. 3 Clutch Plate (B)

      Install the 6 No. 3 clutch plates, 6 No. 3 clutch discs and No. 3 clutch flange to the reverse clutch drum sub-assembly.

      Install in order
      *4 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
      No. 3 Clutch Plate Thickness
      Item Thickness
      No. 3 Clutch Plate (A) 1.8 mm (0.0709 in.)
      No. 3 Clutch Plate (B) 3.5 mm (0.138 in.)

      Note

      Make sure that the No. 3 clutch discs, No. 3 clutch plates and the No. 3 clutch flange are installed in the correct order.

    2. B00206XE01
      Text in Illustration
      *1 Snap Ring

      Install the snap ring to the reverse clutch drum sub-assembly.

  31. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH

    Click here

  32. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B001YEGE01
      Text in Illustration
      *1 Front Planetary Gear Radial Needle Roller Bearing

      Install the front planetary gear radial needle roller bearing to the front planetary gear assembly.

      Note

      Do not expand the front planetary gear radial needle roller bearing excessively.

    2. B001VWCE05
      Text in Illustration
      *1 Oil Seal Ring

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

      Note

      Do not expand the oil seal ring ends excessively.

    3. B001VULE02
      Text in Illustration
      *1 Oil Seal Ring

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

      Note

      Do not expand the oil seal ring ends excessively.

    4. B001X79E01
      Text in Illustration
      *1 Planetary Carrier Thrust Washer

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

      Note

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

    5. B001WS3E01
      Text in Illustration
      *1 Front Planetary Sun Gear

      Install the front planetary sun gear to the front planetary gear assembly.

    6. B001YTWE01
      Text in Illustration
      *1 Front Planetary Gear Assembly

      Assemble the front planetary gear assembly together with the front planetary sun gear to the overdrive and reverse multiple disc clutch assembly.

  33. INSPECT PACK CLEARANCE OF NO. 1 BRAKE

    Click here

  34. INSTALL OVERDRIVE AND REVERSE MULTIPLE DISC CLUTCH ASSEMBLY AND FRONT PLANETARY GEAR ASSEMBLY


    1. B001XHYE01
      Text in Illustration
      *1 Overdrive and Reverse Multiple Disc Clutch Assembly and Front Planetary Gear Assembly
      *2 Thrust Needle Roller Bearing (A)
      *3 Thrust Bearing Race (A)

      Install the thrust bearing race, thrust needle roller bearing, and overdrive and reverse multiple disc clutch assembly and front planetary gear assembly to the automatic transmission case sub-assembly.

      Thrust Needle Roller Bearing and Thrust Bearing Race Diameter
      Item Inside Outside
      Thrust needle roller bearing (A) 36.2 mm (1.425 in.) 58.2 mm (2.291 in.)
      Thrust bearing race (A) 44.0 mm (1.732 in.) 62.0 mm (2.441 in.)

      Note


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

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

    2. Install the snap ring to the automatic transmission case sub-assembly.

  35. INSTALL NO. 1 BRAKE DISC SET


    1. B001YQ0E01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate

      Install the selected No. 1 brake flange, 6 No. 1 brake discs and 6 No. 1 brake plates to the automatic transmission case sub-assembly.

      Install in order
      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3

      Note

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

  36. INSTALL OVERDRIVE BRAKE PLATE STOPPER SPRING


    1. B001X3D

      Install the overdrive brake plate stopper spring to the automatic transmission case sub-assembly as shown in the illustration.

      Note

      Install the overdrive brake plate stopper spring so that the wider side is facing inwards.

  37. INSTALL OIL PUMP ASSEMBLY


    1. B001Z8PE01
      Text in Illustration
      *1 Oil Pump Assembly
      *2 Oil Pump O-ring

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

    2. Clean and degrease the threads of the 11 bolts and the contact surfaces of the automatic transmission case sub-assembly and the oil pump assembly with non-residue solvent.

      Note

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

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

    4. Hold the input shaft, and lightly press the oil pump assembly to slide the oil seal rings into the front planetary gear assembly.

      Note

      Be careful not to damage the O-ring and oil seal rings.

    5. B001XUN

      Install the 11 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  38. INSPECT INDIVIDUAL PISTON OPERATION

    Click here

  39. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B001WU9E01
      Text in Illustration
      *1 Manual Detent Spring Sub-assembly
      *2 Manual Detent Spring Cover

      Install the manual detent spring sub-assembly and manual detent spring cover with the bolt.

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

  40. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B001ZGTE03
      Text in Illustration
      *A for RH Side
      *B for LH Side

      Using SST and a hammer, tap in 2 new manual valve lever shaft oil seals.

      SST
      09350-30020   ( 09350-07110 )
      Standard depth
      -0.2 to 0.4 mm (-0.00788 to 0.0157 in.)

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

  41. INSTALL PARKING LOCK PAWL SHAFT


    1. B001W0BE01
      Text in Illustration
      *1 Parking Lock Pawl
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 E-ring

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

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

  42. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. B001XKQE01
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Parking Lock Rod Sub-assembly

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

  43. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B001ZREE01
      Text in Illustration
      *1 Spacer

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

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

    3. B001W2TE01
      Text in Illustration
      *1 Spring Pin

      Using a hammer, install 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. B001WJ7

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

    6. Check that the spacer does not turn.

  44. INSTALL PARKING LOCK PAWL BRACKET


    1. B001YNBE04

      Install the parking lock pawl bracket to the automatic transmission case sub-assembly with the 3 bolts, in several steps in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    2. B001YRV

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

  45. INSTALL TRANSMISSION REVOLUTION SENSOR (SP2)

    Click here

  46. INSTALL TRANSMISSION WIRE

    Click here

  47. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    Click here

  48. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    Click here

  49. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Click here

  50. INSTALL AUTOMATIC TRANSMISSION CASE PLUG


    1. B001XI6E01
      Text in Illustration
      *A for LH Side
      *B for Rear Side

      for T55H "TORX" Type:


      1. Install the 2 new O-rings to the 2 automatic transmission case plugs.

      2. Using a T55H "TORX" socket wrench, install the 2 automatic transmission case plugs to the automatic transmission case sub-assembly.

        Torque:
        40 N*m  { 403 kgf*cm, 30 ft.*lbf }
    2. B001Z2X

      for 17 mm Hexagon Type:


      1. Install a new O-ring to the automatic transmission case plug.

      2. Install the automatic transmission case plug to the automatic transmission case sub-assembly.

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

  51. INSTALL REFILL PLUG


    1. Install a new O-ring to the refill plug.

    2. Install the refill plug.

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

  52. INSTALL OIL COOLER TUBE UNION


    1. Install the 2 new O-rings to the 2 oil cooler tube unions.

    2. B001VPHE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length
      *b 18 to 22°
      *c 43 to 47°

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

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

      Tech Tips


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

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

  53. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    Click here

  54. INSTALL REAR TRANSFER ADAPTER


    1. Coat a new O-ring with ATF and install it to the rear transfer adapter.

    2. B001YNR

      Install the rear transfer adapter with the 10 bolts.

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

  55. INSTALL TRANSFER CASE ADAPTER REAR OIL SEAL


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

    2. B001Y1PE01

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

      SST
      09223-50010
      09710-30031   ( 09710-03171 )
      Standard depth
      0 to 1 mm (0 to 0.0393 in.)

  56. INSTALL AUTOMATIC TRANSMISSION HOUSING


    1. B001WM8

      Remove the automatic transmission assembly from the overhaul attachment.

    2. B00203M

      Install the automatic transmission housing to the automatic transmission case sub-assembly with the 16 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  57. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B001YLWE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *2 No. 1 Breather Plug
      *3 Breather Plug Hose
      *4 Clamp
      *5 Breather Plug O-ring

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

      Note

      Ensure that the breather plug O-ring is not twisted.

    2. Install the No. 1 breather plug and No. 2 breather plug to the breather plug hose.

    3. Install the clamp to the breather plug hose.

    4. B001Z5V

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

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