AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    B001GDBE01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A 74.3 to 74.6 mm (2.93 to 2.94 in.)/87.4 to 87.7 mm (3.44 to 3.45 in.) 72.0 to 72.3 mm (2.83 to 2.85 in.)/85.3 to 85.6 mm (3.36 to 3.37 in.) -
    B 37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.) 34.7 to 34.9 mm (1.366 to 1.374 in.)/51.6 to 51.9 mm (2.03 to 2.04 in.) -
    C - 21.4 to 21.6 mm (0.841 to 0.850 in.)/40.8 to 41.0 mm (1.606 to 1.614 in.) 22.7 to 22.9 mm (0.892 to 0.902 in.)/60.0 to 60.4 mm (2.36 to 2.38 in.)
    D 33.3 to 33.5 mm (1.31 to 1.32 in.)/56.3 to 56.6 mm (2.22 to 2.23 in.) 38.5 to 38.7 mm (1.515 to 1.524 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) -
    E - 42.6 to 42.8 mm (1.68 to 1.69 in.)/60.8 to 61.1 mm (2.39 to 2.41 in.) -
    F 38.0 to 38.2 mm (1.496 to 1.504 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) 43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.4 mm (2.28 to 2.30 in.) -
    G - 55.8 to 56.0 mm (2.197 to 2.204 in.)/76.1 to 76.4 mm (2.996 to 3.008 in.) 53.8 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.)
    H 33.4 to 33.6 mm (1.31 to 1.32 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.) 32.2 to 32.3 mm (1.268 to 1.272 in.)/49.0 to 49.2 mm (1.93 to 1.94 in.) 32.2 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)
    I - 21.5 to 21.8 mm (0.846 to 0.858 in.)/40.5 to 40.8 mm (1.59 to 1.61 in.) -
    J - 43.6 to 43.9 mm (1.72 to 1.73 in.)/60.6 to 60.9 mm (2.39 to 2.40 in.) 47.2 to 47.4 mm (1.86 to 1.87 in.)/66.9 to 67.1 mm (2.63 to 2.64 in.)

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

    B001H1SE17
    Text in Illustration
    *1 New O-Ring

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

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

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

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

    B001HDO

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

      Note


      • Do not damage the O-rings.

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

  4. INSTALL 1ST AND REVERSE BRAKE PISTON

    B001HMN

    1. Coat a new O-ring with ATF.

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

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

      Note

      Be careful not to damage the O-ring.

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

    B001H9V

    1. Install the brake return spring to the 1st and reverse brake piston.

    2. B001GOPE01

      Place SST on the spring retainer and compress the return spring.

      SST
      09350-30020   ( 09350-07050 )

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )
      Text in Illustration
      *1 Snap Ring

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY

    B001I12

    1. Install the No. 9 thrust bearing race.

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race J 47.2 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.)
    2. B001DTLE04
      Text in Illustration
      *1 Bearing I
      *2 Bearing J

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing J 43.6 to 43.9 mm (1.72 to 1.73 in.) 60.6 to 60.9 mm (2.39 to 2.40 in.)
      Bearing I 21.5 to 21.8 mm (0.846 to 0.858 in.) 40.5 to 40.8 mm (1.59 to 1.61 in.)
    3. B001DBC

      Install the rear planetary gear assembly.

  7. SELECT 1ST AND REVERSE BRAKE FLANGE


    1. B001IMVE01

      Using a vernier caliper, measure distance A (from the top surface of the 1st and reverse brake piston to the step in the transmission case) in the illustration.

      Note

      Make sure the 1st and reverse brake piston is installed securely to the transmission case.

      Tech Tips

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

    2. B001HO8E04

      Assemble the 2 flanges, 8 discs and 7 plates, and using a vernier caliper, measure distance B in the illustration at both ends across the diameter, and calculate the average.

      Tech Tips

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

    3. Select a 1st and reverse brake flange so that the value of measured distance A minus distance B is 2.85 to 3.15 mm (0.112 to 0.124 in.).

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

  8. INSTALL NO. 4 BRAKE DISC

    B001IMJE01
    Text in Illustration
    *1 Flange
    *2 Disc
    *3 Plate

    1. Install the 2 flanges, 8 discs and 7 plates.

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

  9. INSTALL BRAKE PLATE STOPPER SPRING

    B001EBB

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    B001CSAE26
    Text in Illustration
    *1 Race H Rear
    *2 Race H Front

    1. Install the thrust bearing race, thrust needle roller bearing, thrust bearing race and planetary ring gear flange to the intermediate shaft.

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      Race H Rear 32.2 to 32.4 mm (1.27 to 1.28 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)
      Bearing H 32.2 to 32.3 mm (1.268 to 1.272 in.) 49.0 to 49.2 mm (1.93 to 1.94 in.)
      Race H Front 33.4 to 33.6 mm (1.31 to 1.32 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)

  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

    B001H8O

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

  12. INSTALL INTERMEDIATE SHAFT

    B001ICT

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

    2. B001FY5E20

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

    B001IKS

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

    2. Coat the thrust bearing race with petroleum jelly and install it to the center planetary gear.

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

  14. INSTALL NO. 2 BRAKE PISTON


    1. B001I6DE19
      Text in Illustration
      *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

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

  15. INSTALL NO. 2 BRAKE DISC

    B001HTTE12

    1. Install the brake piston return spring.

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

      Install in order
      *1 - *2 - *1 - *2 - *1 - *2 - *3
      Text in Illustration
      *1 Plate
      *2 Disc
      *3 Flange
    3. B001HIOE16

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

      SST
      09351-40010

  16. INSTALL NO. 1 BRAKE PISTON

    B001GO3E04
    Text in Illustration
    *1 New O-Ring

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

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

      Note

      Be careful not to damage the O-rings.

  17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    B001FAU

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

  18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

    B001DFEE11

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

      SST
      09351-40010

  19. SELECT NO. 1 BRAKE FLANGE


    1. B001EWB

      Using a feeler gauge, measure the distance between the snap ring and flange.

      Tech Tips

      0.42 to 0.72 mm (0.0165 to 0.0283 in.)

      If the distance is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the distance is still outside the specification, select No. 1 brake flange so that the value of measured distance is 0.42 to 0.72 mm (0.0165 to 0.0283 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.)

  20. INSTALL NO. 1 BRAKE DISC

    B001CB0E11
    Text in Illustration
    *1 Plate
    *2 Disc
    *3 Flange

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

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

  21. INSTALL CENTER PLANETARY RING GEAR


    1. B001FSE

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

    2. B001FZR

      Using a screwdriver, install the snap ring.

  22. INSTALL FRONT PLANETARY RING GEAR

    B001HPD

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

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

  23. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    B001GRBE27

    1. Install the thrust washer and thrust needle roller bearing.

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

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      Bearing F 43.4 to 43.6 mm (1.71 to 1.72 in.) 58.0 to 58.4 mm (2.28 to 2.30 in.)
      Race F 38.0 to 38.2 mm (1.496 to 1.504 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Text in Illustration
      *1 Bearing F
      *2 Race F
    3. B001EG0

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

  24. INSTALL 2ND BRAKE PISTON

    B001G1RE23

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

      Text in Illustration
      *1 New O-Ring

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

      Note

      Be careful not to damage the O-rings.

    3. Install the return spring to the 2nd brake cylinder.

    4. B001EBXE15

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

      SST
      09351-40010

      Note

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

  25. INSTALL 2ND BRAKE CYLINDER

    B001IJ6

    1. Install the 2nd brake cylinder to the case.

  26. INSTALL 1-WAY CLUTCH ASSEMBLY

    B001DSI

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

  27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

    B001FY5E21

    1. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  28. INSTALL NO. 3 BRAKE DISC

    B001DRRE15
    Text in Illustration
    *1 Cushion Plate
    *2 Plate
    *3 Disc
    *4 Flange

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

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

  29. INSTALL NO. 3 BRAKE SNAP RING

    B001DYU

    1. Using a screwdriver, install the snap ring.

  30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

    B001GAQE13

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

      Text in Illustration
      *1 New O-Ring
    2. B001HZI

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

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

      Note

      Be careful not to damage the O-rings.

    4. B001DP9E15

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

      Note

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

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

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

      Note

      Do not expand the snap ring excessively.

    6. B001H5AE20
      Text in Illustration
      *1 Stopper

      Position the end gap of the snap ring as shown in the illustration

      Note

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

  31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. B001DN2E12
      Text in Illustration
      *1 New O-Ring

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

    2. B001FXZE12
      Text in Illustration
      *1 New O-Ring

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

    3. B001CRX

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

      Note

      Be careful not to damage the O-ring.

  32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B001G6OE18
      Text in Illustration
      *1 New O-Ring

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

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

  33. INSTALL NO. 3 CLUTCH BALANCER


    1. B001GG0E14

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

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

      Note

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

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

      Note

      Do not expand the snap ring excessively.

    3. B001HLJ

      Position the end gap of the snap ring as shown in the illustration.

      Note

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

  34. INSTALL DIRECT CLUTCH DISC


    1. B001FQ5E02
      Text in Illustration
      *1 Plate
      *2 Disc
      *3 Flange

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

      Install in order
      *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3
    2. B001GRC

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

    3. B001CQ5E01

      Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air (392 kPa, 4.0 kgf/ cm2, 57 psi) into the oil hole as shown in the illustration.

      Standard moving distance (A)
      0.65 to 0.95 mm (0.0256 to 0.0374 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.

      If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

      Flange Thickness
      Mark Thickness
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)

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

  35. SELECT REVERSE CLUTCH FLANGE

    B001GN7

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

      Note

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

    2. B001DZAE03
      Text in Illustration
      *1 Flange
      *2 Disc
      *3 Plate
      *4 Cushion Plate

      Install the 2 flanges, 5 discs, 4 plates, cushion plate and reverse clutch reaction sleeve to the clutch drum.

      Install in order
      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1 - *4
    3. B001CSL

      Using a screwdriver, install the hole snap ring.

    4. Using a dial indicator, measure the moving distance (A minus B) of the top surface of the reverse clutch piston (A) and cushion plate at both ends across the diameter (B) while applying compressed air (392 kPa, 4.0 kgf/ cm2, 57 psi) into the oil hole as shown in the illustration. Then choose a flange of an appropriate thickness from the table so that the measured value is within the standard range.

      B001GBOE01
      Standard moving distance (A minus B)
      0.56 to 0.86 mm (0.0220 to 0.0339 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position indicated by the shaded area in the illustration.

      Tech Tips

      Distance (A) = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

      Distance (B) = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

      Flange Thickness
      Mark Thickness
      0 2.75 to 2.85 mm (0.108 to 0.112 in.)
      1 2.85 to 2.95 mm (0.112 to 0.116 in.)
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)
    5. B001CEJ

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

  36. REMOVE REVERSE CLUTCH REACTION SLEEVE

    B001CSL

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

    2. B001CEJ

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

  37. INSTALL INPUT SHAFT OIL SEAL RING


    1. B001IDR

      Coat 3 new oil seal rings with ATF.

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

      Note

      Do not excessively widen the rings.

      Tech Tips

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

  38. INSTALL FORWARD CLUTCH PISTON

    B001FWME06
    Text in Illustration
    *1 New O-Ring

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

    2. Install the forward clutch piston to the input shaft.

  39. INSTALL NO. 1 CLUTCH BALANCER

    B001H0LE08

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

      Text in Illustration
      *1 New O-Ring
    2. B001CSC

      Install the forward clutch return spring and clutch balancer.

      Note

      Be careful not to damage the O-ring.

    3. B001HFZE05

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

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

      Note

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

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

      Note

      Do not expand the snap ring excessively.

    5. B001IIS

      Position the end gap of the snap ring as shown in the illustration.

      Note

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

  40. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC


    1. B001GU9E02
      Text in Illustration
      *1 Flange
      *2 Disc
      *3 Plate

      Install the 2 flanges, 7 discs and 6 plates to the input shaft assembly.

      Install in order
      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
    2. B001HU9

      Using a screwdriver, temporarily install the snap ring.

    3. B001DVVE01

      Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air (196 kPa, 2.0 kgf/ cm2, 28 psi) into the oil hole as shown in the illustration.

      Standard moving distance (A)
      0.81 to 1.01 mm (0.0319 to 0.0398 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.

      Tech Tips

      Moving distance (A): 0.26 to 1.36 mm (0.0102 to 0.0535 in.)

      If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

      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.)
      9 3.85 to 3.95 mm (0.148 to 0.152 in.)
      A 3.95 to 4.05 mm (0.152 to 0.159 in.)

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

  41. INSTALL INPUT SHAFT ASSEMBLY


    1. B001CTT

      Install the input shaft to the clutch drum.

    2. B001HZG

      Install the thrust needle roller bearing to the clutch drum.

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

  42. INSTALL MULTIPLE DISC CLUTCH HUB


    1. B001EREE12
      Text in Illustration
      *1 No. 3 Race
      *2 Race D

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

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 3 Race 22.7 to 22.9 mm (0.892 to 0.902 in.) 60.0 to 60.4 mm (2.36 to 2.38 in.)
      Race D 33.3 to 33.5 mm (1.31 to 1.32 in.) 56.3 to 56.6 mm (2.22 to 2.23 in.)
    2. B001HN4

      Install the multiple disc clutch hub to the clutch drum.

  43. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. B001HK5E10
      Text in Illustration
      *1 Bearing D
      *2 Bearing E

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing D 38.5 to 38.7 mm (1.515 to 1.524 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Bearing E 42.6 to 42.8 mm (1.68 to 1.69 in.) 60.8 to 61.1 mm (2.39 to 2.41 in.)
    2. B001DK4

      Install the forward clutch hub to the clutch drum.

  44. INSTALL REAR CLUTCH DISC


    1. B001FZQE24
      Text in Illustration
      *1 Disc
      *2 Plate
      *3 Flange
      *4 Cushion Plate

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

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

  45. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. B001CPU

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

  46. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. B001ETJ

      Install the reverse clutch hub to the clutch drum.

    2. B001D2H

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

  47. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY


    1. B001CAN

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

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

  48. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    B001I74E02

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside
      Bearing A 72.0 to 72.3 mm (2.83 to 2.85 in.) 85.3 to 85.6 mm (3.36 to 3.37 in.)
      Bearing B 34.7 to 34.9 mm (1366 to 1.374 in.) 51.6 to 51.9 mm (2.03 to 2.04 in.)
      Text in Illustration
      *1 Bearing A
      *2 Bearing B
    2. B001EC5

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

  49. INSTALL OIL PUMP ASSEMBLY

    B001IFPE02

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

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race A 74.3 to 74.6 mm (2.93 to 2.94 in.) 87.4 to 87.7 mm (3.44 to 3.45 in.)
      Race B 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.)
      Text in Illustration
      *1 Race A
      *2 Race B
    2. B001HLWE08
      Text in Illustration
      *1 New O-Ring

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

    3. Slide the oil pump onto the input shaft, align the bolt holes of the oil pump assembly with the bolt holes of the transmission case and install the oil pump.

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

      Note

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

    5. B001DP7

      Install the 10 bolts.

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

  50. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    B001HGNE08

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

      SST
      09350-30020   ( 09350-07110 )

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

  51. INSPECT INDIVIDUAL PISTON OPERATION

    Click here

  52. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    B001FCSE08

    1. Install a new spacer to the manual valve lever.

      Text in Illustration
      *1 Spacer
      *2 Manual Valve Lever

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

    3. B001I9Z

      Using a hammer, tap in a new spring pin.

    4. B001EBJ

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

    5. Check that the shaft rotates smoothly.

  53. INSTALL PARKING LOCK PAWL SHAFT

    B001IFRE11
    Text in Illustration
    *1 E-Ring
    *2 Parking Lock Pawl
    *3 Spring

    1. Install the E-ring to the shaft.

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

  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    B001DTN

    1. Connect the parking lock rod to the manual valve lever to install it.

  55. INSTALL PARKING LOCK PAWL BRACKET

    B001DW8

    1. Install the parking lock pawl bracket to the transmission case with the 3 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. B001IEPE18
      Text in Illustration
      *1 Manual Valve Lever
      *2 Planetary Ring Gear
      *3 Parking Lock Pawl

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

  56. INSTALL C-1 ACCUMULATOR VALVE


    1. B001HHL

      Install the 2 springs and accumulator valve to the hole.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-1 Inner

      30.40 mm (1.20 in.)

      11.40 mm (0.449 in.)

      		 Pink
      C-1 Outer

      48.76 mm (1.92 in.)

      16.60 mm (0.654 in.)

      		 Light Green

  57. INSTALL C-3 ACCUMULATOR PISTON

    B001FOSE03
    Text in Illustration
    *1 New O-Ring

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

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

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3 Inner

      44.0 mm (1.73 in.)

      14.0 mm (0.551 in.)

      		 Yellow
      C-3 Outer

      73.35 mm (2.89 in.)

      19.90 mm (0.784 in.)

      		 Red

  58. INSTALL B-3 ACCUMULATOR PISTON

    B001FYKE03
    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.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3

      70.5 mm (2.78 in.)

      19.7 mm (0.776 in.)

      		 Purple

  59. INSTALL C-2 ACCUMULATOR PISTON

    B001H4XE03
    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.

      Accumulator Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-2

      62.0 mm (2.44 in.)

      15.9 mm (0.626 in.)

      		 White

  60. INSTALL BRAKE DRUM GASKET

    B001HR7

    1. Install the 3 brake drum gaskets.

  61. INSTALL TRANSMISSION CASE GASKET

    B001GLX

    1. Install the 3 transmission case gaskets.

  62. INSTALL CHECK BALL BODY

    B001HP5E28
    Text in Illustration
    *1 Spring
    *2 Check Ball Body

    1. Install the spring and check ball body.

  63. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    B001HHOE11

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

      Text in Illustration
      *1 Pin
    2. B001H6NE10

      Install the transmission valve body assembly with 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

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

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

  64. INSTALL TRANSMISSION WIRE

    B001FQC

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

    2. Install the transmission wire harness.

    3. Install the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. B001CD2E11

      Connect the 7 solenoid connectors.

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

    6. 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 }
      Text in Illustration
      *1 No. 1 Temperature Sensor
      *2 No. 2 Temperature Sensor

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

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

  65. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    B001IAQ

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

    2. Install the oil strainer with the 4 bolts.

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

  66. INSTALL TRANSMISSION OIL CLEANER MAGNET

    B001GTLE07

    1. Install the 4 magnets.

  67. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install a new gasket to the oil pan.

    2. Install the oil pan with the 20 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    3. Install the drain plug.

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

  68. INSTALL REAR TRANS CASE ADAPTOR OIL RECEIVER

    B001F03

    1. Install the trans case adaptor oil receiver to the rear adaptor transfer.

    2. Using snap ring pliers, install the snap ring.

  69. INSTALL TRANSMISSION CASE ADAPTER REAR OIL SEAL

    B001CVXE08
    *1 0 to 0.5 mm

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

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

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

  70. INSTALL TRANSFER ADAPTER REAR


    1. Clean the threads of the bolts and case.

    2. B001GO1E09
      Text in Illustration
      *1 Seal Packing

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

      Seal packing
      Toyota Genuine Seal Packing 1281,
      Three Bond 1281 or equivalent
      Seal diameter
      1.0 to 1.5 mm (0.0394 to 0.0591 in.)
    3. B001GKWE05

      Install the transmission case adapter with the 8 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      50 mm (1.97 in.) for bolt A

      40 mm (1.57 in.) for bolt B

  71. INSTALL AUTOMATIC TRANSMISSION HOUSING

    B001FOXE02

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

    2. Install the transmission housing with the 10 bolts.

      Torque:
      for 14 mm head bolt A
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }
      for 17 mm head bolt B
      57 N*m  { 579 kgf*cm, 42 ft.*lbf }
      for 14 mm head bolt C
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

  72. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

    B001CAJ

    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 }

  73. INSTALL SPEED SENSOR


    1. B001CHQ

      Coat 2 new O-rings with ATF and install one to each speed sensor.

    2. Install the 2 speed sensors.

    3. Install the 2 bolts.

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

  74. INSTALL OIL COOLER TUBE UNION


    1. B001F5ZE02
      Text in Illustration
      *A w/ Warmer:
      *B w/o Warmer:

      Coat a new O-ring with ATF and install one to each oil cooler tube union.

    2. Install the oil cooler tube union.

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

  75. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    B001G5B

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

    2. Install a new lock washer and the nut.

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

    3. Temporarily install the control shaft lever.

    4. B001HITE05

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

    5. Remove the control shaft lever.

    6. B001D74E06
      Text in Illustration
      *1 Neutral Basic Line
      *2 Groove

      Align the neutral basic line with the switch groove, and tighten the adjusting bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    7. B001FCC

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  76. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH

    B001F58

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

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }