AUTOMATIC TRANSMISSION UNIT REASSEMBLY

PROCEDURE


  1. BEARING POSITION

    B0025M0N01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A 74.2 mm (2.92 in.) / 87.74 mm (3.45 in.) 71.9 mm (2.83 in.) / 85.6 mm (3.37 in.) -
    B 37.0 mm (1.46 in.) / 52.3 mm (2.06 in.) 34.6 mm (1.36 in.) / 52.0 mm (2.05 in.) -
    C - 21.3 mm (0.839 in.) / 41.1 mm (1.62 in.) 22.6 mm (0.890 in.) / 45.0 mm (1.77 in.)
    D 38.4 mm (1.51 in.) / 56.5 mm (2.22 in.) 33.3 mm (1.31 in.) / 51.5 mm (2.03 in.) -
    E - 42.5 mm (1.67 in.) / 61.2 mm (2.41 in.) -
    F 38.0 mm (1.50 in.) / 57.0 mm (2.24 in.) 43.4 mm (1.71 in.) / 58.3 mm (2.30 in.) -
    G - 55.7 mm (2.19 in.) / 76.4 mm (3.01 in.) 53.7 mm (2.11 in.) / 74.0 mm (2.91 in.)
    H 33.4 mm (1.31 in.) / 49.0 mm (1.93 in.) 32.1 mm (1.26 in.) / 49.35 mm (1.94 in.) 32.1 mm (1.26 in.) / 49.0 mm (1.93 in.)
    I - 21.5 mm (0.846 in.) / 40.8 mm (1.61 in.) -
    J - 43.55 mm (1.71 in.) / 61.0 mm (2.40 in.) 47.1 mm (1.85 in.) / 67.1 mm (2.64 in.)

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

    B002695C01
    *1 O-ring
    *2 Brake Reaction Sleeve
    *3 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. Install the No. 4 brake piston to the brake reaction sleeve.

      Note

      Be careful not to damage the O-rings.

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

    B0026IZC01
    *1 Brake Reaction Sleeve
    *2 No. 4 Brake Piston

    1. Install the No. 4 brake piston with brake reaction sleeve to the automatic transmission case sub-assembly.

      Note

      Be careful not to damage the O-ring.

  4. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. Coat a new O-ring with ATF.

    2. B0024U2C01
      *1 1st and Reverse Brake Piston

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

    3. With the spring seat of the 1st and reverse brake piston facing upwards (front side), place the 1st and reverse brake piston in the automatic transmission case sub-assembly.

      Note

      Be careful not to damage the O-ring.

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


    1. A01W8GC

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

    2. B00285FC01
      *1 Snap Ring

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

      SST
      09350-30020   ( 09350-07050 )

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. Install the No. 9 thrust bearing race.

      Thrust Bearing Race Diameter
      Item Inside Outside

      No. 9 Thrust Bearing Race

      (Rear race J)

      		 47.1 mm (1.85 in.) 67.1 mm (2.64 in.)
    2. B00248AC03
      *1

      Thrust Needle Roller Bearing

      (Thrust Bearing I)
      *2

      Thrust Needle Roller Bearing

      (Thrust Bearing J)

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

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside

      Thrust needle roller bearing

      (Thrust bearing J)

      		 43.55 mm (1.71 in.) 61.0 mm (2.40 in.)

      Thrust needle roller bearing

      (Thrust bearing I)

      		 21.5 mm (0.846 in.) 40.8 mm (1.61 in.)

    3. Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

    Click here

  8. INSTALL NO. 4 BRAKE DISC


    1. B00254XC01
      *1 No. 4 Brake Flange
      *2 No. 4 Brake Disc
      *3 No. 4 Brake Plate

      Install the 2 flanges, 8 discs and 7 plates.

      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.

  9. INSTALL BRAKE PLATE STOPPER SPRING


    1. A01WBN1

      Install the brake plate stopper spring.

  10. INSTALL REAR PLANETARY RING GEAR


    1. B0025GVC01
      *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. B002705C01
      *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.

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


    1. B0026ZZC01
      *1

      No. 7 Thrust Bearing Race

      (Front Race H)
      *2

      Thrust Needle Roller Bearing

      (Thrust Bearing H)
      *3

      No. 8 Thrust Bearing Race

      (Rear Race H)
      *4 Rear Planetary Ring Gear Flange Sub-assembly

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

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside

      No. 7 thrust bearing race

      (Front Race H)

      		 33.4 mm (1.31 in.) 49.0 mm (1.93 in.)

      Thrust needle roller bearing

      (Thrust bearing H)

      		 32.1 mm (1.26 in.) 49.35 mm (1.94 in.)

      No. 8 thrust bearing race

      (Rear race H)

      		 32.1 mm (1.26 in.) 49.0 mm (1.93 in.)

  12. INSTALL NO. 3 ONE-WAY CLUTCH ASSEMBLY

    B0026QBC01
    *1 No. 3 One-way Clutch Assembly
    *2 One-way Clutch Inner Race

    1. Install the No. 3 one-way clutch assembly and one-way clutch inner race to the intermediate shaft.

  13. INSTALL INTERMEDIATE SHAFT


    1. Install the intermediate shaft with the No. 3 one-way clutch assembly to the automatic transmission case sub-assembly.

    2. B0028XHN01

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  14. INSTALL CENTER PLANETARY GEAR ASSEMBLY

    B0026GIC01
    *1

    No. 4 Thrust Bearing Race

    (Rear Race G)
    *2 Center Planetary Gear Assembly
    *3 Planetary Sun Gear

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

    2. Coat the No. 4 thrust bearing race with ATF, and install it onto the center planetary gear assembly.

      Thrust Bearing Race Diameter
      Item Inside Outside

      No. 4 thrust bearing race

      (Rear race G)

      		 53.7 mm (2.11 in.) 74.0 mm (2.91 in.)

  15. INSTALL NO. 2 BRAKE PISTON


    1. B0025Q1C01
      *1 O-ring

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

    2. Press the No. 2 brake piston into the No. 2 brake cylinder.

      Note

      Be careful not to damage the O-rings.

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

      Tech Tips

      Install the No. 2 brake cylinder so that the projection protrudes from the upside of the automatic transmission case sub-assembly.

    4. A01W9N0

      Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the automatic transmission case sub-assembly.

  16. INSTALL NO. 2 BRAKE DISC

    B0024YUC01
    *1 No. 2 Brake Plate
    *2 No. 2 Brake Disc
    *3 No. 2 Brake Flange
    *4 No. 2 Brake Piston Return Spring Sub-assembly

    1. Install the No. 2 brake flange, 3 No. 2 brake plates, 3 No. 2 brake discs and No. 2 brake piston return spring sub-assembly.

      Note


      • Make sure that the No. 2 brake piston return spring sub-assembly, 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 piston return spring sub-assembly, and then install the thinner one.

    2. B002537C01
      *a Protective Tape

      Using SST and a screwdriver, compress the No. 2 brake piston return spring sub-assembly and install the snap ring to the automatic transmission case sub-assembly.

      SST
      09351-40010   ( 09351-04010, 09351-04020, 09351-04040, 09351-04050 )

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  17. INSTALL NO. 1 BRAKE PISTON

    B0027TAC01
    *1 O-ring

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

    2. Press the No. 1 brake piston into the No. 1 brake cylinder.

      Note

      Be careful not to damage the 2 O-rings.

  18. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    B0026LAC01
    *1 Brake Piston Return Spring Sub-assembly
    *2 No. 1 Brake Cylinder

    1. Install the brake piston return spring sub-assembly and the No. 1 brake piston with the No. 1 brake cylinder to the automatic transmission case sub-assembly.

    2. A01WA00

      Check that the oil pressure apply hole of the No. 1 brake cylinder aligns with the oil pressure apply hole of the automatic transmission case sub-assembly.

    3. B00263CC01
      *a Protective Tape

      Using SST and a screwdriver, compress the brake piston return spring sub-assembly and install the snap ring to the automatic transmission case sub-assembly.

      SST
      09351-40010   ( 09351-04010, 09351-04030, 09351-04040, 09351-04050 )

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  19. INSTALL CENTER PLANETARY RING GEAR


    1. B0025WQC01
      *1 Center Planetary Ring Gear
      *2 Front Planetary Ring Gear Flange
      *3 Front Planetary Ring Gear

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

    2. B0025I0C01
      *a Protective Tape

      Using a screwdriver, install the snap ring.

      Note


      • Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.

      • Be careful not to damage the front planetary ring gear.

      Tech Tips

      Tape the screwdriver tip before use.

  20. INSTALL FRONT PLANETARY RING GEAR


    1. Coat the thrust needle roller bearing with ATF, and install it to the front planetary ring gear flange.

      Thrust Bearing Race Diameter
      Item Inside Outside

      Thrust needle roller bearing

      (Thrust bearing G)

      		 55.7 mm (2.19 in.) 76.4 mm (3.01 in.)
    2. A01W9C6

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

    3. B0027ABC01
      *1 No. 2 Planetary Carrier Thrust Washer
      *2

      Thrust Needle Roller Bearing

      (Thrust Bearing F)
      *3

      No. 3 Thrust Bearing Race

      (Front Race F)

      Coat the No. 2 planetary carrier thrust washer and thrust needle roller bearing, and install them.

    4. Coat the No. 3 thrust bearing race with ATF, and install it onto the front planetary ring gear.

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside

      Thrust needle roller bearing

      (Thrust bearing F)

      		 43.4 mm (1.71 in.) 58.3 mm (2.30 in.)

      No. 3 thrust bearing race

      (Front race F)

      		 38.0 mm (1.50 in.) 57.0 mm (2.24 in.)

  21. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. B00289UC01
      *1 One-way Clutch Inner Race
      *2 Front Planetary Gear Assembly

      Install the front planetary gear assembly and one-way clutch inner race to the automatic transmission case sub-assembly.

  22. INSPECT PACK CLEARANCE OF NO. 1 BRAKE PISTON

    Click here

  23. INSTALL NO. 1 BRAKE DISC

    B0027GBC01
    *1 No. 1 Brake Plate
    *2 No. 1 Brake Disc
    *3 No. 1 Brake Flange

    1. Install the 3 No. 1 brake plates, 3 No. 1 brake discs and No. 1 brake flange.

      Note


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

      • Install the thicker No. 1 brake plate, and then install the thinner one.

  24. INSTALL 2ND BRAKE PISTON


    1. B0028B4C01
      *1 O-ring

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

    2. Press the 2nd brake piston into the 2nd brake cylinder.

      Note

      Be careful not to damage the 2 O-rings.

    3. B0025R3C01
      *a Protective Tape

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

      SST
      09351-40010   ( 09351-04060, 09351-04070 )

      Note


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

      • Be careful not to damage the 2nd brake cylinder.

      Tech Tips

      Tape the screwdriver tip before use.

  25. INSTALL 2ND BRAKE CYLINDER


    1. A01W9P8

      Install the 2nd brake cylinder to the automatic transmission case sub-assembly.

    2. A01W8NE

      Check that the oil pressure apply hole of the brake cylinder aligns with the oil pressure apply hole of the automatic transmission case sub-assembly.

    3. B0024AQN01

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY

    A01WAR4

    1. Install the one-way clutch assembly and No. 1 planetary carrier thrust washer to the automatic transmission case sub-assembly.

  27. INSTALL NO. 3 BRAKE DISC


    1. B0024FPC01
      *1 Brake Cushion Plate
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc
      *4 No. 3 Brake Flange

      Install the break cushion plate, 4 No. 3 brake plates, 4 No. 3 brake discs and No. 3 brake flange to the case.

      Note


      • Make sure that the brake cushion plate, No. 3 brake discs, No. 3 brake plates and No. 3 brake flange are installed in the correct order.

      • Install the thicker brake cushion plate, and then install the thinner one.

    2. B00271NC01
      *a Protective Tape

      Using a screwdriver, install the snap ring.

      CAUTION:

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

      Tech Tips

      Tape the screwdriver tip before use.

  28. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

    B0025XWC01
    *1 O-ring

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

    2. B0024PKC01
      *1 Direct Clutch Piston Sub-assembly
      *2 Direct Clutch Return Spring Sub-assembly
      *3 No. 2 Clutch Balancer

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

    3. Press the direct clutch piston sub-assembly into the reverse clutch drum sub-assembly by hands.

      Note

      Be careful not to damage the 2 O-rings.

    4. B0026IRN01

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

      SST
      09320-89010

      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


      • 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.

    6. B002777C01
      *a Stopper

      Install the snap ring so that the outside line fits against the stopper of the No. 2 clutch balancer as shown in the illustration.

  29. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. B0027SNC01
      *1 O-ring

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

    2. B0028QKC01
      *1 O-ring

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

    3. B00292FC01
      *1 Reverse Clutch Piston Sub-assembly
      *2 Clutch Drum

      Press the clutch drum into the reverse clutch piston sub-assembly with both hands.

      Note

      Do not damage the O-rings.

  30. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B0025FQC01
      *1 Reverse Clutch Return Spring Sub-assembly
      *2 O-ring
      *3 Reverse Clutch Piston Sub-assembly

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

    2. Install the reverse clutch return spring sub-assembly onto the reverse clutch piston sub-assembly.

  31. INSTALL NO. 3 CLUTCH BALANCER


    1. Install the No. 3 clutch balancer to the reverse clutch return spring sub-assembly.

    2. B0028QSN01

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

      SST
      09387-00070

      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.

    3. 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.

    4. B0026E3C01
      *1 Snap Ring
      *a Correct
      *b Incorrect

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

      Note

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

  32. INSTALL DIRECT CLUTCH DISC


    1. B00284XC01
      *1 Clutch Plate
      *2 Direct Clutch Disc
      *3 Direct Clutch Flange

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

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

      Note


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

      • Install the clutch plate, and then install the thinner one.

    2. B0028L6C01
      *a Protective Tape

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

      Note

      Be careful not to damage the clutch drum.

      Tech Tips

      Tape the screwdriver tip before use.

  33. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

    Click here

  34. INSTALL REVERSE CLUTCH FLANGE


    1. A01WB18

      Install the reverse clutch flange to the clutch drum.

      Note

      Install the flange that is 3 mm thick.

  35. INSTALL REVERSE CLUTCH REACTION SLEEVE

    B0027XPC01
    *1 Reverse Clutch Disc
    *2 Clutch Plate
    *3 Reverse Clutch Flange
    *4 Clutch Cushion Plate
    *5 Reverse Clutch Reaction Sleeve

    1. Install the 5 reverse clutch discs, 4 clutch plates, reverse clutch flange, clutch cushion plate and reverse clutch reaction sleeve to the reverse clutch piston sub-assembly.

      Install in order
      *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *3 - *4 - *5

      Note


      • Make sure that the reverse clutch discs, clutch plates, reverse clutch flange, clutch cushion plate and reverse clutch reaction sleeve are installed in the correct order.

      • Install the reverse clutch disc, and then install the thinner one.

    2. Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the reverse clutch piston sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  36. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

    Click here

  37. REMOVE REVERSE CLUTCH REACTION SLEEVE

    B0027GOC01
    *a Protective Tape

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

      Note

      Be careful not to damage the reverse clutch drum sub-assembly and reverse clutch sleeve.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01W8W5

      Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch piston sub-assembly.

  38. INSTALL FORWARD CLUTCH PISTON

    B00247OC01
    *1 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 assembly.

      Note

      Be careful not to damage the 2 O-rings.

  39. INSTALL NO. 1 CLUTCH BALANCER

    B0026NHC01
    *1 O-ring

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

    2. B0027J9C01
      *1 No. 1 Clutch Balancer
      *2 Forward Clutch Return Spring Sub-assembly

      Install the No. 1 clutch balancer and forward clutch return spring assembly.

      Note

      Be careful not to damage the O-ring.

    3. B0024VQN03

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

      SST
      09350-30020   ( 09350-07040 )

      Note

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

    4. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    5. B0028IUC02
      *1 Snap Ring
      *a Correct
      *b Incorrect

      Set the end gap of the snap ring in the No. 1 clutch balancer as shown in the illustration.

  40. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC


    1. B0028KNC01
      *1 Forward Clutch Flange
      *2 Forward Multiple Disc Clutch Disc
      *3 Clutch Plate

      Install the 2 forward clutch flanges, 7 forward multiple disc clutch discs and 6 clutch plates to the input shaft assembly.

      Note


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

      • Install the forward clutch flange, and then install the thinner one.

      • If the forward clutch flanges have different thicknesses, first install the thinner flange.

    2. B00249YC01
      *a Protective Tape

      Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the input shaft.

      Tech Tips

      Tape the screwdriver tip before use.

  41. INSTALL INPUT SHAFT OIL SEAL RING


    1. Coat 3 new input shaft oil seal rings with ATF.

    2. A01W9JN

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

      Note

      Do not excessively widen the input shaft oil seal ring.

      Tech Tips

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

  42. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

    Click here

  43. INSTALL INPUT SHAFT ASSEMBLY


    1. A01WACO

      Install the input shaft assembly to the clutch drum.

    2. A01WASE

      Coat the thrust needle roller bearing with ATF and Install it to the clutch drum.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside

      Thrust needle roller bearing

      (Thrust bearing C)

      		 21.3 mm (0.839 in.) 41.1 mm (1.62 in.)

  44. INSTALL MULTIPLE DISC CLUTCH HUB


    1. B00269PC01
      *1

      No. 3 Thrust Bearing Race

      (Rear Race C)
      *2

      No. 4 Thrust Bearing Race

      (Front Race D)

      Coat the No. 3 thrust bearing race and No. 4 thrust bearing race with ATF and install them to the multiple disc clutch hub.

      Thrust Bearing Race Diameter
      Item Inside Outside

      No. 3 thrust bearing race

      (Rear race C)

      		 22.6 mm (0.890 in.) 45.0 mm (1.77 in.)

      No. 4 thrust bearing race

      (Front race D)

      		 38.4 mm (1.51 in.) 56.5 mm (2.22 in.)
    2. A01W8GX

      Install the multiple disc clutch hub to the reverse clutch piston sub-assembly.

  45. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. B0024CYC01
      *1

      Thrust Needle Roller Bearing

      (Thrust Bearing D)
      *2

      Thrust Needle Roller Bearing

      (Thrust 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 Outside

      Thrust needle roller bearing

      (Thrust bearing D)

      		 33.3 mm (1.31 in.) 51.5 mm (2.02 in.)

      Thrust needle roller bearing

      (Thrust bearing E)

      		 42.5 mm (1.67 in.) 61.2 mm (2.41 in.)
    2. A01W9KD

      Install the forward clutch hub sub-assembly to the reverse clutch piston sub-assembly.

  46. INSTALL REVERSE CLUTCH DISC


    1. B002507C01
      *1 Reverse Clutch Disc
      *2 Clutch Plate
      *3 Reverse Clutch Flange
      *4 Clutch Cushion Plate

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

      Note


      • Make sure that the reverse clutch discs, clutch plates, reverse clutch flange and clutch cushion plate are installed in the correct order.

  47. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. A01W8RX

      Install the reverse clutch reaction sleeve to the reverse clutch hub sub-assembly.

  48. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A01W8JD

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

    2. B002922C01
      *a Protective Tape

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

      Note

      Be careful not to damage the reverse clutch piston sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  49. INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY


    1. B0025M8C01
      *1 No. 2 One-way Clutch Assembly
      *2 No. 2 Clutch Drum Thrust Washer
      *3 Reverse Clutch Piston sub-assembly

      Install the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer to the reverse clutch piston sub-assembly.

      Note

      Be sure to install the No. 2 clutch drum thrust washer in the correct direction.

  50. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    B0028JPC01
    *1

    Thrust Needle Roller Bearing

    (Thrust Bearing A)
    *2

    Thrust Needle Roller Bearing

    (Thrust Bearing B)
    *3 Clutch Drum Thrust Washer

    1. Coat the 2 thrust needle roller bearings and clutch drum thrust washer with ATF and install them to the reverse clutch piston sub-assembly.

      Thrust Needle Roller Bearing Diameter
      Item Inside Outside

      Thrust needle roller bearing

      (Thrust bearing A)

      		 71.9 mm (2.83 in.) 85.6 mm (3.37 in.)

      Thrust needle roller bearing

      (Thrust bearing B)

      		 34.6 mm (1.36 in.) 52.0 mm (2.05 in.)
    2. A01WBBF

      Install the reverse clutch piston sub-assembly to the automatic transmission case sub-assembly.

  51. INSTALL OIL PUMP ASSEMBLY

    B0026FXC01
    *1

    No. 1 Thrust Bearing Race

    (Front Race A)
    *2

    No. 2 Thrust Bearing Race

    (Front Race B)

    1. Coat the No. 1 thrust bearing race and No. 2 thrust bearing race with ATF, and install them to the oil pump assembly.

      Thrust Bearing Race Diameter
      Item Inside Outside

      No. 1 thrust bearing race

      (Front race A)

      		 74.2 mm (2.92 in.) 87.74 mm (3.45 in.)

      No. 2 Thrust bearing race

      (Front race B)

      		 37.0 mm (1.46 in.) 52.3 mm (2.06 in.)
    2. B0025AXC01
      *1 O-ring

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

    3. Clean the bolt and the bolt hole.

    4. 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.

    5. Hold the input shaft assembly, and lightly press the oil pump assembly to slide the input shaft oil seal rings into the reverse clutch piston sub-assembly.

      Note

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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    7. Install the 10 bolts.

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

  52. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. Coat the manual valve lever shaft oil seal lips with MP grease.

    2. B002748C02
      *a RH Side
      *b LH Side

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

      SST
      09350-30020   ( 09350-07110 )
      Oil seal drive in depth
      -0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

  53. INSPECT INDIVIDUAL PISTON OPERATION

    Click here

  54. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    B0028JKC01
    *1 Spacer
    *2 Manual Valve Lever Sub-assembly

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

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

    3. A01WA6R

      Using a hammer, tap in a new spring pin.

    4. A01WBJ3

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

    5. Check that the shaft rotates smoothly.

  55. INSTALL PARKING LOCK PAWL SHAFT

    B00248IC01
    *1 Parking Lock Pawl
    *2 E-ring
    *3 Parking Lock Pawl Shaft
    *4 Spring

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

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

  56. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A01WATI

    1. Connect the parking lock rod sub-assembly to the manual valve lever sub-assembly as shown in the illustration.

  57. INSTALL PARKING LOCK PAWL BRACKET


    1. A01W9UO

      Place the parking lock pawl bracket onto the automatic transmission case sub-assembly and tighten the 3 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. B0024EPC01
      *1 Manual Valve Lever Sub-assembly
      *2 Planetary Ring Gear
      *3 Parking Lock Pawl

      Shift the manual valve lever sub-assembly to the P, and confirm that the planetary gear is correctly locked up by the parking lock pawl.

  58. INSTALL C-1 ACCUMULATOR VALVE

    B002892C01
    *1 Outer Spring
    *2 Inner Spring

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

      C-1 Accumulator Spring
      Inner Spring
      Free Length Outer Diameter Color
      30.40 mm (1.20 in.) 11.40 mm (0.449 in.) Pink
      Outer Spring
      Free Length Outer Diameter Color
      48.76 mm (1.92 in.) 16.60 mm (0.654 in.) Light green

  59. INSTALL C-3 ACCUMULATOR PISTON

    B0028F2C01
    *1 Outer Spring
    *2 Inner Spring
    *3 O-ring

    1. Coat 2 new O-rings with ATF, and install them to the C-3 accumulator piston.

    2. Install the 2 springs and C-3 accumulator piston to the hole.

      C-3 Accumulator Spring
      Inner Spring
      Free Length Outer Diameter Color
      44.0 mm (1.73 in.) 14.0 mm (0.551 in.) Yellow
      Outer Spring
      Free Length Outer Diameter Color
      73.35 mm (2.89 in.) 19.90 mm (0.783 in.) Red

  60. INSTALL B-3 ACCUMULATOR PISTON

    B0028MMC01
    *1 O-ring
    *2 Spring

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

    2. Install the spring and B-3 accumulator piston to the hole.

      B-3 Accumulator Spring
      Free Length Outer Diameter Color
      70.5 mm (2.78 in.) 19.7 mm (0.776 in.) Purple

  61. INSTALL C-2 ACCUMULATOR PISTON

    B0027KZC01
    *1 Spring
    *2 O-ring

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

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

      C-2 Accumulator Spring
      Free Length Outer Diameter Color
      62.0 mm (2.44 in.) 15.9 mm (0.626 in.) White

  62. INSTALL CHECK BALL BODY


    1. B0028LN

      Install the spring and check ball body.

  63. INSTALL BRAKE DRUM GASKET


    1. A01W9JK

      Install a new 3 brake drum gaskets.

  64. INSTALL TRANSMISSION CASE GASKET


    1. A01WBGH

      Coat 3 new transmission case gaskets with ATF, and install the transmission case gaskets.

  65. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    Click here

  66. INSTALL TRANSMISSION WIRE

    Click here

  67. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    Click here

  68. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install the automatic transmission oil pan sub-assembly.

      Click here

    2. Install a new gasket and the drain plug.

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

    3. Install a new gasket and the overflow plug.

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

  69. INSTALL REAR TRANSFER CASE ADAPTER OIL RECEIVER


    1. A01WAD9

      Install the transfer case adapter oil receiver to the rear transfer adaptor.

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

  70. INSTALL TRANSFER ADAPTER OIL SEAL

    B0028B1N04

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

    2. Using SST and a hammer, tap in a new transfer adapter oil seal.

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

  71. INSTALL TRANSFER ADAPTER SUB-ASSEMBLY


    1. Clean the threads of the bolts and the automatic transmission case sub-assembly and transfer adapter sub-assembly with non-residue solvent.

      Note

      Using a razor blade and gasket scraper, remove all the old seal packing material from the gasket surfaces.

    2. B0025WLC04
      *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 approximately 1.2 mm (0.0472 in.)) along the sealing surface.

      • Parts must be assembled within 10 minutes of application. Otherwise, the seal packing material must be removed and reapplied.

    3. Apply a few drops of adhesive to 2 or 3 threads of each of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    4. B00276ON01

      Install the extension housing sub-assembly with 8 bolts.

      Torque:
      33.9 N*m  { 346 kgf*cm, 25 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 40 mm (1.57 in.)
      Bolt B 50 mm (1.97 in.)

  72. INSTALL AUTOMATIC TRANSMISSION HOUSING


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

    2. A01WBAO

      Install the automatic transmission housing to the automatic transmission case sub-assembly with the 6 bolts.

      Torque:
      33.9 N*m  { 346 kgf*cm, 25 ft.*lbf }

    3. Apply a few drops of adhesive to 2 or 3 threads of each of the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    4. B0028W8N02

      Install the 4 bolts to the automatic transmission housing.

      Torque:
      for Bolt A (14 mm head)
      33.9 N*m  { 346 kgf*cm, 25 ft.*lbf }
      for Bolt B (17 mm head)
      56.8 N*m  { 579 kgf*cm, 42 ft.*lbf }

  73. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE


    1. B0027I8C01
      *1 No. 1 Breather Plug
      *2 Automatic Transmission Breather Hose
      *3 Automatic Transmission Breather Tube
      *4 O-ring

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

    2. Install the No. 1 breather plug and automatic transmission breather hose to the automatic transmission breather tube.

    3. A01W95L

      Install the automatic transmission breather tube with the 2 bolts.

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

  74. INSTALL TRANSMISSION REVOLUTION SENSOR (SP2)

    Click here

  75. INSTALL TRANSMISSION REVOLUTION SENSOR (NT)

    Click here

  76. INSTALL OIL COOLER TUBE UNION


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

    2. B0025V5C01
      *a -18 to -22°

      Temporarily install the 2 oil cooler tube unions as shown in the illustration.

    3. B0024OJC01
      *a Torque Wrench Fulcrum Length
      *b Hold

      Using a SST, hold the oil cooler tube union and tighten the 2 oil cooler tube unions.

      SST
      09268-78010
      Specified tightening torque
      29.4 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 (1.36 in.)) + torque wrench (fulcrum length of 300 mm (11.8 in.)): 26.4 N*m (269 kgf*cm, 19 ft.*lbf)

      Note

      After tightening, check that the oil cooler tube union does not move.

  77. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    Tech Tips

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


    1. Clean the bolt and the bolt hole.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01W99H

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

    4. Install the lock washer. Install and tighten the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    5. B00257ZN02

      Using the transmission control shaft lever LH, turn the manual lever shaft clockwise until it stops, and then turn it counterclockwise 2 notches to set it to N.

    6. B0027RGC02
      *a Neutral Basic Line
      *b Groove

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

      Torque:
      12.8 N*m  { 131 kgf*cm, 9 ft.*lbf }
    7. A01W9PG

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  78. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH


    1. A01W93A

      Install the transmission control shaft lever LH with the spring washer and nut.

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