AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A015594E01
    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

    A0156T0E09

    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

    A015BDWE03

    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

    A015E2AE03

    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), place the piston in the transmission case.

      Note

      Be careful not to damage the O-ring.

    4. A01573SE01

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

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


    1. A0155F6E01

      Place SST on a new spring retainer, and compress the return spring.

      SST
      09350-30020   ( 09350-07050 )

    2. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A0159TYE02

      Install the No. 9 thrust bearing race.

      Thrust Bearing Race Diameter
      Item Inside Outside
      No. 9 Race 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. A0158CPE05

      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. A0156H4E01

      Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. A0155EVE01

      Make sure the 1st and reverse brake piston moves smoothly when applying and releasing compressed air into the transmission case.

    2. A0156X0E01

      Using a vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.

      Note

      The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.

      Tech Tips

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

    3. A0157F4E03

      Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, 7 No. 4 brake plates and 8 No. 4 brake discs all together at both ends across a diameter, and calculate the average.

      Tech Tips

      Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.00984 to 0.0709 in.)

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

      Standard pack clearance
      0.8 to 1.1 mm (0.0315 to 0.0433 in.)

      If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

      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


    1. A015DTEE01

      Install the 2 flanges, 8 discs and 7 plates.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

  9. INSTALL BRAKE PLATE STOPPER SPRING

    A01559OE01

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. A0157NLE11

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

      Thrust Needle Roller Bearing and Race Diameter
      Item Inside Outside
      No. 7 Race 33.4 to 33.6 mm (1.31 to 1.32 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)
      Bearing 32.2 to 32.3 mm (1.268 to 1.272 in.) 49.0 to 49.2 mm (1.93 to 1.94 in.)
      No. 8 Race 32.2 to 32.4 mm (1.27 to 1.28 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)

  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY


    1. A0155S7E01

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

  12. INSTALL INTERMEDIATE SHAFT


    1. A01593ZE01

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

    2. A015C4EE03

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. A0157H6E01

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

    2. Coat the No. 6 thrust bearing race with petroleum jelly, and install it to the center planetary gear.

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race 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. A0159PJE07

      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

    A01558NE04

    1. Install the brake piston return spring.

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

    3. A0156EZE03

      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


    1. A01580PE10

      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


    1. A0156OGE01

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

  18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING


    1. A01598UE04

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

      SST
      09351-40010

  19. INSTALL NO. 1 BRAKE DISC

    A015CY1E04

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

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

  20. INSTALL CENTER PLANETARY RING GEAR


    1. A015676E01

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

    2. A0158CGE01

      Using a screwdriver, install the snap ring.

  21. INSTALL FRONT PLANETARY RING GEAR


    1. A0157LLE01

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

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

  22. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A0159LEE04

      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 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 38.0 to 38.2 mm (1.496 to 1.504 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
    3. A0157V4E01

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

  23. INSPECT PISTON STROKE OF NO. 1 BRAKE PISTON


    1. A0155NLE01

      Make sure the No. 1 brake piston moves smoothly when applying and releasing compressed air into the transmission case.

    2. A0159L6E01

      Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.

      Standard piston stroke
      0.42 to 0.72 mm (0.0165 to 0.0283 in.)

      If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange.

      Tech Tips

      There are 4 different thicknesses for the flange.

      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.)

  24. INSTALL 2ND BRAKE PISTON


    1. A015651E11

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

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

      Note

      Be careful not to damage the O-rings.

    3. A0159E0E04

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

      SST
      09351-40010

      Note

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

  25. INSTALL 2ND BRAKE CYLINDER


    1. A015CKEE01

      Install the 2nd brake cylinder to the case.

  26. INSTALL 1-WAY CLUTCH ASSEMBLY


    1. A015DKLE01

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

  27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING


    1. A015C4EE03

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  28. INSTALL NO. 3 BRAKE DISC


    1. A0159LWE05

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

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

      Tech Tips

      C = Cushion plate

      P = Plate

      D = Disc

      F = Flange

  29. INSTALL NO. 3 BRAKE SNAP RING


    1. A01593WE01

      Using a screwdriver, install the snap ring.

  30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A0158SCE02

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

    2. A015653E01

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

    3. A0155K8E02

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

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

      Note

      Be careful not to damage the O-rings.

    5. A0158B5E05

      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 (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

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

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

      Note

      Do not expand the snap ring excessively.

    7. A01585HE07

      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.

  31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. A015CFRE02

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

    2. A0159T7E02

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

    3. A0156URE01

      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. A0155PVE02

      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. A015B37E04

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

      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.

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

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

      Note

      Do not expand the snap ring excessively.

    3. A015AH0E02

      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.

  34. INSTALL DIRECT CLUTCH DISC

    A015D08E01

    1. Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

    2. A015E6YE01

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

  35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A015BT1E02

      Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)

      Note

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

      Tech Tips

      Flange moving distance A = 0.26 to 1.14 mm (0.0102 to 0.0449 in.)

      Pack clearance = Flange moving distance A - 0.05 mm (0.00197 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      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.)

  36. INSTALL REVERSE CLUTCH FLANGE


    1. A0158TYE01

      Install the reverse clutch flange to the clutch drum.

  37. INSTALL REVERSE CLUTCH REACTION SLEEVE

    A015AGXE02

    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 hub.

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

      S = Sleeve

    2. Using a screwdriver, install the hole snap ring.

  38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH


    1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at both ends across a diameter while applying air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)

      Note

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

      Tech Tips

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

      Flange moving distance B = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

      Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.00236 in.)

      A015DCSE02

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      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.)

  39. REMOVE REVERSE CLUTCH REACTION SLEEVE


    1. A0158VLE01

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

    2. A0158WIE01

      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.

  40. INSTALL FORWARD CLUTCH PISTON


    1. A015AGGE02

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

  41. INSTALL NO. 1 CLUTCH BALANCER


    1. A015D2NE02

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

    2. A0156G3E01

      Install the clutch balancer and forward clutch return spring.

      Note

      Be careful not to damage the O-ring.

    3. A0157RTE02

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

      Note

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

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

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

      Note

      Do not expand the snap ring excessively.

    5. A015DRCE02

      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.

  42. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC

    A015AKNE02

    1. Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

    2. A015DEFE01

      Using a screwdriver, install the hole snap ring.

  43. INSTALL INPUT SHAFT OIL SEAL RING


    1. A015BUUE01

      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 ring.

      Tech Tips

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

  44. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


    1. A015DWEE02

      Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.6 to 0.9 mm (0.0236 to 0.0354 in.)

      Note

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

      Tech Tips

      Flange moving distance A = 0.26 to 1.36 mm (0.0102 to 0.0535 in.)

      Pack clearance = Flange moving distance A - 0.01 mm (0.000394 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      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.)

  45. INSTALL INPUT SHAFT ASSEMBLY


    1. A015B5NE01

      Install the input shaft to the clutch drum.

    2. A01562KE01

      Install the thrust needle roller bearing to the clutch drum.

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

  46. INSTALL MULTIPLE DISC CLUTCH HUB


    1. A015AHQE06

      Coat the 2 thrust bearing races with petroleum jelly, and install them onto 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.)
      No. 4 Race 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. A0155DQE01

      Install the multiple disc clutch hub to the clutch drum.

  47. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. A015D50E05

      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. A015CLDE01

      Install the forward clutch hub to the clutch drum.

  48. INSTALL REAR CLUTCH DISC


    1. A01597UE14

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

      C = Cushion plate

  49. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. A0156JJE01

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

  50. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A0157F2E01

      Install the reverse clutch hub to the clutch drum.

    2. A015D4TE01

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

  51. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY


    1. A015E4KE01

      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.

  52. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY


    1. A015797E01

      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 A 34.7 to 34.9 mm (1366 to 1.374 in.) 51.6 to 51.9 mm (2.03 to 2.04 in.)
    2. A01582VE01

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

  53. INSTALL OIL PUMP ASSEMBLY


    1. A01577RE01

      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
      No. 1 Race 74.3 to 74.6 mm (2.93 to 2.94 in.) 87.4 to 87.7 mm (3.44 to 3.45 in.)
      No. 2 Race 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.)
    2. A0155MQE02

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

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

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

      Note

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

    5. A015E1EE01

      Install the 10 bolts.

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

  54. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A0155BBE02

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

      SST
      09350-30020   ( 09350-07110 )

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

  55. INSPECT INDIVIDUAL PISTON OPERATION


    1. A015BLKE02

      Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

      Tech Tips

      When inspecting the O/D direct clutch, check with the accumulator piston holes indicated in the illustration.

      If there is no sound, disassemble and check the installation condition of the parts.


      1. No. 2 clutch (C2)

      2. No. 3 clutch (C3)

      3. No. 1 clutch (C1)

      4. No. 3 brake (B3)

      5. No. 1 brake (B1)

      6. No. 2 brake (B2)

      7. No. 4 brake (B4)

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A0156QQE02

      Install a new spacer to the 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. A0157QEE01

      Using a hammer, tap in a new spring pin.

    4. A015B5TE01

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

    5. Check that the shaft rotates smoothly.

  57. INSTALL PARKING LOCK PAWL SHAFT


    1. A0155HWE04

      Install the E-ring to the shaft.

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

  58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A015BMYE01

      Connect the parking lock rod to the manual valve lever.

  59. INSTALL PARKING LOCK PAWL BRACKET


    1. A015BHBE01

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

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A015E0CE03

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

  60. INSTALL C-1 ACCUMULATOR VALVE


    1. A0158XEE06

      Coat a new O-ring with ATF, and install it to the accumulator valve.

    2. A01558HE01

      Install the spring 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

  61. INSTALL C-3 ACCUMULATOR PISTON


    1. A0158XEE07

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

    2. A0157BDE01

      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

  62. INSTALL B-3 ACCUMULATOR PISTON


    1. A0158XEE08

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

    2. A015CSNE01

      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

  63. INSTALL C-2 ACCUMULATOR PISTON


    1. A0158XEE09

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

    2. A0156IRE01

      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

  64. INSTALL CHECK BALL BODY


    1. A01574PE05

      Install the spring and check ball body.

  65. INSTALL BRAKE DRUM GASKET


    1. A0157FFE01

      Install the 3 brake drum gaskets.

  66. INSTALL TRANSMISSION CASE GASKET


    1. A01597DE08

      Install the 3 transmission case gaskets.

  67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A0155EZE01

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

    2. A015CVFE01

      Install the transmission valve body assembly with the 19 bolts.

      Torque:
      11 N*m  { 110 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 }

  68. INSTALL TRANSMISSION WIRE


    1. A01557RE01

      Install a new O-ring to the transmission wire.

    2. Install the transmission wire harness.

    3. Install the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. A0157RUE02

      Connect the 7 solenoid connectors.

    5. Install the 2 ATF temperature sensors.

    6. Install the 2 clamps and 2 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

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

  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A0156DPE01

      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  { 100 kgf*cm, 7 ft.*lbf }

  70. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A0156GKE02

      Install the 4 magnets.

  71. 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:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

    3. Install the drain plug.

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

  72. INSTALL TRANSFER CASE ADAPTER RADIAL BALL BEARING

    A015DD2E01

    1. Using SST and a press, press in the bearing until it stops.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )

    2. Using a screwdriver, install the snap ring.

  73. INSTALL TRANSMISSION CASE ADAPTER REAR OIL SEAL

    A01567QE01

    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.)

  74. INSTALL TRANSFER ADAPTER REAR


    1. Clean the threads of the bolts and case.

    2. A0155TVE01

      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. A0157UNE02

      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

      45 mm (1.77 in.) for bolt B

  75. INSTALL AUTOMATIC TRANSMISSION HOUSING

    A015AJSE02

    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  { 581 kgf*cm, 42 ft.*lbf }
      for 14 mm head bolt C
      34 N*m  { 345 kgf*cm, 25 ft.*lbf }

  76. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

    A0157FBE01

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

    2. Install the breather tube with the 2 bolts.

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

  77. INSTALL SPEED SENSOR


    1. A0156ZL

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

    2. Install the 2 speed sensors.

    3. Install the 2 bolts.

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

  78. INSTALL OIL COOLER TUBE UNION


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

    2. A01582K

      Using a union nut wrench, install the 2 oil cooler tube unions.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  79. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A015B7QE01

    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. A01589CE01

      Push the control shaft rearward as much as possible.

    4. Return the control shaft lever 2 notches to the N position.

    5. A015C18E10

      Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    6. A015DVIE01

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  80. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH


    1. A015E3T

      Install the control shaft lever with the washer and nut.

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