AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A01EOOCE01
    Bearing and Race Diameter
    Mark Front Race Diameter Inside / Outside Thrust Bearing Diameter Inside / Outside Rear Race Diameter Inside / Outside
    A 74.26 to 74.56 mm (2.92 to 2.94 in.) / 87.39 to 87.74 mm (3.44 to 3.45 in.) 71.96 to 72.26 mm (2.83 to 2.84 in.) / 85.25 to 85.6 mm (3.36 to 3.37 in.) -
    B 38.0 to 38.3 mm (1.50 to 1.51 in.) / 53.9 to 54.1 mm (2.12 to 2.13 in.) 36.45 to 36.7 mm (1.44 to 1.45 in.) / 52.96 to 53.26 mm (2.09 to 2.10 in.) -
    C - 21.05 to 21.3 mm (0.829 to 0.839 in.) / 39.63 to 39.88 mm (1.56 to 1.57 in.) 22.8 to 23.1 mm (0.898 to 0.909 in.) / 44.5 to 44.75 mm (1.75 to 1.76 in.)
    D - 39.45 to 39.7 mm (1.55 to 1.56 in.) / 60.5 to 60.75 mm (2.38 to 2.39 in.) -
    E - 46.45 to 46.7 mm (1.83 to 1.84 in.) / 64.3 to 64.55 mm (2.53 to 2.54 in.) -
    F 55.0 to 55.2 mm (2.165 to 2.173 in.) / 68.8 to 69.3 mm (2.71 to 2.73 in.) 54.55 to 54.8 mm (2.15 to 2.16 in.) / 70.0 to 70.5 mm (2.76 to 2.78 in.) -
    G - 65.35 to 65.6 mm (2.57 to 2.58 in.) / 85.6 to 85.95 mm (3.37 to 3.38 in.) 62.85 to 63.1 mm (2.47 to 2.48 in.) / 82.3 to 82.6 mm (3.24 to 3.25 in.)
    H 39.67 to 39.87 mm (1.56 to 1.57 in.) / 56.5 to 57.0 mm (2.22 to 2.24 in.) 36.5 to 36.6 mm (1.437 to 1.441 in.) / 56.62 to 56.92 mm (2.23 to 2.24 in.) 36.45 to 36.7 mm (1.435 to 1.445 in.) / 56.5 to 57.0 mm (2.22 to 2.24 in.)
    I 21.05 to 21.3 mm (0.829 to 0.839 in.) / 39.5 to 39.8 mm (1.56 to 1.57 in.) 23.2 to 23.4 mm (0.913 to 0.921 in.) / 43.9 to 44.15 mm (1.73 to 1.74 in.) -
    J - 43.6 to 43.9 mm (1.72 to 1.73 in.) / 62.3 to 62.8 mm (2.45 to 2.47 in.) 47.15 to 47.4 mm (1.86 to 1.87 in.) / 66.9 to 67.1 mm (2.63 to 2.64 in.)

  2. INSTALL 1ST AND REVERSE BRAKE PISTON

    A01EOE7E01

    1. Coat 3 new O-rings with ATF, and install them to the 1st and reverse brake piston.

    2. A01ENZLE01

      Install the 1st and reverse brake piston to the transmission case.

      Note


      • Be careful not to damage the O-ring.

      • Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston protrusion to the transmission case spline grooves.

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

    A01ENJ1E01

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

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080, 09381-06120, 09381-06130, 09381-05040, 09381-05050 )

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

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

  4. SELECT NO. 4 BRAKE FLANGE

    A01EQHNE01

    1. Measure distance A (from the tip of the 1st and reverse brake piston to the step in the transmission case) in the illustration.*1

      Tech Tips

      Standard distance A: 27.82 to 28.42 mm (1.09 to 1.12 in.)

    2. A01EP9ME01

      Assemble the No. 4 brake flange, 7 No. 4 brake discs and 6 No. 4 brake plates, and measure distance B in the illustration.*2

      Tech Tips

      Standard distance B: 25.98 to 27.01 mm (1.02 to 1.06 in.)

    3. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 4 brake selective flange indicated by the graph point.

      A01ES9UE01

    4. Measure length H of the selected flange as shown in the illustration.

      Tech Tips

      Make sure that when the B measurement and H dimension of the selected flange are subtracted from the A measurement, the value is 0.961 to 1.261 mm (0.0378 to 0.0495 in.).

      No. 4 Brake Selected Flange Length H
      Mark Length H
      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.)

  5. INSTALL REAR PLANETARY GEAR ASSEMBLY

    A01EO7LE01

    1. Install the thrust bearing race.

      Tech Tips

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

      Bearing Race Diameter
      Item Inside Outside
      Race J 47.15 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.)
    2. A01EQJSE01

      Install the 2 thrust needle roller bearings to the rear planetary gear.

      Bearing Diameter
      Item Inside Outside
      Bearing I 23.2 to 23.4 mm (0.913 to 0.921 in.) 43.9 to 44.15 mm (1.73 to 1.74 in.)
      Bearing J 43.6 to 43.9 mm (1.72 to 1.73 in.) 62.3 to 62.8 mm (2.45 to 2.47 in.)

      Tech Tips

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

    3. A01EQBV

      Install the rear planetary gear assembly.

  6. INSTALL BRAKE PLATE STOPPER SPRING

    A01EO5B

  7. INSTALL REAR PLANETARY RING GEAR

    A01ENKD

    1. Install the rear planetary ring gear flange to the rear planetary ring gear.

    2. Using a screwdriver, install the snap ring.

    3. A01EQTNE02

      Install the 3 thrust bearing races, thrust needle roller bearing and planetary ring gear with the rear planetary ring gear flange to the intermediate shaft.

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Front race H 39.67 to 39.87 mm (1.56 to 1.57 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Bearing H 36.5 to 36.6 mm (1.437 to 1.441 in.) 56.62 to 56.92 mm (2.23 to 2.24 in.)
      Rear race H 36.45 to 36.7 mm (1.435 to 1.445 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.)
      Race I 21.05 to 21.3 mm (0.829 to 0.839 in.) 39.5 to 39.8 mm (1.56 to 1.57 in.)

  8. INSTALL INTERMEDIATE SHAFT WITH REAR PLANETARY RING GEAR FLANGE AND REAR PLANETARY RING GEAR

    A01EN00

    1. Install the intermediate shaft with the rear planetary ring gear flange and rear planetary ring gear to the transmission case.

  9. INSTALL NO. 4 BRAKE DISC SET

    A01EOHJE01

    1. Install the flange, 7 discs, 6 plates and selected flange.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  10. INSTALL NO. 3 1-WAY CLUTCH INNER RACE

    A01EOUTE01

    1. Install the 1-way clutch inner race to the No. 3 1-way clutch assembly.

      Note

      Do not mistake the direction of the 1-way clutch inner race.

  11. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

    A01EODAE01

    1. Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

  12. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

    A01EOIC

    1. Install the 1-way clutch assembly to the transmission case.

    2. A01ERIZE01

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL NO. 2 BRAKE PISTON

    A01EP81E02

    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.

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


    1. A01EQ0G

      Install the No. 2 brake cylinder with piston to the transmission case.

      Note


      • A01ES94

      • When installing the No. 2 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.

      • Make sure the No. 2 brake cylinder with piston is securely inserted into the transmission case.

  15. SELECT NO. 2 BRAKE FLANGE

    A01ERY5E01

    1. Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.

    2. Place SST on the brake flange and compress the brake return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06070, 09381-06090, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

    4. A01EMYPE01

      Measure distance A (from the top surface of the snap ring to the top surface of the brake piston return spring retainer) in the illustration.*1

      Tech Tips

      Standard distance A: 21.00 to 21.76 mm (0.834 to 0.857 in.)

    5. A01ER46E01

      Assemble the 4 discs, 3 plates and flange as shown in the illustration. Then with a fixture of 165.2 mm (6.50 in.) or less placed on the flange, measure distance B.*2

      Tech Tips

      Standard distance B: 16.54 to 17.15 mm (0.651 to 0.675 in.)

    6. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the flange indicated by the graph point.

      A01EN6IE02

      Tech Tips

      Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 2.20 to 2.50 mm (0.0866 to 0.0984 in.).

      Flange Thickness
      Mark Thickness
      0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      1 2.05 to 2.15 mm (0.0807 to 0.0846 in.)
      2 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
      3 2.25 to 2.35 mm (0.0886 to 0.0925 in.)
      4 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      5 2.45 to 2.55 mm (0.0965 to 0.100 in.)
      6 2.55 to 2.65 mm (0.100 to 0.104 in.)
      7 2.65 to 2.75 mm (0.104 to 0.108 in.)

    7. Remove the snap ring, flange and No. 2 brake piston return spring from the transmission case.

  16. INSTALL NO. 2 BRAKE DISC SET

    A01ERQCE01

    1. Install the brake piston return spring, selected flange, 4 discs, 3 plates and flange.

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

      Tech Tips

      S/F = Selected flange

      D = Disc

      P = Plate

      F = Flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. A01ERY5E01

      Place SST on the brake flange and compress the brake return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06070, 09381-06090, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

  17. INSTALL CENTER PLANETARY GEAR ASSEMBLY

    A01ERRUE01

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

      Note

      Make sure to install the center planetary sun gear with the groove facing the transmission case.

  18. INSTALL NO. 1 BRAKE PISTON

    A01EPZCE02

    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.

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


    1. A01ENCU

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

      Note


      • A01EQAAE01

      • When installing the No. 1 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.

      • Make sure the No. 1 brake cylinder with piston is securely inserted into the transmission case.

    2. A01EQDNE01

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

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )

    3. Using a screwdriver, install the snap ring to the transmission case.

  20. SELECT NO. 1 BRAKE FLANGE

    A01ERE2E01

    1. Measure distance A (from the step in the transmission case to the tip of the No. 1 brake piston) in the illustration.*1

      Tech Tips

      Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)

    2. A01ENKPE01

      Assemble the 4 plates and 4 discs and measure distance B in the illustration.*2

      Tech Tips

      Standard distance B: 16.72 to 17.19 mm (0.658 to 0.677 in.)

    3. Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the flange indicated by the graph point.

      A01EOTWE01

      Tech Tips

      Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 0.56 to 0.86 mm (0.0220 to 0.0339 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.)

  21. INSTALL CENTER PLANETARY RING GEAR

    A01EMZR

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

    2. A01EPSL

      Using a screwdriver, install the snap ring.

  22. INSTALL FRONT PLANETARY RING GEAR

    A01ES54

    1. Install the front planetary ring gear to the center planetary ring gear.

  23. INSTALL FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY AND CENTER PLANETARY RING GEAR

    A01EPLTE01

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

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Race 62.85 to 63.1 mm (2.47 to 2.48 in.) 82.3 to 82.6 mm (3.24 to 3.25 in.)
      Bearing 65.35 to 65.6 mm (2.57 to 2.58 in.) 85.6 to 85.95 mm (3.37 to 3.38 in.)

    2. Install the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear to the transmission case.

  24. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    A01ENDJ

    1. Install the No. 2 planetary carrier thrust washer to the front planetary gear.

      Tech Tips

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

    2. A01EPO8E01

      Install the thrust needle roller bearing, thrust bearing race, front planetary sun gear and front planetary gear.

      Tech Tips

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

      Bearing Diameter
      Item Inside Outside
      Bearing 54.55 to 54.8 mm (2.15 to 2.16 in.) 70.0 to 70.5 mm (2.76 to 2.78 in.)
      Race 55.0 to 55.2 mm (2.165 to 2.173 in.) 68.8 to 69.3 mm (2.71 to 2.73 in.)

  25. INSTALL 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY

    A01EQDZ

    1. Apply the No. 1 planetary carrier thrust washer to the 1-way clutch inner race, and then install them to the 1-way clutch.

      Tech Tips

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

  26. INSPECT 1-WAY CLUTCH ASSEMBLY

    A01EQBYE01

    1. Install the 1-way clutch to the 1-way clutch inner race.

    2. Hold the 1-way clutch inner race and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

    3. Remove the 1-way clutch from the 1-way clutch inner race.

  27. INSTALL 1-WAY CLUTCH ASSEMBLY WITH 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY

    A01ES2T

    1. Install the 1-way clutch with the 1-way clutch inner race to the transmission case.

  28. INSTALL NO. 1 BRAKE DISC SET

    A01EOMBE01

    1. Install the 4 plates, 4 discs and flange.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  29. INSTALL NO. 3 BRAKE PISTON

    A01END9E02

    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.

    3. A01ENFGE01

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

      SST
      09380-60010   ( 09381-06020, 09381-06040, 09381-06060, 09381-06100, 09381-06110 )

      Note

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

  30. INSTALL NO. 3 BRAKE CYLINDER WITH NO. 3 BRAKE PISTON AND NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01EN5F

    1. Install the No. 3 brake cylinder with the No. 3 brake piston and No. 3 brake piston return spring to the transmission case.

      Note


      • A01EPSDE01

        Align the oil holes of the No. 3 brake cylinder and transmission case as shown in the illustration.

      • Make sure the No. 3 brake piston and cylinder are securely inserted into the transmission case.

  31. INSTALL NO. 3 BRAKE PISTON HOLE SNAP RING

    A01ENNNE01

    1. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  32. INSTALL NO. 3 BRAKE DISC SET

    A01EPOJE01

    1. Install the "O" mark flange, 4 discs, 3 plates and "A" mark flange to the transmission case.

      Install in order
      OF - D - P - D - P - D - P - D - AF

      Tech Tips

      OF = "O" mark flange

      P = Plate

      D = Disc

      AF = "A" mark flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  33. INSTALL NO. 3 BRAKE SNAP RING

    A01EN88

    1. Using a screwdriver, install the snap ring.

  34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A01EOKME01

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

    2. A01EPNZ

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

    3. A01ES0U

      Press the direct clutch piston with the clutch return spring and clutch balancer into the reverse clutch piston with both hands.

      Note

      Be careful not to damage the O-ring.

    4. A01ERUBE01

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

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080 )

      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.

    5. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    6. A01ENQ1E07

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

      Note

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

  35. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

    A01ES81E01

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

    2. A01EOQ8E01

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

    3. A01EQ9U

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

      Note


      • Be careful not to damage the O-ring.

      • Make sure to align the holes of the reverse clutch piston and clutch drum as shown in the illustration.

      • Make sure to align the protrusions of the reverse clutch piston and the cutout of the clutch drum.

  36. INSTALL NO. 3 CLUTCH BALANCER

    A01EPF3E01

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

    2. Install the reverse clutch return spring and balancer onto the reverse clutch piston.

    3. A01EQVXE01

      Place SST on the clutch balancer, and compress the clutch balancer with a press.

      SST
      09380-60010   ( 09381-06020, 09381-06030, 09381-06040, 09381-06050, 09381-06070, 09381-06080 )

      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.

    4. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    5. A01EPZX

      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.

  37. INSTALL DIRECT CLUTCH DISC

    A01ENXTE01

    1. Place the oil pump onto the torque converter clutch, and then place the clutch drum onto the oil pump.

    2. 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

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

    3. A01ERAP

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

    4. Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard value.

      Standard moving distance (A)
      0.72 to 1.02 mm (0.0283 to 0.0402 in.)
      A01ENP5E01
      Flange Thickness
      Mark Thickness
      0 3.45 to 3.55 mm (0.136 to 0.140 in.)
      1 3.55 to 3.65 mm (0.140 to 0.144 in.)
      2 3.65 to 3.75 mm (0.144 to 0.148 in.)
      3 3.75 to 3.85 mm (0.148 to 0.152 in.)
      4 3.85 to 3.95 mm (0.152 to 0.156 in.)
      5 3.95 to 4.05 mm (0.156 to 0.159 in.)
      6 4.05 to 4.15 mm (0.159 to 0.163 in.)
      7 4.15 to 4.25 mm (0.163 to 0.167 in.)
      8 4.25 to 4.35 mm (0.167 to 0.171 in.)

    5. Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

  38. SELECT REVERSE CLUTCH FLANGE

    A01ER63

    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. A01EOXLE01

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

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected flange

      C = Cushion plate

    3. A01EO9P

      Using a screwdriver, install the hole snap ring.

    4. Using a dial indicator, measure the moving distance (A minus B) of the tip of the reverse clutch piston (A) and cushion plate at both ends across the diameter (B) while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard value.

      A01ESHCE01
      Standard moving distance (A minus B)
      0.59 to 0.89 mm (0.0232 to 0.0350 in.)
      Flange Thickness
      Mark Thickness
      0 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      1 2.45 to 2.55 mm (0.0965 to 0.100 in.)
      2 2.55 to 2.65 mm (0.100 to 0.104 in.)
      3 2.65 to 2.75 mm (0.104 to 0.108 in.)
      4 2.75 to 2.85 mm (0.108 to 0.112 in.)
      5 2.85 to 2.95 mm (0.112 to 0.116 in.)
      6 2.95 to 3.05 mm (0.116 to 0.120 in.)
      7 3.05 to 3.15 mm (0.120 to 0.124 in.)
      8 3.15 to 3.25 mm (0.124 to 0.128 in.)
      A 3.25 to 3.35 mm (0.128 to 0.132 in.)
      B 3.35 to 3.45 mm (0.132 to 0.136 in.)
      C 3.45 to 3.55 mm (0.136 to 0.140 in.)
    5. A01ESDSE01

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

  39. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY AND COAST CLUTCH PISTON

    A01ESLRE01

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

    2. A01EPNS

      Install the forward clutch piston and coast clutch piston to the input shaft.

    3. A01EQA9E01

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

    4. A01EO3P

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

      Note

      Be careful not to damage the O-rings.

    5. A01ER76E01

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

      SST
      09350-30020   ( 09350-07040 )

      Note

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

    6. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    7. A01EOIGE01

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

      Note

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

  40. INSTALL COAST CLUTCH DISC SET

    A01EPANE01

    1. Install the 4 plates, 4 discs and flange.

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

      Tech Tips

      P = Plate

      D = Disc

      F = Flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. A01ERQ8

      Temporarily install the snap ring.

    3. A01EOHYE01

      Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 11 flange thicknesses in the table so that the measured value is within the standard value.

      Standard moving distance (A)
      0.41 to 0.71 mm (0.0161 to 0.0280 in.)
      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.)
      A 3.85 to 3.95 mm (0.152 to 0.156 in.)
      B 3.95 to 4.05 mm (0.156 to 0.159 in.)

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

  41. INSTALL NO. 4 1-WAY CLUTCH ASSEMBLY

    A01ES4H

    1. Install the No. 2 clutch hub thrust washer to the coast clutch hub.

      Tech Tips

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

    2. Install the 1-way clutch to the coast clutch hub.

  42. INSPECT NO. 4 1-WAY CLUTCH ASSEMBLY

    A01EQEIE01

    1. Hold the coast clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

  43. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY WITH NO. 4 1-WAY CLUTCH ASSEMBLY

    A01EOTLE01

    1. Install the 2 thrust needle roller bearings, thrust bearing race and coast clutch hub with the No. 4 1-way clutch to the input shaft.

      Tech Tips

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

      Bearing and Race Diameter
      Item Inside Outside
      Bearing C 21.05 to 21.3 mm (0.829 to 0.839 in.) 39.63 to 39.88 mm (1.56 to 1.57 in.)
      Race 22.8 to 23.1 mm (0.898 to 0.909 in.) 44.5 to 44.75 mm (1.75 to 1.76 in.)
      Bearing D 39.45 to 39.7 mm (1.55 to 1.56 in.) 60.5 to 60.75 mm (2.38 to 2.39 in.)

  44. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC SET

    A01EQ9OE01

    1. Install the cushion plate, 6 plates, 6 discs and flange to the input shaft.

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

      Tech Tips

      C = Cushion plate

      P = Plate

      D = Disc

      F = Flange

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. A01ERIIE01

      Temporarily install the snap ring.

    3. A01ENJ8E01

      Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard value.

      Standard moving distance (A)
      0.85 to 1.15 mm (0.0335 to 0.0453 in.)
      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.)
      A 3.85 to 3.95 mm (0.152 to 0.156 in.)
      B 3.95 to 4.05 mm (0.156 to 0.159 in.)
      C 4.05 to 4.15 mm (0.159 to 0.163 in.)

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

  45. INSTALL INPUT SHAFT OIL SEAL RING

    A01EPVOE01

    1. Overlap the seal ring edges in the axial direction.

      Note


      • Overlapping the seal ring edges in the axial direction prevents damage to the seal ring.

      • Do not overlap the seal ring edges in the radial direction, as this may damage the seal ring.

    2. A01EQ1CE01

      Coat 4 new oil seal rings with ATF.

    3. Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.

      Note

      Do not excessively widen the rings.

      Tech Tips

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

  46. INSTALL INPUT SHAFT ASSEMBLY

    A01ER8S

    1. Install the input shaft to the clutch drum.

  47. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

    A01EOMO

    1. Install the No. 3 clutch hub thrust washer, forward clutch hub and thrust needle roller bearing to the clutch drum.

      Note

      Before installing the forward clutch hub, apply ATF to the forward clutch hub bush sliding surfaces. After the installation, check that the forward clutch hub rotates smoothly.

      Tech Tips

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

      Bearing Diameter
      Item Inside Outside
      Bearing 46.45 to 46.7 mm (1.83 to 1.84 in.) 64.3 to 64.55 mm (2.53 to 2.54 in.)

  48. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

    A01EORN

    1. Install the reverse clutch hub to the clutch drum.

      Note

      Before installing the reverse clutch hub, apply ATF to the reverse clutch hub bush sliding surfaces. After the installation, check that the reverse clutch rotates smoothly.

  49. INSTALL REAR CLUTCH DISC SET

    A01ENRXE01

    1. Install the flange, 5 discs, 4 plates, selected flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

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

      Tech Tips

      F = Flange

      D = Disc

      P = Plate

      S/F = Selected flange

      C = Cushion plate

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

  50. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY

    A01ENY3

    1. Install the clutch drum thrust washer to the clutch drum.

      Tech Tips

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

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

  51. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY

    A01EMV5E01

    1. Hold the reverse clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

  52. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01EN4NE01

    1. Install the 2 thrust needle roller bearings.

      Tech Tips

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

      Bearing Diameter
      Item Inside Outside
      Bearing A 71.96 to 72.26 mm (2.83 to 2.84 in.) 85.25 to 85.6 mm (3.36 to 3.37 in.)
      Bearing B 36.45 to 36.7 mm (1.44 to 1.45 in.) 52.96 to 53.26 mm (2.09 to 2.10 in.)

    2. Coat the clutch drum thrust washer with petroleum jelly and install it onto the clutch drum and input shaft assembly.

    3. A01EO61

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

  53. INSTALL OIL PUMP ASSEMBLY

    A01EMXOE01

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

    2. Install the 2 thrust bearing races to the front oil pump.

      Thrust Bearing Race Diameter
      Item Inside Outside
      Race A 74.26 to 74.56 mm (2.92 to 2.94 in.) 87.39 to 87.74 mm (3.44 to 3.45 in.)
      Race B 38.0 to 38.3 mm (1.50 to 1.51 in.) 53.9 to 54.1 mm (2.12 to 2.13 in.)
    3. A01ERXG

      Pass the input shaft through the center hole of the oil pump, 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.

    5. Apply seal packing to the flanges of the bolts.

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

      Note

      Do not allow seal packing to contact the bolt threads.

    6. Install the 10 bolts.

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

      Note

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

  54. INSPECT INDIVIDUAL PISTON OPERATION

    A01ENM2E01

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

      Tech Tips

      When inspecting the 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. 4 clutch (C4)

      4. No. 1 clutch (C1)

      5. No. 3 brake (B3)

      6. No. 1 brake (B1)

      7. No. 2 brake (B2)

      8. No. 4 brake (B4)

  55. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A01EQ8GE01

    1. Using SST, tap in 2 new oil seals.

      SST
      09350-30020   ( 09350-07110 )

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

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    A01EN7TE01

    1. 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 shaft.

    3. A01EPI0

      Using a hammer, tap in a new spring pin.

    4. A01ERVB

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

    5. Check that the shaft rotates smoothly.

  57. INSTALL PARKING LOCK PAWL

    A01EN91E02

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

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

  58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A01EOWLE01

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

  59. INSTALL PARKING LOCK PAWL BRACKET

    A01ERC8

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

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    2. A01ERZRE01

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

  60. INSTALL B-1 ACCUMULATOR VALVE

    A01ESBJ

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-1 Inner

      44.98 mm (1.77 in.)

      11.30 mm (0.445 in.)

      		 Natural
      B-1 Outer

      46.36 mm (1.83 in.)

      17.10 mm (0.673 in.)

      		 Natural

  61. INSTALL C-3 ACCUMULATOR PISTON

    A01EQ0DE01

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-3

      76.65 mm (3.02 in.)

      20.1 mm (0.791 in.)

      		 Natural

  62. INSTALL B-3 ACCUMULATOR PISTON

    A01EP3RE01

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      B-3

      64.50 mm (2.54 in.)

      19.5 mm (0.768 in.)

      		 Orange

  63. INSTALL C-2 ACCUMULATOR PISTON

    A01EQXRE01

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

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

      Spring Diameter
      Spring

      Free Length

      Outer Diameter

      		 Color
      C-2

      68.0 mm (2.68 in.)

      16.1 mm (0.634 in.)

      		 Light green

  64. INSTALL CHECK BALL BODY

    A01EN2BE01

    1. Install the spring and check ball body.

  65. INSTALL BRAKE DRUM GASKET

    A01ERA1E01

    1. Install 3 new brake drum gaskets.

  66. INSTALL TRANSMISSION CASE GASKET

    A01EQOLE01

    1. Install 3 new transmission case gaskets.

  67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A01ENF0E01

    1. Align the hole of the manual valve with the pin of the lever.

    2. A01EOYAE01

      Install 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

      45 mm (1.77 in.) for bolt C

      50 mm (1.97 in.) for bolt D

    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

    A01EQS9E01

    1. Install 2 new O-rings to the transmission wires.

    2. A01EOUM

      Install the transmission wire harnesses.

    3. Install the bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. A01EN5YE02

      Connect the 9 connectors to the solenoid valves.

    5. 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 }

      Tech Tips

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A01EQU2

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

    2. Install the oil strainer with the 4 bolts.

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

  70. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01ENINE01

    1. Install the 4 magnets.

    2. Install a new gasket to the oil pan.

    3. Install the oil pan with the 12 bolts.

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

      Note


      • A01ENE9E01

      • Make sure that there is no oil or foreign matter on the gasket seal surface and oil pan contact surface.

      • Install the gasket so that there is no slack in the gasket, and make sure the entire circumference of the seal surface is level.

      • Make sure that the 9 gasket drop prevention protrusions are set on the oil pan.

      • When tightening the bolts of the oil pan, make sure that the gasket is not pinched between the gasket tightening area sleeve and the transmission seal surface.

    4. Install the drain plug.

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

  71. INSTALL TRANSFER CASE ADAPTER RADIAL BALL BEARING

    A01EN2HE01

    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.

  72. INSTALL TRANSMISSION CASE ADAPTER OIL SEAL

    A01EPAGE02

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

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

      Standard depth
      0 to 1 mm (0 to 0.0394 in.)
      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )

  73. INSTALL TRANSFER ADAPTER REAR

    A01EOJXE01

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

    2. Apply seal packing to the rear adaptor transfer.

      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. A01ERAJ

      Install the rear adaptor transfer with the 10 bolts.

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

  74. INSTALL AUTOMATIC TRANSMISSION HOUSING

    A01ESGU

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

    2. Install the transmission housing with the 14 bolts.

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

  75. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

    A01EQ4D

    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 }

  76. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Air Cooled Transmission Oil Cooler)

    A01ENSCE01

    1. Coat 4 new O-rings with ATF.

    2. Install the 4 O-rings, transmission oil thermostat and transmission oil cooler to the automatic transmission.

    3. Temporarily install bolt A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt A to the specified torque.

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

  77. INSTALL OIL COOLER TUBE UNION (w/ Air Cooled Transmission Oil Cooler)

    A01EPE2E01

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

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

      Torque:
      without union nut wrench
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      with union nut wrench
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).

  78. INSTALL SPEED SENSOR

    A01EPAL

    1. 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 }

  79. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01ERWAE01

    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. 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 RH.

    4. A01EN4FE01

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

    5. Remove the control shaft lever RH.

    6. A01EPPZE10

      Align the groove with the neutral basic line.

    7. Hold the switch in position and tighten the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    8. A01EQ45E01

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

  80. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH

    A01ENQS

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

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