AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A01J4TKE02
    Bearing diameter
    Mark Front Race Diameter Inside / Outside Thrust Bearing Diameter Inside / Outside Rear Race Diameter Inside / Outside
    A 73.6 mm (2.898 in.) / 102.0 mm (4.016 in.) 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) -
    B 38.0 mm (1.496 in.) / 57.0 mm (2.244 in.) 43.4 mm (1.709 in.) / 58.3 mm (2.295 in.) -
    C - 55.7 mm (2.193 in.) / 76.4 mm (3.008 in.) 53.7 mm (2.114 in.) / 74.0 mm (2.913 in.)
    D 33.4 mm (1.315 in.) / 49.0 mm (1.929 in.) 32.1 mm (1.264 in.) / 49.35 mm (1.943 in.) 32.1 mm (1.2649 in.)/ 49.0 mm (1.929 in.)
    E - 21.5 mm(0.847 in.) / 40.8 mm (1.606 in.) -
    F 48.5 mm (1.909 in.) / 62.7 mm (2.469 in.) 45.9 mm (1.807 in.) / 64.0 mm (2.520 in.) -

  2. INSTALL NO. 4 BRAKE PISTON

    A01J413E06

    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 BRAKE REACTION SLEEVE

    A01J5FME03

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

    2. With the No. 1 brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case.

      Note

      Be careful not to damage the O-rings.

  4. INSTALL 1ST AND REVERSE BRAKE PISTON

    A01J2ZHE03

    1. Coat a new O-ring with ATF.

    2. Install the O-ring on 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. A01J4QTE01

      Place the piston return spring onto the No. 4 brake piston.

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

    A01J7KHE01

    1. Place SST on the 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

    A01J50ME01

    1. Install the thrust needle roller bearing.

      Standard thrust needle roller bearing diameter
      Item Inside Outside
      Thrust needle roller bearing 45.9 mm (1.807 in.) 64.0 mm (2.520 in.)
    2. A01J36KE03

      Install the thrust needle roller bearing.

    3. Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear.

      Standard bearing and race diameter
      Item Inside Outside
      Bearing 21.5 mm (0.847 in.) 40.8 mm (1.606 in.)
      Race 48.5 mm (1.909 in.) 62.7 mm (2.469 in.)
    4. A01J6CSE01

      Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

    A01J5I7E01

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

    2. A01J50OE01

      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 (1.431 to 1.460 in.)

    3. A01J6XJE03

      Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether 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 (0.010 to 0.071 in.)

      Length B = 36.04 to 37.14 mm (1.419 to 1.462 in.)

      Pack clearance
      0.8 to 1.1 mm (0.031 to 0.043 in.)

    4. If the pack clearance is not within the standard, select and install a brake flange that makes the pack clearance within the standard.

      H thickness
      No. Thickness No. Thickness
      0 0 mm (0 in.) 8 0.8 mm (0.032 in.)
      2 0.2 mm(0.008 in.) 10 1.0 mm (0.039 in.)
      4 0.4 mm (0.016 in.) 12 1.2 mm (0.047 in.)
      6 0.6 mm (0.024 in.) 14 1.4 mm (0.055 in.)

  8. INSTALL NO. 4 BRAKE DISC

    A01J6AWE01

    1. 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

      P = Plate

      D = Disc

      F = Flange

  9. INSTALL BRAKE PLATE STOPPER SPRING

    A01J7NEE01

    1. Install the brake stopper spring.

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01J3U3E05

    1. 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.

      Standard bearing and race diameter
      Item Inside Outside
      No. 7 thrust bearing race 33.4 mm (1.315 in.) 49.0 mm (1.929 in.)
      Thrust needle roller bearing 32.1 mm (1.264 in.) 49.35 mm (1.943 in.)
      No. 8 thrust bearing race 32.1 mm (1.264 in.) 49.0 mm (1.929 in.)

  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

    A01J6ZHE01

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

  12. INSTALL INTERMEDIATE SHAFT

    A01J452E01

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

    2. A01J6S6E03

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07050, 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

    A01J6VAE01

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

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

      Standard race diameter
      Item Inside Outside
      Race 53.7 mm (2.114 in.) 74.0 mm (2.913 in.)

  14. INSTALL NO. 2 BRAKE PISTON

    A01J6OSE03

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

    2. Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.

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

  15. INSTALL NO. 2 BRAKE DISC

    A01J6BWE04

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

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

      Tech Tips

      D = Disc

      P = Plate

      F = Flange

    2. A01J4AGE03

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

      SST
      09351-40010

  16. INSTALL NO. 1 BRAKE PISTON

    A01J4PBE03

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

    2. Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.

  17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01J6UUE01

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

  18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

    A01J3DNE03

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

      SST
      09351-40010

  19. INSTALL NO. 1 BRAKE DISC

    A01J4RPE04

    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

    A01J5W1E01

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

    2. A01J7P6E01

      Using a screwdriver, install the snap ring.

  21. INSTALL FRONT PLANETARY RING GEAR

    A01J4R2E01

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

      Standard thrust needle roller bearing diameter
      Item Inside Outside
      Thrust needle roller bearing 55.7 mm (2.193 in.) 76.4 mm (3.008 in.)

  22. INSTALL FRONT PLANETARY GEAR ASSEMBLY

    A01J50PE04

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

    2. Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear.

      Standard thrust needle roller bearing and race diameter
      Item Inside Outside
      Thrust needle roller bearing 43.4 mm (1.709 in.) 58.3 mm (2.295 in.)
      Race 38.0 mm (1.496 in.) 57.0 mm (2.244 in.)
    3. A01J746E01

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

  23. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON

    A01J6NFE01

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

    2. A01J3Y3E01

      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 (0.017 to 0.028 in.)

      If the piston stroke is not within the specification, parts may have been reassembled incorrectly.

      Perform the reassembly again.

      If the piston stroke is still not within the specification, select another flange.

      Tech Tips

      There are 4 different thicknesses for the flange.

      Standard flange thickness
      No. Thickness No. Thickness
      0 2.0 mm (0.079 in.) 2 2.4 mm (0.094 in.)
      1 2.2 mm (0.087 in.) 3 2.6 mm (0.102 in.)

  24. INSTALL 2ND BRAKE PISTON

    A01J7ETE04

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

    2. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands.

    3. A01J68FE03

      Using SST and press, 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

    A01J7CBE01

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

  26. INSTALL 1-WAY CLUTCH ASSEMBLY

    A01J78ME01

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

  27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

    A01J6S6E02

    1. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  28. INSTALL NO. 3 BRAKE DISC

    A01J3URE04

    1. Install the flanges, 4 discs, 4 plates and cushion plate on the case.

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

      Tech Tips

      C = Cushion

      P = Plate

      D = Disc

      F = Flange

  29. INSTALL NO. 3 BRAKE SNAP RING

    A01J3QAE01

    1. Using a screwdriver, install the snap ring.

  30. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY

    A01J66KE01

    1. Coat the race with petroleum jelly and install it onto the No. 2 clutch drum thrust washer.

    2. Install the No. 2 1-way clutch assembly washer.

  31. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01J3Y9E02

    1. Install the thrust needle roller bearing.

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

      Standard thrust needle roller bearing and diameter
      Item Inside Outside
      Thrust needle roller bearing 71.9 mm (2.831 in.) 85.6 mm (3.370 in.)
      Race 73.6 mm (2.898 in.) 102.0 mm (4.016 in.)
    3. A01J3BZE01

      Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.

  32. INSTALL OIL PUMP ASSEMBLY

    A01J4K9E01

    1. Install the No. 1 thrust bearing race to the front oil pump

      Standard No. 1 thrust bearing race diameter
      Item Inside Outside
      Race 74.2 mm (2.921 in.) 87.74 mm (3.454 in.)
    2. A01J6KRE01

      Coat a new O-ring with ATF, and install it around 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 push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum.

    5. A01J7BLE01

      Install the 10 bolts.

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

  33. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

    A01J5K2E02

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

      SST
      09350-30020   ( 09350-07110 )

    2. Coat the oil seal lips with MP grease.

  34. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION

    A01J5YWE02

    1. 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 C3 accumulator piston holes indicated in the illustration.

      If there is no sound, disassembly 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 (B1)

      • (5) No. 1 brake (B1)

      • (6) No. 2 brake (B2)

      • (7) No. 4 brake (B4)

  35. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

    A01J6O9E01

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

    2. Install the manual valve lever shaft to the transmission case through the manual valve lever.

    3. A01J7DNE01

      Using a hammer, tap in a new spring pin.

    4. A01J5XUE01

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

    5. Make sure the shaft rotates smoothly.

  36. INSTALL PARKING LOCK PAWL SHAFT

    A01J4VLE04

    1. Install the E-ring to the shaft.

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

  37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

    A01J4QDE01

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

  38. INSTALL PARKING LOCK PAWL BRACKET

    A01J5E1E01

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

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A01J437E03

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

  39. INSTALL C-1 ACCUMULATOR VALVE

    A01J30PE01

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

    2. A01J46FE01

      Install the spring and accumulator valve to the hole.

      Standard accumulator spring
      Spring

      Free length

      Outer diameter

      		 Color
      C-1 Inner

      30.40 mm (1.197 in.)

      11.40 mm (0.449 in.)

      		 Pink
      C-1 Outer

      48.76 mm (1.920 in.)

      16.60 mm (0.654 in.)

      		 Light green

  40. INSTALL C-3 ACCUMULATOR PISTON

    A01J30PE05

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

    2. A01J44SE01

      Install the spring and accumulator piston to the hole.

      Standard accumulator spring
      Spring

      Free length

      Outer diameter

      		 Color
      C-3 Inner

      44.0 mm (1.732 in.)

      14.0 mm (0.551 in.)

      		 Yellow
      C-3 Outer

      73.35 mm (2.888 in.)

      19.90 mm (0.784 in.)

      		 Red

  41. INSTALL B-3 ACCUMULATOR PISTON

    A01J30PE03

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

    2. A01J4LGE01

      Install the spring and accumulator piston to the hole.

      Standard accumulator spring
      Spring

      Free length

      Outer diameter

      		 Color
      B-3

      70.5 mm (2.776 in.)

      19.7 mm (0.776 in.)

      		 Purple

  42. INSTALL C-2 ACCUMULATOR PISTON

    A01J30PE04

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

    2. A01J4HLE01

      Install the spring and accumulator piston to the hole.

      Standard accumulator spring
      Spring

      Free length

      Outer diameter

      		 Color
      C-2

      62.0 mm (2.441 in.)

      15.9 mm (03626 in.)

      		 White

  43. INSTALL CHECK BALL BODY

    A01J3F7E04

    1. Install the check ball body and spring.

  44. INSTALL BRAKE DRUM GASKET

    A01J6ZKE01

    1. Install the 3 brake drum gaskets.

  45. INSTALL TRANSAXLE CASE GASKET

    A01J4AAE04

    1. Install the 3 transaxle case gaskets.

  46. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

    A01J5KVE01

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

    2. A01J3T8E02

      Install the 19 bolts.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      25 mm (0.98 in.) for bolt A
      36 mm (1.42 in.) for bolt B

  47. INSTALL TRANSMISSION WIRE

    A01J5VHE01

    1. 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. Connect the solenoid connector.

    5. A01J331E03

      Connect the 7 solenoid connectors.

    6. Install the ATF temperature sensor.

    7. Install the clamp and the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf, for bolt A }
      10 N*m  { 100 kgf*cm, 7 ft.*lbf, for bolt B }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      36 mm (1.42 in.) for bolt A
      12 mm (0.47 in.) for bolt B

  48. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

    A01J6MUE01

    1. Coat a new O-ring with ATF, and install them 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 }

  49. INSTALL TRANSMISSION OIL CLEANER MAGNET

    A01J7A9E02

    1. Install the 4 transmission oil cleaner magnets.

  50. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install a new gasket on the oil pan.

    2. Install and torque 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 }

  51. INSTALL TRANSMISSION CASE ADAPTER OIL SEAL

    A01J3YSE01

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

      SST
      09226-10010

  52. INSTALL TRANSMISSION CASE ADAPTER SUB-ASSEMBLY

    A01J3VBE02

    1. Apply seal packing or equivalent to the 8 bolts.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
    2. A01J77RE01

      Install the transmission case adapter sub-assembly with the 8 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      50 mm (1.969 in.) for bolt A
      40 mm (1.575 in.) for bolt B

  53. INSTALL AUTOMATIC TRANSMISSION HOUSING

    A01J6EIE01

    1. Clean the threads of the bolts and case with white gasoline.

    2. Install the transmission housing with the 10 bolts.

      Torque:
      34 N*m  { 345 kgf*cm, 25 ft.*lbf, for bolt A }
      57 N*m  { 581 kgf*cm, 42 ft.*lbf, for bolt B }
      34 N*m  { 345 kgf*cm, 25 ft.*lbf, for bolt C }

      Tech Tips

      Bolt A: 14 mm head

      Bolt B: 17 mm head

      Bolt C: 14 mm head

  54. INSTALL AUTOMATIC TRANSAXLE BREATHER TUBE

    A01J5JJE01

    1. Install a new O-ring to the breather tube.

    2. Install the breather tube with the 3 bolts.

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

  55. INSTALL SPEED SENSOR

    A01J39F

    1. Coat 2 new O-rings with ATF, and install it to the transmission revolution sensor.

    2. Install the 2 transmission revolution sensor.

    3. Install the 2 bolts.

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

  56. INSTALL OIL COOLER TUBE UNION

    A01J48WE01

    1. Coat a new O-ring with ATF, and install it to oil cooler tube union.

    2. Install the oil cooler tube union.

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

  57. 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. A01J6JYE01

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

    2. Install a new lock washer. Install and torque the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    3. A01J3SBE01

      Push the control shaft rearward as much as possible.

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

    5. A01J49CE04

      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. A01J4W3E01

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  58. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH

    A01J30IE02

    1. Install the washer and nut to the control shaft lever LH.

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