AUTOMATIC TRANSMISSION UNIT REASSEMBLY


  1. BEARING POSITION

    A01FFGQE01
    Mark

    Front Race Diameter

    Inside/Outside

    Thrust Bearing Diameter

    Inside/Outside

    Rear Race Diameter

    Inside/Outside
    A 74.2 mm (2.92 in.) / 87.74 mm (3.45 in.) 71.9 mm (2.83 in.) / 85.6 mm (3.37 in.) -
    B 37 mm (1.46 in.) / 52.3 mm (2.06 in.) 34.6 mm (1.36 in.) / 52.0 mm (2.05 in.) -
    C 37.0 mm (1.46 in.) / 52.3 mm (2.06 in.) 34.6 mm (1.36 in.) / 52.0 mm (2.05 in.) -
    D - 21.3 mm (0.839 in.) / 41.1 mm (1.62 in.) 22.6 mm (0.890 in.) / 44.8 mm (1.76 in.)
    E - 35.6 mm (1.40 in.) / 56.6 mm (2.23 in.) -
    F - 42.5 mm (1.67 in.) / 61.2 mm (2.41 in.) -
    G 38.0 mm (1.50 in.) / 57.0 mm (2.24 in.) 43.4 mm (1.71 in.) / 58.3 mm (2.30 in.) -
    H - 55.7 mm (2.19 in.) / 76.4 mm (3.01 in.) -
    I - - 53.7 mm (2.11 in.) / 74.0 mm (2.91 in.)
    J 33.4 mm (1.31 in.) / 49.0 mm (1.93 in.) 32.1 mm (1.26 in.) / 49.35 mm (1.94 in.) 32.1 mm (1.26 in.) / 49.0 mm (1.93 in.)
    K - 21.5 mm (0.846 in.) / 40.8 mm (1.61 in.) -
    L - 43.6 mm (1.72 in.) / 61.0 mm (2.40 in.) 47.1 mm (1.85 in.) / 67.1 mm (2.64 in.)
    M 36.9 mm (1.45 in.) / 49.7 mm (1.96 in.) 36.1 mm (1.42 in.) / 52.5 mm (2.07 in.) 36.1 mm (1.42 in.) / 51.0 mm (2.01 in.)

  2. INSTALL NO. 4 BRAKE PISTON


    1. A01FHOIE12
      Text in Illustration
      *1 O-ring
      *2 Brake Reaction Sleeve
      *3 No. 4 Brake Piston

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

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

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

      Note

      Be careful not to damage the 4 O-rings.

  3. INSTALL BRAKE REACTION SLEEVE


    1. A01FD8FE08
      Text in Illustration
      *1 Brake Reaction Sleeve
      *2 No. 4 Brake Piston

      With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and No. 4 brake piston to the transmission case.

      Note

      Be careful not to damage the O-ring.

  4. INSTALL 1ST AND REVERSE BRAKE PISTON


    1. A01FG0SE05
      Text in Illustration
      *1 1st and Reverse Brake Piston

      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 1st and reverse brake piston facing upwards (front side), place the 1st and reverse brake piston in the transmission case.

      Note

      Be careful not to damage the O-ring.

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


    1. A01FINM

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

    2. A01FE1LE04

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

      SST
      09350-30020   ( 09350-07050 )

    3. Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07070 )
      Text in Illustration
      *1 Snap Ring
    4. A01FIL5

      Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

      Note

      Attach the 1st and reverse brake piston claw with the protrusion of the brake apply tube.

  6. INSTALL REAR PLANETARY GEAR ASSEMBLY


    1. A01FE2G

      Install the No. 9 thrust bearing race.

      Race Diameter
      Inside Outside
      No. 9 thrust bearing race 47.1 mm (1.85 in.) 67.1 mm (2.64 in.)
    2. A01FGWTE04
      Text in Illustration
      *1 Thrust Needle Roller Bearing A
      *2 Thrust Needle Roller Bearing B

      Install the 2 thrust needle roller bearings.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      Thrust needle roller bearing A 21.5 mm (0.846 in.) 40.8 mm (1.61 in.)
      Thrust needle roller bearing B 43.6 mm (1.72 in.) 61.0 mm (2.40 in.)
    3. A01FEJE

      Install the rear planetary gear assembly.

  7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE PISTON


    1. A01FF6Q

      Make sure that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      If the 1st and reverse brake piston does not move smoothly, check the oil path of the transmission case, 1st and reverse brake piston and O-ring.

    2. A01FICQE02

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

      Note

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

      Tech Tips

      Dimension A = 22.05 to 22.91 mm (0.869 to 0.901 in.)

    3. A01FF2UE02

      Using a vernier caliper and while applying compression of 4.9 N (0.5 kgf, 1.1 lbf) or less, measure the thickness (dimension B) of the No. 4 brake flange, 4 No. 4 brake plates and 4 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.

      Tech Tips

      Dimension B = 23.11 to 23.89 mm (0.910 to 0.941 in.)

      Pack Clearance = Dimension A - Dimension B - 0.22 mm (0.00866 in.) + 1.8 mm (0.0709 in.)

      Pack clearance
      0.4 to 0.7 mm (0.0158 to 0.0275 in.)

    4. If the pack clearance is outside the standard range, select and install a No. 4 brake flange that brings the pack clearance to be within the standard range.

      Tech Tips

      There are 11 types of No. 4 brake flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

      Thickness H
      Part No. Mark Thickness H
      35689-60270 0 0 mm (0 in.)
      35689-60280 1 0.17 mm (0.00669 in.)
      35689-60290 3 0.31 mm (0.0122 in.)
      35689-60300 4 0.45 mm (0.0177 in.)
      35689-60310 5 0.59 mm (0.0232 in.)
      35689-60320 7 0.73 mm (0.0287 in.)
      35689-60330 8 0.87 mm (0.0343 in.)
      35689-60340 10 1.01 mm (0.0398 in.)
      35689-60350 11 1.15 mm (0.0453 in.)
      35689-60360 12 1.29 mm (0.0508 in.)
      35689-60370 14 1.43 mm (0.0563 in.)

  8. INSTALL NO. 4 BRAKE DISC


    1. A01FF6SE05
      Text in Illustration
      *1 No. 4 Brake Flange
      *2 No. 4 Brake Disc
      *3 No. 4 Brake Plate
      *4 Rear Cover Sleeve

      Install the rear cover sleeve, 4 No. 4 brake plates, 4 No. 4 brake discs and No. 4 brake flange.

      Installation order
      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *4

  9. INSTALL BRAKE PLATE STOPPER SPRING


    1. A01FH2N

      Install the brake plate stopper spring.

  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. A01FFA7E16
      Text in Illustration
      *1 No. 7 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 No. 8 Thrust Bearing Race
      *4 Rear Planetary Ring Gear Flange Sub-assembly

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

      Bearing and Race Diameter
      Inside Outside
      No. 7 thrust bearing race 33.4 mm (1.31 in.) 49.0 mm (1.93 in.)
      Thrust needle roller bearing 32.1 mm (1.26 in.) 49.35 mm (1.94 in.)
      No. 8 thrust bearing race 32.1 mm (1.26 in.) 49.0 mm (1.93 in.)

  11. INSTALL NO. 3 ONE-WAY CLUTCH ASSEMBLY


    1. A01FDFFE03
      Text in Illustration
      *1 No. 3 One-way Clutch Assembly
      *2 One-way Clutch Inner Race

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

  12. INSTALL INTERMEDIATE SHAFT


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

    2. A01FIW6E03

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY


    1. A01FE2CE01
      Text in Illustration
      *1 No. 4 Thrust Bearing Race
      *2 Center Planetary Gear Assembly
      *3 Planetary Sun Gear

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

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

      Race Diameter
      Inside Outside
      No. 4 thrust bearing race 53.7 mm (2.11 in.) 74.0 mm (2.91 in.)

  14. INSTALL NO. 2 BRAKE PISTON


    1. A01FHVDE08
      Text in Illustration
      *1 O-ring

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

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

      Note

      Be careful not to damage the 2 O-rings.

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

      Tech Tips

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

    4. A01FGJL

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

  15. INSTALL NO. 2 BRAKE DISC


    1. A01FHI3E07
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate
      *4 No. 2 Brake Piston Return Spring Sub-assembly

      Install the 2 No. 2 brake flanges, 3 No. 2 brake plates, 4 No. 2 brake discs and No. 2 brake piston return spring sub-assembly.

      Installation order
      *4 -*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
    2. A01FI29E05

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

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

  16. INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON


    1. Inspect piston stroke of the No. 2 brake piston.


      1. A01FFAV

        Make sure that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

        If the No. 2 brake piston does not move smoothly, check the oil path of the transmission case, No. 2 brake piston and O-rings.

      2. A01FH3VE04

        Using SST and a dial indicator, measure the moving distance (distance A) of the No. 2 brake disc at both ends across a diameter while blowing air (392 kPa, 4.0 kgf/cm2, 57 psi) into the oil hole as shown in the illustration, and calculate the average.

        SST
        09350-30020   ( 09350-06120 )
        Piston stroke
        0.6 to 0.9 mm (0.0237 to 0.0354 in.)

      3. If the piston stroke is outside the standard range, select and install a No. 2 brake flange that brings the piston stroke within the standard range.

        Tech Tips

        There are 8 types of No. 2 brake flanges that can be used to adjust the piston stroke. Select one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35678-60020 0 2.0 mm (0.0787 in.)
        35678-60030 1 2.1 mm (0.0827 in.)
        35678-60040 2 2.2 mm (0.0866 in.)
        35678-60050 3 2.3 mm (0.0906 in.)
        35678-60060 4 2.4 mm (0.0945 in.)
        35678-60070 5 2.5 mm (0.0984 in.)
        35678-60080 6 2.6 mm (0.102 in.)
        35678-60090 7 2.7 mm (0.106 in.)

  17. INSTALL NO. 1 BRAKE PISTON


    1. A01FGQ8E11
      Text in Illustration
      *1 O-ring

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

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

      Note

      Be careful not to damage the 2 O-rings.

  18. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A01FHGBE05
      Text in Illustration
      *1 Brake Piston Return Spring Sub-assembly
      *2 No. 1 Brake Cylinder

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

      Tech Tips

      Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.

    2. A01FGBY

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

    3. A01FF4KE06
      Text in Illustration
      *1 Protective Tape

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

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  19. INSTALL CENTER PLANETARY RING GEAR


    1. Install the thrust needle roller bearing to the front planetary ring thrust flange.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      Thrust needle roller bearing 55.7 mm (2.19 in.) 76.4 mm (3.01 in.)
    2. A01FJ1VE02
      Text in Illustration
      *1 Center Planetary Ring Gear
      *2 Front Planetary Ring Thrust Flange
      *3 Front Planetary Ring Gear

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

    3. A01FGGYE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, install the snap ring.

      Note


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

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

      Tech Tips

      Tape the screwdriver tip before use.

  20. INSTALL FRONT PLANETARY RING GEAR


    1. A01FI3M

      Install the front planetary ring gear to the transmission case.

  21. INSTALL FRONT PLANETARY GEAR ASSEMBLY


    1. A01FIFVE15
      Text in Illustration
      *1 No. 2 Planetary Carrier Thrust Washer
      *2 Thrust Needle Roller Bearing
      *3 No. 3 Thrust Bearing Race

      Install the thrust needle roller bearing and the No. 2 planetary carrier thrust washer.

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

      Thrust Needle Roller Bearing and Race Diameter
      Inside Outside
      Thrust needle roller bearing 43.4 mm (1.71 in.) 58.3 mm (2.30 in.)
      No. 3 thrust bearing race 38.0 mm (1.50 in.) 57.0 mm (2.24 in.)
    3. A01FILKE04
      Text in Illustration
      *1 One-way Clutch Inner Race
      *2 Front Planetary Gear Assembly

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

  22. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON


    1. Inspect piston stroke of the No. 1 brake piston.


      1. A01FFJ4

        Make sure that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

        If the No. 1 brake piston does not move smoothly, check the oil path of the transmission case, No. 1 brake piston and O-rings.

      2. A01FGQME02

        Using a vernier caliper, and while applying compression of 4.9 N (0.5 kgf, 1.1 lbf) or less, measure the level difference (dimension A) between the upper surface of the No. 1 brake piston and the contact surface of the No. 1 brake flange at both ends across the No. 1 brake piston diameter.

      3. Using a vernier caliper, measure the thickness (dimension B) of the No. 1 brake flange, 3 No. 1 brake plates and 3 No. 1 brake discs altogether at both ends across a diameter, and calculate the average.

        Tech Tips

        Dimension A = 15.29 to 15.77 mm (0.602 to 0.621 in.)

        Dimension B = 14.72 to 15.12 mm (0.580 to 0.595 in.)

        Piston stroke = Dimension A - Dimension B

        Piston stroke
        0.42 to 0.72 mm (0.0166 to 0.0283 in.)

        If the piston stroke is outside the specified range, parts may have been assembled incorrectly, so check and reassemble them again.

        If the piston stroke is still outside the standard range, select another No. 1 brake flange that brings the piston stroke within the standard range.

        Tech Tips

        There are 4 different thicknesses for the No. 1 brake flange that bring the piston stroke within the specified range.

        Flange Thickness
        Part No. Mark Thickness
        35676-60080 0 2.0 mm (0.0787 in.)
        35676-60090 1 2.2 mm (0.0866 in.)
        35676-60100 2 2.4 mm (0.0945 in.)
        35676-60110 3 2.6 mm (0.102 in.)

  23. INSTALL NO. 1 BRAKE DISC


    1. A01FI7BE08
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate

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

      Installation order
      *1 - *2 - *3 - *2 - *3 - *2 - *3

  24. INSTALL 2ND BRAKE PISTON


    1. A01FHA5E12
      Text in Illustration
      *1 O-ring

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

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

      Note

      Be careful not to damage the 2 O-rings.

    3. A01FGBEE06
      Text in Illustration
      *1 Protective Tape

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

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

      Note


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

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

      Note

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

  25. INSTALL 2ND BRAKE CYLINDER


    1. A01FHQ7

      Install the 2nd brake cylinder to the transmission case.

    2. A01FEBS

      Check that the oil pressure apply hole of the brake cylinder aligns with the oil pressure apply hole of the transmission case.

    3. A01FIK2E05

      Using SST, install the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  26. INSTALL ONE-WAY CLUTCH ASSEMBLY


    1. A01FJ44

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

  27. INSTALL NO. 3 BRAKE DISC SET


    1. A01FDNHE08
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 Cushion Plate
      *4 No. 3 Brake Disc

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

      Installation order
      *1 - *4 - *2 - *4 - *2 - *4 - *2 - *4 - *2 - *3
    2. A01FDM9E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Tape the screwdriver tip before use.

  28. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


    1. A01FIIEE03
      Text in Illustration
      *1 O-ring

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

    2. A01FIDFE05
      Text in Illustration
      *1 No. 2 Clutch Balancer
      *2 Direct Clutch Return Spring Sub-assembly
      *3 Direct Clutch Piston Sub-assembly

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

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

      Note

      Do not damage the 2 O-rings.

    4. A01FGUUE01

      Place SST on the direct clutch piston sub-assembly, and compress the direct clutch return spring sub-assembly with a press.

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

      Note

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

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

      Note


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

      • Do not expand the snap ring excessively.

    6. A01FE0QE08
      Text in Illustration
      *1 Stopper

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

  29. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. A01FDE9E03
      Text in Illustration
      *1 O-ring

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

    2. A01FDTIE03
      Text in Illustration
      *1 O-ring

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

    3. A01FFWQE02
      Text in Illustration
      *1 Reverse Clutch Piston Sub-assembly
      *2 Reverse Clutch Drum Sub-assembly

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

      Note

      Do not damage the O-rings.

  30. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


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

    2. A01FHYME05
      Text in Illustration
      *1 Reverse Clutch Return Spring Sub-assembly
      *2 O-ring
      *3 Reverse Clutch Piston Sub-assembly

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

  31. INSTALL NO. 3 CLUTCH BALANCER


    1. A01FFNNE02

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

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

      SST
      09387-00070

      Note

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

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

      SST
      09350-30020   ( 09350-07070 )

      Note


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


      • Do not expand the snap ring excessively.

    4. A01FGZZE09
      Text in Illustration
      *1 Snap Ring
      *a Correct
      *b Incorrect

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

  32. INSTALL NO. 2 DIRECT CLUTCH DISC SET


    1. A01FHH8E05
      Text in Illustration
      *1 No. 2 Clutch Plate
      *2 No. 2 Direct Clutch Disc
      *3 Reverse Clutch Flange

      Install the reverse clutch flange, 6 No. 2 clutch plates and 5 No. 2 direct clutch discs on the reverse clutch drum sub-assembly.

      Installation order
      *3 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *1
    2. A01FEBGE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, install the 2 snap rings on the reverse clutch drum sub-assembly.

      Note

      Be careful not to damage the reverse clutch drum.

      Tech Tips

      Tape the screwdriver tip before use.

  33. INSPECT PACK CLEARANCE OF NO. 2 DIRECT CLUTCH


    1. A01FHFZE02

      Inspect the pack clearance of the No. 2 direct clutch.


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

        Tech Tips

        Flange moving distance A = 0.36 to 1.24 mm (0.0142 to 0.0488 in.)

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

        Pack clearance
        0.5 to 0.8 mm (0.0197 to 0.0314 in.)

        Note

        Install a selective flange {t = 3.4 mm (0.1339 in.)} when measuring the moving distance (shaded area in the illustration).

      2. If the pack clearance is outside the specified range, select and install a reverse clutch flange that brings the pack clearance within the specified range.

        Tech Tips

        There are 9 types of reverse clutch flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35649-60030 0 3.0 mm (0.118 in.)
        35649-60040 1 3.1 mm (0.122 in.)
        35649-60050 2 3.2 mm (0.126 in.)
        35649-60060 3 3.3 mm (0.130 in.)
        35649-60070 4 3.4 mm (0.134 in.)
        35649-60080 5 3.5 mm (0.138 in.)
        35649-60090 6 3.6 mm (0.142 in.)
        35649-60100 7 3.7 mm (0.146 in.)
        35649-60110 8 3.8 mm (0.150 in.)

  34. INSTALL REVERSE CLUTCH FLANGE


    1. A01FEZD

      Install the reverse clutch flange to the reverse clutch drum sub-assembly.

  35. INSTALL NO. 3 CLUTCH DISC SET


    1. A01FILPE06
      Text in Illustration
      *1 Reverse Clutch Reaction Sleeve
      *2 Clutch Cushion Plate
      *3 Reverse Clutch Flange
      *4 No. 3 Clutch Disc
      *5 No. 3 Clutch Plate

      Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 No. 3 clutch discs and 4 No. 3 clutch plates to the reverse clutch hub sub-assembly.

      Installation order
      *1 - *2 - *3 - *4 - *5 - *4 - *5 - *4 - *5 - *4 - *5 - *4

    2. Using a screwdriver, install the snap ring.

  36. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH


    1. Inspect the pack clearance of the No. 3 clutch.


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

        A01FGSZE02

        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.)

        Pack clearance
        0.5 to 0.8 mm (0.0197 to 0.0314 in.)

        Note

        Install a selective flange {t = 3.3 mm (0.130 in.)} when measuring the moving distance (shaded area in the illustration).

      2. If the pack clearance is outside the specified range, select and install a reverse clutch flange that brings the pack clearance within the specified range.

        Tech Tips

        There are 11 types of reverse clutch flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35649-60010 0 2.8 mm (0.110 in.)
        35649-60020 1 2.9 mm (0.114 in.)
        35649-60030 2 3.0 mm (0.118 in.)
        35649-60040 3 3.1 mm (0.122 in.)
        35649-60050 4 3.2 mm (0.126 in.)
        35649-60060 5 3.3 mm (0.130 in.)
        35649-60070 6 3.4 mm (0.134 in.)
        35649-60080 7 3.5 mm (0.138 in.)
        35649-60090 8 3.6 mm (0.142 in.)
        35649-60100 9 3.7 mm (0.146 in.)
        35649-60110 A 3.8 mm (0.150 in.)

  37. REMOVE REVERSE CLUTCH REACTION SLEEVE


    1. A01FGJQE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01FG10E02

      Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 No. 3 reverse clutch discs and 4 No. 3 clutch plates from the reverse clutch hub sub-assembly.

  38. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01FGT1E03
      Text in Illustration
      *1 Coast Clutch Piston
      *2 Forward Clutch Piston Sub-assembly

      Install the coast clutch piston to the forward clutch piston sub-assembly.

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

    3. Install the forward clutch piston sub-assembly to the input shaft.

  39. INSTALL NO. 1 CLUTCH BALANCER


    1. A01FIKME03
      Text in Illustration
      *1 D-ring

      Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.

    2. A01FENLE02
      Text in Illustration
      *1 No. 1 Clutch Balancer
      *2 Forward Clutch Return Spring Sub-assembly

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

      Note

      Do not damage the D-ring.

    3. A01FGL8E01

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

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

      Note

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

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

      Note


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


      • Do not expand the snap ring excessively.

    5. A01FJ3CE05
      Text in Illustration
      *1 Snap Ring
      *a Correct
      *b Incorrect

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

  40. INSTALL COAST CLUTCH DISC SET


    1. A01FEKPE05
      Text in Illustration
      *1 Reverse Clutch Flange
      *2 Coast Clutch Plate
      *3 Coast Clutch Disc

      Install the reverse clutch flange, 3 coast clutch discs and 3 coast clutch plates to the forward clutch piston sub-assembly.

      Installation order
      *1 - *3 - *2 - *3 - *2 - *3 - *2

    2. Using a screwdriver, install the snap ring.

  41. INSPECT PACK CLEARANCE OF COAST CLUTCH


    1. A01FDAFE02

      Inspect the pack clearance of the coast clutch hub sub-assembly.


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

        Tech Tips

        Flange moving distance A = 0.38 to 1.48 mm (0.0150 to 0.0582 in.)

        Pack clearance = Flange moving distance A - 0.02 mm (0.000787 in.)

        Pack clearance
        0.3 to 0.6 mm (0.0119 to 0.0236 in.)

        Note

        Install a selective flange {t = 3.0 mm (0.118 in.)} when measuring the moving distance (shaded area in the illustration).

      2. If the pack clearance is outside the specified range, select and install a reverse clutch flange that brings the pack clearance within the specified range.

        Tech Tips

        There are 10 types of reverse clutch flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35675-50010 1 3.0 mm (0.118 in.)
        35675-50020 2 3.1 mm (0.122 in.)
        35675-50030 3 3.2 mm (0.126 in.)
        35675-50040 4 3.3 mm (0.130 in.)
        35675-50050 5 3.4 mm (0.134 in.)
        35675-50060 6 3.5 mm (0.138 in.)
        35675-50070 7 3.6 mm (0.142 in.)
        35675-50080 8 3.7 mm (0.146 in.)
        35675-50090 9 3.8 mm (0.150 in.)
        35675-50100 A 3.9 mm (0.154 in.)

  42. INSTALL NO. 1 CLUTCH DISC


    1. A01FEXNE05
      Text in Illustration
      *1 Flange
      *2 No. 1 Clutch Plate
      *3 Clutch Cushion Plate
      *4 No. 1 Clutch Disc

      Install the flange, 4 No. 1 clutch discs, 4 No. 1 clutch plates and clutch cushion plate to the forward clutch piston sub-assembly.

      Installation order
      *1 - *4 - *2 - *4 - *2 - *4 - *2 - *4 - *2 - *3
    2. A01FGJQE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, install the snap ring.

      Note

      Be careful not to damage the input shaft.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01FF7YE03
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race
      *3 Reverse Clutch Drum Sub-assembly

      Install the thrust needle roller bearing and thrust bearing race.

      Thrust Needle Roller Bearing and Race Diameter
      Inside Outside
      Thrust needle roller bearing 34.6 mm (1.36 in.) 52.0 mm (2.05 in.)
      Thrust bearing race 37.0 mm (1.46 in.) 52.3 mm (2.06 in.)

  43. INSTALL INPUT SHAFT OIL SEAL RING


    1. A01FDSO

      Coat 4 new input shaft oil seal rings with ATF.

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

      Note

      Do not expand the ring ends excessively.

      Tech Tips

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

  44. INSPECT PACK CLEARANCE OF NO. 1 CLUTCH


    1. Inspect the pack clearance of the No. 1 clutch.


      1. A01FGWUE02

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

        Tech Tips

        Flange moving distance A = 0.36 to 1.50 mm (0.0142 to 0.0590 in.)

        Pack clearance = Flange moving distance A - 0.11 mm (0.00433 in.)

        Pack clearance
        0.56 to 0.86 mm (0.0221 to 0.0338 in.)

        Note

        Install a selective flange {t = 3.4 mm (0.134 in.)} when measuring the moving distance (shaded area in the illustration).

      2. If the pack clearance is outside the specified range, select and install a reverse clutch flange that brings the pack clearance within the specified range.

        Tech Tips

        There are 11 types of reverse clutch flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35635-60010 0 3.0 mm (0.118 in.)
        35635-60020 1 3.1 mm (0.122 in.)
        35635-60030 2 3.2 mm (0.126 in.)
        35635-60040 3 3.3 mm (0.130 in.)
        35635-60050 4 3.4 mm (0.134 in.)
        35635-60060 5 3.5 mm (0.138 in.)
        35635-60070 6 3.6 mm (0.142 in.)
        35635-60080 7 3.7 mm (0.146 in.)
        35635-60090 8 3.8 mm (0.150 in.)
        35635-60100 9 3.9 mm (0.154 in.)
        35635-60110 A 4.0 mm (0.158 in.)

  45. INSTALL INPUT SHAFT


    1. A01FI3O

      Install the input shaft to the reverse clutch drum sub-assembly.

    2. A01FFZ3

      Install the thrust needle roller bearing to the reverse clutch drum sub-assembly.

      Thrust Needle Roller Bearing Diameter
      Inside Outside
      Thrust needle roller bearing 21.3 mm (0.839 in.) 41.1 mm (1.62 in.)

  46. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY


    1. A01FISHE05
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Coast Clutch Hub Sub-assembly
      *3 Clutch Hub Thrust Washer
      *4 Underdrive One-way Clutch Assembly

      Install the underdrive one-way clutch assembly, clutch hub thrust washer and thrust bearing race to the coast clutch hub sub-assembly.

      Bearing and Race Diameter
      Inside Outside
      Input shaft rear thrust bearing race 22.6 mm (0.890 in.) 44.8 mm (1.76 in.)
    2. A01FGUS

      Install the coast clutch hub sub-assembly to the reverse clutch drum sub-assembly.

  47. INSTALL CLUTCH HUB SUB-ASSEMBLY


    1. A01FIVTE01
      Text in Illustration
      *1 Bearing A
      *2 Bearing B

      Install the 2 thrust needle roller bearings to the clutch hub sub-assembly.

      Bearing and Race Diameter
      Inside Outside
      Bearing A 42.5 mm (1.67 in.) 61.2 mm (2.41 in.)
      Bearing B 35.6 mm (1.40 in.) 56.6 mm (2.23 in.)
    2. A01FES1E03
      Text in Illustration
      *1 Clutch Hub Sub-Assembly
      *2 Clutch Hub Thrust Washer

      Install the clutch hub thrust washer and clutch hub sub-assembly to the reverse clutch drum sub-assembly.

  48. INSTALL NO. 3 CLUTCH DISC


    1. A01FGJ6E19
      Text in Illustration
      *1 Cushion Plate
      *2 Reverse Clutch Flange
      *3 No. 3 Clutch Plate
      *4 No. 3 Clutch Disc

      Install the clutch cushion plate, reverse clutch flange, 4 No. 3 clutch plates and 5 No. 3 clutch discs to the reverse clutch hub sub-assembly.

      Installation order
      *1 - *2 - *4 - *3 - *4 - *3 - *4 - *3 - *4 - *3 - *4

  49. INSTALL REVERSE CLUTCH REACTION SLEEVE


    1. A01FIY9

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

  50. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A01FIXHE02

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

    2. A01FE4QE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  51. INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY


    1. A01FFV4E03
      Text in Illustration
      *1 No. 2 One-way Clutch Assembly
      *2 No. 2 Clutch Drum Thrust Washer
      *3 Clutch Drum and Input Shaft

      Install the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer to the clutch drum and input shaft.

  52. INSTALL CLUTCH DRUM AND INPUT SHAFT


    1. A01FIASE14
      Text in Illustration
      *1 Thrust Needle Roller Bearing A
      *2 Bearing Race
      *3 Thrust Needle Roller Bearing B
      *4 No. 2 Clutch Drum Thrust Washer

      Install the 2 thrust needle roller bearings and No. 2 clutch drum thrust washer.

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

      Thrust Needle Roller Bearing and Race Diameter
      Inside Outside
      Thrust needle roller bearing A 71.9 mm (2.83 in.) 85.6 mm (3.37 in.)
      Thrust needle roller bearing B 34.6 mm (1.36 in.) 52.0 mm (2.05 in.)
      Bearing Race 37.0 mm (1.46 in.) 52.3 mm (2.06 in.)
    3. A01FEZA

      Install the clutch drum and input shaft into the transmission case.

  53. INSTALL OIL PUMP ASSEMBLY


    1. A01FHO3

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

      Thrust Bearing Race Diameter
      Inside Outside
      Thrust bearing race 74.2 mm (2.92 in.) 87.74 mm (3.45 in.)
    2. A01FGCWE04
      Text in Illustration
      *1 O-ring

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

    3. Place the oil pump assembly 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 assembly to slide the input shaft oil seal rings into the clutch drum and input shaft.

    5. A01FE81

      Install the 10 bolts.

      Torque:
      21 N*m  { 215 kgf*cm, 16 ft.*lbf }

  54. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


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

    2. A01FEHGE02
      Text in Illustration
      *a RH Side
      *b LH Side

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

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

  55. INSPECT INDIVIDUAL PISTON OPERATION


    1. A01FIEKE07
      Text in Illustration
      *1 No. 1 Clutch
      *2 No. 2 Clutch
      *3 No. 3 Clutch
      *4 No. 4 Clutch
      *5 No. 1 Brake
      *6 No. 2 Brake
      *7 No. 3 Brake
      *8 No. 4 Brake (In)
      *9 No. 4 Brake (Out)

      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 the operating sound with the C3 accumulator piston hole closed.

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


      1. No. 2 Clutch (C2)

      2. No. 4 Clutch (C4)

      3. No. 3 Clutch (C3)

      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)

  56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A01FDX9E07
      Text in Illustration
      *1 Manual Valve Lever
      *2 Spacer

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

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

    3. A01FGBO

      Using a hammer, drive in a new spring pin.

    4. A01FGB4

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

    5. Make sure that the shaft rotates smoothly.

  57. INSTALL PARKING LOCK PAWL SHAFT


    1. A01FDZVE12
      Text in Illustration
      *1 Parking Lock Pawl
      *2 E-ring
      *3 Parking Lock Pawl Shaft
      *4 Spring

      Install a new E-ring to the parking lock pawl shaft.

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

  58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01FETV

      Connect the parking lock rod sub-assembly to the manual valve lever sub-assembly.

  59. INSTALL PARKING LOCK PAWL BRACKET


    1. A01FI4R

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

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
    2. A01FFYSE07
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Planetary Ring Gear
      *3 Parking Lock Pawl

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

  60. INSTALL B-1 ACCUMULATOR VALVE


    1. A01FISN
      A01FIBAE03

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

      B-1 Accumulator Spring
      Inner Spring
      Free Length Outer Diameter Color
      44.98 mm (1.77 in.) 11.30 mm (0.445 in.) Natural
      Outer Spring
      Free Length Outer Diameter Color
      46.36 mm (1.83 in.) 17.10 mm (0.673 in.) Natural
      Text in Illustration
      *1 Outer Spring
      *2 Inner Spring

  61. INSTALL C-3 ACCUMULATOR PISTON


    1. A01FDBB

      Using a screwdriver, install the spring sub-assembly to the C-3 accumulator piston with the snap ring.

      C-3 Accumulator Spring Sub-assembly
      Free Length Coil Outer Diameter Color
      23.0 mm (0.906 in.) 14.0 mm (0.551 in.) Pink

      Note

      Be careful not to damage the C-3 accumulator piston.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01FHL4E04

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

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

      C-3 Accumulator Spring
      Inner Spring
      Free Length Outer Diameter Color
      44.0 mm (1.73 in.) 14.0 mm (0.551 in.) Yellow
      Outer Spring
      Free Length Outer Diameter Color
      76.65 mm (3.02 in.) 20.10 mm (0.791 in.) Natural
      Text in Illustration
      *1 Outer Spring
      *2 Inner Spring
      *3 O-ring

  62. INSTALL B-3 ACCUMULATOR PISTON


    1. A01FDBB

      Using a screwdriver, install the spring sub-assembly to the B-3 accumulator piston with the snap ring.

      B-3 Accumulator Spring Sub-assembly
      Free Length Coil Outer Diameter Color
      30.0 mm (1.181 in.) 16.2 mm (0.638 in.) White

      Note

      Be careful not to damage the B-3 accumulator piston.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01FIPPE04

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

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

      Accumulator Spring
      Free Length Outer Diameter Color
      64.5 mm (2.54 in.) 19.5 mm (0.768 in.) Orange
      Text in Illustration
      *1 B-3 Accumulator Piston
      *2 Spring
      *3 O-ring

  63. INSTALL C-2 ACCUMULATOR PISTON


    1. A01FDBB

      Using a screwdriver, install the spring sub-assembly to the C-2 accumulator piston with the snap ring.

      C-2 Accumulator Spring Sub-assembly
      Free Length Coil Outer Diameter Color
      18.50 mm (0.728 in.) 14.0 mm (0.551 in.) Green

      Note

      Be careful not to damage the C-2 accumulator piston.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01FHJIE04

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

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

      Accumulator Spring
      Free Length Outer Diameter Color
      63.14 mm (2.49 in.) 16.0 mm (0.630 in.) Light Gray
      Text in Illustration
      *1 C-2 Accumulator Piston
      *2 Spring
      *3 O-ring

  64. INSTALL CHECK BALL BODY


    1. A01FIFPE10
      Text in Illustration
      *1 Check Ball Body
      *2 Spring

      Install the check ball body and spring.

  65. INSTALL BRAKE DRUM GASKET


    1. A01FJ52

      Install 3 new brake drum gaskets.

  66. INSTALL TRANSAXLE CASE GASKET


    1. A01FEW2E11

      Install 3 new transaxle case gaskets.

  67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


    1. A01FFWIE08
      Text in Illustration
      *1 Pin

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

    2. A01FI9KE03

      Install the 20 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      Bolt A
      25 mm (0.984 in.)
      Bolt B
      36 mm (1.42 in.)
      Bolt C
      45 mm (1.77 in.)
      Bolt D
      50 mm (1.97 in.)
    3. A01FF73

      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. A01FGH6E05
      Text in Illustration
      *1 O-ring

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

    2. A01FJ2F

      Install the transmission wire with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    3. A01FHLD

      Connect the 9 solenoid valve connectors.

    4. Coat the ATF temperature sensor O-ring with ATF.

    5. A01FG08

      Install the ATF temperature sensor and the temperature sensor clamp with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    6. A01FJ42E01

      Install the 2 valve body wire harness clamps with the 2 bolts.

      Torque:
      Bolt A
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }
      Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


    1. A01FDGFE10
      Text in Illustration
      *1 O-ring

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

    2. A01FF3T

      Install the valve body oil strainer assembly with the 4 bolts.

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

  70. INSTALL TRANSMISSION OIL CLEANER MAGNET


    1. A01FEFBE05
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

      Install the 3 transmission oil cleaner magnets.

  71. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Install a new automatic transmission oil pan gasket on the automatic transmission oil pan sub-assembly.

    2. A01FG5K

      Install and tighten the 20 bolts.

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

    3. Install a new gasket and the drain plug.

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

    4. Install a new gasket and the overflow plug.

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

  72. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. Coat the lip of a new automatic transmission extension housing oil seal with MP grease.

    2. A01FI1GE01

      Using SST and a hammer, install the automatic transmission extension housing oil seal.

      SST
      09316-60011   ( 09316-00011, 09316-00051 )
      Oil seal drive in depth
      1.8 to 2.2 mm (0.0709 to 0.0866 in.)

  73. INSTALL TRANSMISSION CASE ADAPTER RADIAL BALL BEARING


    1. A01FG6CE01

      Install the transmission case adapter radial ball bearing to the extension housing sub-assembly.

  74. INSTALL REAR COVER SLEEVE


    1. A01FDM6

      Install the 2 washers and rear cover sleeve to the output shaft.

  75. INSTALL EXTENSION HOUSING SUB-ASSEMBLY


    1. A01FIE2

      Install the thrust needle roller bearing and 2 bearing races.

    2. Using a snap ring expander, install the snap ring.

    3. A01FG6E

      Using a feeler gauge, measure the clearance between the snap ring and the bearing race.

      Clearance
      0.02 to 0.12 mm (0.000787 to 0.00472 in.)

      If the clearance is outside the specified range, select another bearing race that brings the clearance within the specified range.

      Tech Tips

      There are 12 different thicknesses for the bearing race.

      Race Thickness
      Part No. Mark Thickness
      35789-35060 A01FELI 3.80 mm (0.150 in.)
      35789-50070 A01FI7G 3.85 mm (0.152 in.)
      35789-35070 A01FHEW 3.90 mm (0.154 in.)
      35789-50080 A01FGK7 3.95 mm (0.156 in.)
      35789-35080 A01FFU5 4.00 mm (0.157 in.)
      35789-50090 A01FGR7 4.05 mm (0.159 in.)
      35789-35090 A01FG2W 4.10 mm (0.161 in.)
      35789-50100 A01FFE7 4.15 mm (0.163 in.)
      35789-35100 A01FDRN 4.20 mm (0.165 in.)
      35789-50110 A01FFUI 4.25 mm (0.167 in.)
      35789-50120 A01FGUR 4.30 mm (0.169 in.)
      35789-50130 A01FDGY 4.35 mm (0.171 in.)

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

    5. A01FG29E08
      Text in Illustration
      *a Seal Packing

      Apply seal packing to the extension housing sub-assembly as shown in the illustration.

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

    6. Apply a few drops of adhesive to 2 or 3 threads of each of the 6 bolts.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    7. A01FEQ8E08

      Install the extension housing sub-assembly with 6 bolts.

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

      Tech Tips

      Each bolt length is indicated below.

      Bolt length
      Bolt A
      35 mm (1.38 in.)
      Bolt B
      45 mm (1.77 in.)

  76. INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY


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

    2. A01FI18E01

      Using SST, install the oil seal to the automatic transmission flange yoke assembly.

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )
      Oil seal drive in depth
      0 to 0.3 mm (0 to 0.0118 in.)

    3. Install the automatic transmission flange yoke assembly to the output shaft with a new lock nut.

      Torque:
      126 N*m  { 1280 kgf*cm, 93 ft.*lbf }

    4. Using a hammer and chisel, stake the nut.

  77. INSTALL AUTOMATIC TRANSMISSION HOUSING


    1. A01FGYV

      Install the automatic transmission housing to the transmission case with the 6 bolts.

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

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

      Adhesive:
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    4. A01FE1RE01

      Install the automatic transmission housing with the 4 bolts.

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

  78. INSTALL AUTOMATIC TRANSMISSION CASE PLUG


    1. A01FHWV

      Coat a new O-ring with ATF, and install it to the automatic transmission case plug.

    2. Using a T55 "TORX" socket wrench, install the automatic transmission case plug to the automatic transmission case sub-assembly.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
    3. A01FH52

      Coat 5 new O-ring with ATF, and install it to the 5 automatic transmission case plug.

    4. Install the 5 automatic transmission case plugs to the automatic transmission case sub-assembly.

      Torque:
      7.4 N*m  { 75 kgf*cm, 68 in.*lbf }

  79. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE


    1. A01FF2V

      Install the automatic transmission breather tube.

    2. Install the 2 bolts.

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

  80. INSTALL TRANSMISSION REVOLUTION SENSOR


    1. A01FHMHE01

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

    2. Install the 2 transmission revolution sensors.

    3. Install the 2 bolts.

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

  81. INSTALL OIL COOLER TUBE UNION (w/o ATF Warmer)


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

    2. A01FIMQE01
      Text in Illustration
      *a -2 to 2°

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

      Torque:
      29 N*m  { 300 kgf*cm, 22 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

  82. INSTALL TRANSMISSION OIL COOLER (w/ ATF Warmer)


    1. A01FFQAE02
      Text in Illustration
      *1 O-ring
      *2 Spacer

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

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

    3. A01FHMP

      Install the spacer and transmission oil cooler with the 3 bolts.

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

  83. 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 assembly as the detent spring may become detached from the manual valve lever shaft.


    1. Clean the bolt and the bolt hole.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A01FIMA

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

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

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }
    5. A01FHS4E01

      Using the transmission control shaft lever RH, turn the manual lever shaft all the way back and then forward 2 notches to select the neutral position.

    6. A01FE9LE28
      Text in Illustration
      *1 Neutral Basic Line
      *2 Groove

      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 }
    7. A01FE8PE01

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

      Tech Tips

      Bend at least 2 of the lock washer tabs.

  84. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH


    1. A01FIRE

      Install the transmission control shaft lever RH, spring washer and nut.

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

  85. INSTALL REFILL PLUG


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

    2. Install the refill plug.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  86. INSTALL TRANSMISSION CASE COVER


    1. A01FDXB

      Install the transmission case cover with the 2 bolts.

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