Automatic Transmission Unit Reassembly

Install the transmission case to an overhaul attachment.

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

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

Install the No. 1 brake piston to the reaction sleeve.

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

NOTICE:

Be careful not to damage the O-rings.

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

With the spring seat of the piston facing upward (the front side), install the piston to the transmission case.

NOTICE:

Be careful not to damage the O-ring.

Install the return spring to the brake piston.

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

SST

09350-30020(09350-07050)

Using SST, install the snap ring. Make sure the end gap of the snap ring is not aligned with a return spring claw.

SST

09350-30020(09350-07070)

Make sure the first and reverse brake pistons move smoothly when compressed air is applied into the transmission case.

Coat the No. 2 planetary carrier thrust washer with petroleum jelly.

Install the No. 2 planetary carrier thrust washer to the rear planetary gear.

HINT:

Make sure that the tabs of the washer fit into the cutout portions of the rear planetary gear.

Install the 1-way clutch to the rear planetary gear.

HINT:

Make sure that the open ends of the guides of the 1-way clutch are facing upward.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the rear planetary gear.

HINT:

Tape the screwdriver tip before use.

While turning the 1-way clutch inner race counterclockwise, install the 1-way clutch inner race to the planetary gear.

Hold the planetary gear and turn the 1-way clutch inner race. Check that the 1-way clutch inner race can be turned counterclockwise freely and locks when turned clockwise.

Text in Illustration

	Lock
	Free

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

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the rear planetary ring gear.

HINT:

Tape the screwdriver tip before use.

Coat the bearing and bearing race with petroleum jelly and install them to the rear planetary ring gear.

Bearing and Bearing Race Diameter:

Item	Inside	Outside
Bearing H	27.65 to 27.8 mm (1.089 to 1.094 in.)	44.2 mm (1.74 in.)
Bearing Race H	28.5 mm (1.12 in.)	44.2 mm (1.74 in.)

Coat the No. 1 planetary carrier thrust washer with petroleum jelly.

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

HINT:

Make sure that the tabs of the washer fit into the cutout portions of the planetary gear.

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

Coat a new oil seal ring with ATF and install it to the output shaft.

HINT:

After installing the oil seal ring, check that it rotates smoothly.

NOTICE:

Do not expand the ring excessively.

Install the output shaft to the rear planetary gear flange.

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

Being careful not to damage the O-rings, press the second brake piston toward the second brake drum with both hands.

Install the piston return spring.

Install the second brake piston return spring seat.

Place SST on the spring seat and compress the return spring with a press.

SST

09350-30020(09350-07040)

NOTICE:

Do not deform the spring seat. Stop compressing the spring when the spring seat is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove.

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

Check that the second brake piston moves smoothly when applying compressed air to and releasing low-pressure compressed air from the second brake drum.

Coat the thrust washer with petroleum jelly and install it.

HINT:

Make sure that the cutout portions of the thrust washer fit onto the teeth of the spring seat.

Install the flange with the rounded edge facing upward.

Install the 6 discs and 6 plates.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3

Coat the bearing with petroleum jelly and install it to the case.

Bearing Diameter:

Item	Inside	Outside
Bearing I	39.38 mm (1.55 in.)	57.94 to 58.24 mm (2.282 to 2.292 in.)

NOTICE:

Make sure the bearing is installed facing the proper direction.

Align the teeth on the flange, discs and plates.

Install the second brake drum to the planetary gear with the snap ring facing upwards.

NOTICE:

Make sure the oil hole in the drum faces towards the lower side of the transmission case (the side where the valve body is installed).

Align the teeth of the planetary gear assembly, indicated by A in the illustration, with the splines of the transmission case, indicated by B in the illustration.

Install the assembled planetary gear.

Place the output shaft on wooden blocks.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Using a feeler gauge, measure the clearance between the plate and second brake drum.

Standard clearance:

0.70 to 1.22 mm (0.0276 to 0.0480 in.)

Flange Thickness:

Mark	Thickness
55	3.94 to 4.06 mm (0.156 to 0.159 in.)
54	4.14 to 4.26 mm (0.163 to 0.167 in.)
53	4.34 to 4.46 mm (0.171 to 0.175 in.)
52	4.54 to 4.66 mm (0.179 to 0.183 in.)
51	4.74 to 4.86 mm (0.187 to 0.191 in.)
50	4.92 to 5.08 mm (0.194 to 0.199 in.)
66	5.10 to 5.30 mm (0.201 to 0.208 in.)
67	5.30 to 5.50 mm (0.209 to 0.216 in.)

Coat a new gasket with ATF and install it.

Install the 1-way clutch as shown in the illustration.

Install the plate (A) with the rounded edge of the plate facing the discs.

Plate Thickness:

Item	Specified Condition
Plate (A)	1.8 mm (0.0709 in.)
Plate (B)	2.5 mm (0.0984 in.)

Install the 5 discs, 5 plates and flange.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *4

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Tape the screwdriver tip before use.

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

Standard clearance:

0.62 to 1.98 mm (0.0244 to 0.0780 in.)

Using a screwdriver, install the snap ring to the planetary sun gear.

NOTICE:

Be careful not to damage the front planetary sun gear sub-assembly.

HINT:

Tape the screwdriver tip before use.

Place the planetary sun gear onto a wooden block or similar object.

Install the input drum to the planetary sun gear.

Using snap ring pliers, install the snap ring.

Coat 2 new oil seal rings with ATF.

Install the 2 oil seal rings to the planetary sun gear.

NOTICE:

Do not expand the rings excessively.

HINT:

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

While turning the sun gear clockwise, install it to the 1-way clutch.

HINT:

Confirm that the thrust washer is installed correctly.

Coat the bearing and bearing race with petroleum jelly and install them to the planetary gear.

Bearing and Bearing Race Diameter:

Item	Inside	Outside
Bearing Race G	33.55 to 33.80 mm (1.321 to 1.330 in.)	47.3 to 47.8 mm (1.87 to 1.88 in.)
Bearing G	35.45 to 35.61 mm (1.396 to 1.401 in.)	47.62 to 47.87 mm (1.875 to 1.884 in.)

Text in Illustration

*1	Bearing Race G
*2	Bearing G

NOTICE:

Make sure the bearing and race are installed facing the proper directions.

Install the planetary gear to the sun gear input drum.

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

Remove the wooden blocks from under the output shaft.

Coat the bearing race with petroleum jelly and install it to the planetary gear.

Bearing Race Diameter:

Item	Inside	Outside
Bearing Race F	34 to 34.5 mm (1.34 to 1.35 in.)	48.5 to 49 mm (1.91 to 1.92 in.)

NOTICE:

Make sure the bearing race is installed facing the proper direction.

Install the brake band to the case.

Install the pin to the brake band as shown in the illustration.

Install the E-ring to the pin.

Coat the 3 new oil seal rings with ATF.

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

NOTICE:

Do not squeeze the rings excessively.

HINT:

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

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

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

Press the clutch piston into the input shaft with both hands to install it.

NOTICE:

Be careful not to damage the O-ring.

Install the piston return spring.

Place SST on the return spring, compress the return spring with a press, and then install the snap ring.

SST

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

NOTICE:

Make sure the end gap of the snap ring is not aligned with the return spring claw.

Install the cushion plate.

Install the 5 plates, 5 discs and flange.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3

Using a screwdriver, install the snap ring.

NOTICE:

1. Make sure the end gap of the snap ring is not aligned with the cutout portion of the input shaft sub-assembly.
   
2. Be careful not to damage the input shaft sub-assembly.
   

HINT:

Tape the screwdriver tip before use.

Using SST and a dial indicator, measure the piston stroke (A) of the clutch flange at both ends across the diameter while applying and releasing compressed air (392 kPa (4.0 kgf/cm², 57 psi))

SST

09350-30020(09350-06120)

Standard piston stroke (A):

0.60 to 1.00 mm (0.0237 to 0.0394 in.)

Flange Thickness:

Mark	Thickness
90	2.95 to 3.05 mm (0.117 to 0.120 in.)
91	3.15 to 3.25 mm (0.125 to 0.127 in.)
92	3.35 to 3.45 mm (0.132 to 0.135 in.)
93	3.55 to 3.65 mm (0.140 to 0.143 in.)
94	3.75 to 3.85 mm (0.148 to 0.151 in.)
95	3.95 to 4.05 mm (0.156 to 0.159 in.)
96	4.15 to 4.25 mm (0.164 to 0.167 in.)
97	4.35 to 4.45 mm (0.172 to 0.175 in.)

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

Press the clutch piston into the clutch drum with both hands to install it.

NOTICE:

Be careful not to damage the O-rings.

Install the direct clutch return spring.

Place SST on the return spring and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

NOTICE:

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

Install the 3 plates and 3 discs.

Install the flange with the flat end facing downward.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *3

Using a screwdriver, install the snap ring.

NOTICE:

1. Make sure the end gap of the snap ring is not aligned with the cutout portion of the direct clutch drum.
   
2. Be careful not to damage the direct clutch drum.
   

HINT:

Tape the screwdriver tip before use.

Place the direct clutch onto the overdrive support.

Using SST and a dial indicator, measure the piston stroke (A) of the clutch flange at both ends across the diameter while applying and releasing compressed air (186 to 206 kPa (1.9 to 2.1 kgf/cm², 27 to 30 psi)).

SST

09350-30020(09350-06120)

Standard piston stroke (A):

0.40 to 0.70 mm (0.0158 to 0.0276 in.)

Flange Thickness:

Mark	Thickness
53	3.25 to 3.35 mm (0.128 to 0.131 in.)
54	3.35 to 3.45 mm (0.132 to 0.135 in.)
55	3.45 to 3.55 mm (0.136 to 0.139 in.)
56	3.55 to 3.65 mm (0.140 to 0.143 in.)
57	3.65 to 3.75 mm (0.144 to 0.147 in.)
58	3.75 to 3.85 mm (0.148 to 0.151 in.)

Install the thrust washer to the input shaft.

Install the direct clutch to the input shaft.

Coat the bearing race and bearing with petroleum jelly and install them to the input shaft.

Bearing and Bearing Race Diameter:

Item	Inside	Outside
Bearing Race E	25.98 mm (1.02 in.)	48.87 mm (1.92 in.)
Bearing E	25.94 to 26.07 mm (1.022 to 1.026 in.)	46.62 to 46.87 mm (1.835 to 1.845 in.)

NOTICE:

Make sure the bearing and race are installed facing the proper directions.

Coat the bearing race with petroleum jelly and install it to the front planetary ring gear.

Bearing Race Diameter:

Item	Inside	Outside
Bearing Race E	26.5 to 27.0 mm (1.044 to 1.062 in.)	47.02 mm (1.85 in.)

NOTICE:

Make sure the bearing race is installed facing the proper direction.

Align the teeth of the discs in the forward clutch.

Align the splines of the planetary ring gear with the teeth of the discs and install the planetary ring gear to the forward clutch.

Coat the bearing with petroleum jelly and install it to the ring gear.

Bearing Diameter:

Item	Inside	Outside
Bearing F	35 to 35.3 mm (1.378 to 1.389 in.)	53.50 to 53.75 mm (2.107 to 2.116 in.)

NOTICE:

Make sure the bearing is installed facing the proper direction.

Install the assembled direct clutch, forward clutch and front planetary ring gear to the transmission case.

Using a vernier caliper, measure the distance between the sun gear input drum and direct clutch drum as shown in the illustration.

Standard distance:

5.3 to 7.3 mm (0.209 to 0.287 in.)

Coat the bearing with petroleum jelly and install it to the forward clutch.

Bearing Diameter:

Item	Inside	Outside
Bearing D	33.55 to 33.80 mm (1.321 to 1.330 in.)	47.62 to 47.87 mm (1.875 to 1.884 in.)

NOTICE:

Make sure the bearing is installed facing the proper direction.

Install the washer plate, compression spring and piston to the piston rod.

Firmly press the piston down to compress the compression spring.

Install the E-ring.

Coat a new oil seal ring with ATF.

Spread the ends of the ring to install the oil seal ring to the piston groove. Then squeeze its ends together.

NOTICE:

Do not spread the ring ends excessively.

Coat 2 new O-rings with ATF and install them to the second coast brake cover.

Install a new spring, piston assembly and cover to the case.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Using a waterproof pen, place a mark on the second coast brake piston rod as shown in the illustration.

Using SST, measure the piston stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm², 57 psi)).

SST

09240-00020

Standard piston stroke:

1.5 to 3.0 mm (0.0591 to 0.118 in.)

Piston Rod Length:

Groove Mark	Length
Without	78.3 to 78.5 mm (3.083 to 3.090 in.)
With	79.8 to 80.0 mm (3.142 to 3.149 in.)

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

Press the brake piston into the overdrive support with both hands to install it.

NOTICE:

Be careful not to damage the O-rings.

Install the return spring to the brake piston.

Place SST on the return spring and compress the return spring with a press.

SST

09350-30020(09350-07030)

Using a screwdriver, install the snap ring.

NOTICE:

1. Make sure the end gap of the snap ring is not aligned with the cutout portion of the overdrive support.
   
2. Be careful not to damage the overdrive support sub-assembly and return spring.
   

HINT:

1. After assembling the overdrive support assembly completely, align the position of the piston with A in the illustration.
   
2. Align the end gap of the snap ring with B in the illustration.
   
3. Make sure that the snap ring is not on top of the part of the return spring that prevents the snap ring from coming off. Check this in all 8 locations.
   
4. Tape the screwdriver tip before use.
   

Place the overdrive support assembly onto the direct clutch assembly.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) into the oil passage and check that the overdrive brake piston moves smoothly.

Coat 2 new oil seal rings with ATF.

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

NOTICE:

Do not squeeze the rings excessively.

HINT:

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

Coat the bearing and bearing race with petroleum jelly and install them to the overdrive brake assembly.

Bearing and Bearing Race Diameter:

Item	Inside	Outside
Bearing C	33.75 to 33.85 mm (1.329 to 1.332 in.)	49.8 to 50.3 mm (1.961 to 1.980 in.)
Bearing Race D	36.5 to 37 mm (1.44 to 1.45 in.)	50.75 to 50.95 mm (1.999 to 2.005 in.)

NOTICE:

Make sure the bearing and race are installed facing the proper directions.

Coat the thrust washer with petroleum jelly and install it to the overdrive support.

HINT:

Make sure that the tab of the washer fits into the groove of the overdrive support.

Using the 2 bolts of SST, aim the bolt and oil holes of the overdrive brake assembly toward the valve body side, and align them with the bolt holes of the transmission case. Then install the overdrive brake assembly.

SST

09350-30020(09350-07020)

Temporarily install the 2 bolts.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Standard distance A:

24 mm (0.945 in.)

HINT:

Install the snap ring with the open end facing toward the valve body.

Tighten the 2 bolts.

Torque:

25 N*m{260 kgf*cm, 19 ft.*lbf}

Using a dial indicator, measure the end play of the output shaft while moving it by hand.

Standard end play:

0.30 to 1.04 mm (0.0119 to 0.0409 in.)

Check that the output shaft rotates smoothly.

Install the 4 plates, 4 discs and flange.

Install in order:

*1 - *2 -*1 - *2 - *1 - *2 - *1 - *2 - *3

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Tape the screwdriver tip before use.

Place SST and a dial indicator on the overdrive brake piston.

SST

09350-30020(09350-06120)

Measure the stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm², 57 psi))

Standard piston stroke:

1.75 to 2.05 mm (0.0689 to 0.0807 in.)

Flange Thickness:

Mark	Thickness
33	3.25 to 3.35 mm (0.128 to 0.131 in.)
35	3.45 to 3.55 mm (0.136 to 0.139 in.)
36	3.55 to 3.65 mm (0.140 to 0.143 in.)
37	3.65 to 3.75 mm (0.144 to 0.147 in.)
38	3.75 to 3.85 mm (0.148 to 0.151 in.)
39	3.85 to 3.95 mm (0.152 to 0.155 in.)
40	3.95 to 4.05 mm (0.156 to 0.159 in.)

Install the ring gear flange to the overdrive planetary ring gear.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the overdrive planetary ring gear and the flange.

HINT:

Tape the screwdriver tip before use.

Coat the bearing race with petroleum jelly and install it to the overdrive planetary ring gear flange.

Bearing Race Diameter:

Item	Inside	Outside
Bearing Race C	37.1 to 37.3 mm (1.461 to 1.468 in.)	58.70 to 58.95 mm (2.311 to 2.320 in.)

NOTICE:

Make sure the bearing race is installed facing the proper direction.

Install the ring gear.

Install the thrust washer to the overdrive planetary gear with the grooves facing upward.

Install the 2 retainers to the 1-way clutch.

Install the 1-way clutch to the outer race with the flange of the 1-way clutch facing upward.

Install the overdrive 1-way clutch and outer race to the overdrive planetary gear.

Install the retaining plate.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the overdrive planetary gear assembly and the plate.

HINT:

Tape the screwdriver tip before use.

Hold the overdrive direct clutch drum and turn the input shaft. Check that the input shaft can be turned clockwise freely and locks when turned counterclockwise.

Text in Illustration

	Lock
	Free

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

Press the clutch piston into the clutch drum with both hands to install it.

NOTICE:

Be careful not to damage the O-rings.

Install the overdrive brake return spring to the overdrive direct clutch piston.

Place SST on the return spring and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

NOTICE:

Make sure the end gap of the snap ring is not aligned with the return spring claw.

Install the 2 plates and 2 discs.

Install in order:

*1 - *2 - *1 - *2

Install the flange with the flat end facing downward.

Using a screwdriver, install the snap ring.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Place the oil pump onto the torque converter clutch, and then place the overdrive direct clutch drum assembly onto the oil pump.

Using SST and a dial indicator, measure the overdrive direct clutch piston stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm², 57 psi)).

SST

09350-30020(09350-06120)

Standard piston stroke:

1.85 to 2.15 mm (0.0728 to 0.0846 in.)

Flange Thickness:

Mark	Thickness
21	3.05 to 3.15 mm (0.1201 to 0.1240 in.)
20	3.15 to 3.25 mm (0.125 to 0.127 in.)
19	3.25 to 3.35 mm (0.128 to 0.131 in.)
18	3.35 to 3.45 mm (0.132 to 0.135 in.)
17	3.45 to 3.55 mm (0.136 to 0.139 in.)
16	3.55 to 3.65 mm (0.140 to 0.143 in.)

Align the teeth of the discs in the direct clutch assembly.

Install the direct clutch drum assembly to the overdrive planetary gear.

Coat the bearing with petroleum jelly and install it to the ring gear.

Bearing Diameter:

Item	Inside	Outside
Bearing B	31.45 to 31.70 mm (1.230 to 1.248 in.)	49.1 to 49.4 mm (1.934 to 1.944 in.)

NOTICE:

Make sure the bearing is installed facing the proper direction.

Coat the bearing race with petroleum jelly and install it to the planetary gear.

Bearing Race Diameter:

Item	Inside	Outside
Bearing Race B	33.0 to 33.25 mm (1.300 to 1.309 in.)	49.9 to 50.4 mm (1.97 to 1.98 in.)

NOTICE:

Make sure the bearing race is installed facing the proper direction.

Install the overdrive planetary gear together with the overdrive direct clutch and 1-way clutch.

Place SST on the transmission case.

SST

09350-36010(09350-06090)

Using a vernier caliper, measure the distance between the top of SST and the clutch drum.

Standard distance:

15.5 to 16.5 mm (0.610 to 0.650 in.)

Coat the bearing with petroleum jelly and install it to the overdrive direct clutch.

Bearing Diameter:

Item	Inside	Outside
Bearing A	29.04 to 29.25 mm (1.144 to 1.151 in.)	50.04 to 50.34 mm (1.970 to 1.981 in.)

NOTICE:

Make sure the bearing is installed facing the proper direction.

Coat the bearing race with petroleum jelly and install it to the oil pump.

Bearing Race Diameter:

Item	Inside	Outside
Bearing Race A	28.45 mm (1.12 in.)	47.1 to 47.35 mm (1.854 to 1.864 in.)

NOTICE:

Make sure the bearing race is installed facing the proper direction.

Coat a new O-ring with ATF and install it to the pump body.

Slide the oil pump onto the input shaft, align the bolt holes of the oil pump assembly with the bolt holes of the transmission case and install the oil pump.

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

NOTICE:

Do not forcefully push on the oil pump as the oil seal rings will stick to the direct clutch drum.

Install the 7 bolts.

Torque:

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

Make sure the input shaft rotates smoothly.

Check the operating sound while applying compressed air to the oil hole indicated in the illustration.

HINT:

When inspecting the overdrive direct clutch, check the operating sound with the C-0 accumulator piston hole closed.

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

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

SST

09350-30020(09350-07110)

Coat the lips of the oil seals with MP grease.

Install a new spacer to the manual valve lever.

Pass the manual valve lever shaft through the transmission case and manual valve lever to install it.

Using a hammer, tap in a new spring pin.

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

Check that the shaft rotates smoothly.

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

Install the parking lock pawl, shaft and spring.

Connect the parking lock rod to the manual valve lever to install it.

Install the parking lock pawl bracket to the transmission case with the 3 bolts.

Torque:

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

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

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

Install the 2 springs and accumulator piston to the hole.

Accumulator Spring Diameter:

Item	Free Length Outer Diameter	Color
C-0 Inner Spring	46.0 mm (1.81 in.) 14.02 mm (0.552 in.)	Yellow
C-0 Outer Spring	74.6 mm (2.94 in.) 20.9 mm (0.823 in.)	Orange

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

Install the spring and accumulator piston to the hole.

Accumulator Spring Diameter:

Item	Free Length Outer Diameter	Color
B-0 Spring	62.0 mm (2.44 in.) 16.0 mm (0.630 in.)	Green

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

Install the 2 springs and accumulator piston to the hole.

Accumulator Spring Diameter:

Item	Free Length Outer Diameter	Color
C-2 Inner Spring	42.06 mm (1.66 in.) 14.7 mm (0.579 in.)	Pink
C-2 Outer Spring	68.53 mm (2.70 in.) 20.2 mm (0.795 in.)	Blue

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

Install the spring and accumulator piston to the hole.

Accumulator Spring Diameter:

Item	Free Length Outer Diameter	Color
B-2 Spring	70.50 mm (2.78 in.) 19.9 mm (0.783 in.)	Light Green

Install the spring and check ball body.

Install the valve body and align the groove of the manual valve with the pin of the manual valve lever.

Install the 20 bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

23 mm (0.906 in.) for A

28 mm (1.10 in.) for B

36 mm (1.42 in.) for C

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

Install the transmission wire to the case.

Install the stopper plate with the bolt.

Torque:

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

Connect the 4 connectors to the 4 shift solenoid valves.

Install 3 new gaskets to the oil strainer.

Install the oil strainer with the 4 bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

14 mm (0.55 in.) for A

20 mm (0.79 in.) for B

23 mm (0.91 in.) for C

Install the 3 magnets.

Remove all old seal packing from the contact surfaces of the transmission case and oil pan.

NOTICE:

Be careful not to drop oil on the contact surfaces of the transmission case and oil pan.

Apply seal packing to the oil pan.

Seal packing:

Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent

Seal diameter:

2 to 3 mm (0.0788 to 0.118 in.)

Install the oil pan with the 19 bolts.

Torque:

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

Install the key to the output shaft.

Align the groove of the sensor rotor with the key and install the sensor rotor.

Using a snap ring expander, install the snap ring.

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

Using snap ring expander, install the snap ring.

Coat the lip of a new oil seal with ATF.

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

SST

09950-60010(09951-00580)
09950-70010(09951-07100)

Standard depth:

0 to 1.0 mm (0 to 0.0393 in.)

NOTICE:

Be careful not to damage the lip of the oil seal.

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

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 1.2 mm (0.0394 to 0.0472 in.)

Install the rear adaptor transfer with the 8 bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

50 mm (1.97 in.) for A

40 mm (1.58 in.) for B

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

Apply adhesive to the 6 bolts.

Adhesive:

Toyota Genuine Adhesive 1324,
Three Bond 1324 or equivalent

Install the transmission housing with the 6 bolts.

Torque:

for 14 mm bolt:

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

for 17 mm bolt:

57 N*m{585 kgf*cm, 42 ft.*lbf}

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

Install the sensor with the bolt.

Torque:

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

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

Install the speed sensor with the bolt.

Torque:

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

Coat 2 new O-rings with ATF and install one to each tube union.

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

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

NOTICE:

Use the formula to calculate special torque value for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

Install the bolt with the wire harness bracket.

Torque:

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

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

Using a 19 mm union nut wrench, Install the ATF temperature sensor.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

NOTICE:

Use the formula to calculate special torque value for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

Connect the ATF temperature sensor clamp to the wire harness bracket.

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

Install a new lock washer and the nut.

Torque:

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

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

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}

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

Install the control shaft lever with the washer and nut.

Torque:

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

Install the breather hose with the bolt.

Torque:

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

Install a new gasket and the drain plug.

Torque:

20 N*m{205 kgf*cm, 15 ft.*lbf}