Automatic Transmission Unit (For 2Tr-Fe) Reassembly

Install the 2 brake plate stopper springs to the automatic transmission case sub-assembly.

NOTICE:

The shapes of the parts are different. Refer to the illustration when installing the parts.

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

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

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

NOTICE:

Be careful not to damage the O-rings.

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

NOTICE:

Be careful not to damage the O-rings.

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

Install the 1st and reverse brake piston to the automatic transmission case sub-assembly while making sure that the protrusion of the 1st and reverse brake piston is positioned as shown in the illustration.

NOTICE:

Be careful not to damage the O-ring.

Install the 1st and reverse brake return spring sub-assembly to the automatic transmission case sub-assembly.

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

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

SST

09380-60011(09381-06030,09381-06040,09381-06080,09381-06120,09381-06130,09381-06140,09381-05040,09381-05050)

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the 1st and reverse brake return spring sub-assembly and automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Coat the thrust bearing race with ATF and install it to the automatic transmission case sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing K	21.0 (0.827)	41.5 (1.634)
Thrust Bearing Race K	23.13 (0.911)	41.5 (1.634)
Thrust Needle Roller Bearing L	43.55 (1.715)	61.0 (2.402)
Thrust Bearing Race L	47.1 (1.854)	67.1 (2.642)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

Coat the 2 thrust needle roller bearings and thrust bearing race with ATF and install them to the rear planetary gear assembly.

Install the rear planetary gear assembly to the automatic transmission case sub-assembly.

Install the 2 No. 4 brake flanges, 5 No. 4 brake discs and 4 No. 4 brake plates to the automatic transmission case sub-assembly.

NOTICE:

1. Make sure that the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are installed in the correct order.
   
2. Install the thicker No. 4 brake flange first, and then install the thinner one.
   

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the intermediate shaft.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing J	32.1 (1.264)	49.35 (1.943)
Thrust Bearing Race J (Rear Race)	32.1 (1.264)	49.0 (1.929)

Install the intermediate shaft to the automatic transmission case sub-assembly.

Install the rear planetary ring gear to the rear planetary ring gear flange sub-assembly.

Using a screwdriver, install the snap ring to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

NOTICE:

Be careful not to damage the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

HINT:

Tape the screwdriver tip before use.

Coat the thrust bearing race with ATF and install it to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race J (Front Race)	33.4 (1.315.)	49.0 (1.929)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

Install the rear planetary ring gear flange sub-assembly with rear planetary ring gear to the automatic transmission case sub-assembly.

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

HINT:

Rotate the one-way clutch inner race clockwise to install it.

Install the No. 3 one-way clutch assembly with one-way clutch inner race to the automatic transmission case sub-assembly.

Using SST, install the snap ring to the automatic transmission case sub-assembly.

SST

09350-30020(09350-07060)

Text in Illustration

*1	Snap Ring
*a	19°
*b	49°
	Front Side

NOTICE:

1. Install the snap ring so that the tapered side is facing out.
   
2. Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.
   

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).

Using a feeler gauge, measure the No. 4 brake pack clearance between the No. 4 brake disc and No. 4 brake flange.

Standard clearance:

0.5 to 0.8 mm (0.0197 to 0.0314 in.)

No. 4 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	1.80 (0.0709)
1	1.97 (0.0776)
3	2.11 (0.0831)
4	2.25 (0.0886)
5	2.39 (0.0941)
7	2.53 (0.0996)
8	2.67 (0.105)
10	2.81 (0.111)
11	2.95 (0.116)
12	3.09 (0.122)
14	3.23 (0.127)

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

With the No. 1 brake piston return spring sub-assembly installed to the No. 1 brake piston, align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston to the No. 1 brake cylinder.

Install the No. 1 brake cylinder with No. 1 brake piston to the automatic transmission case sub-assembly while making sure that the 2 claws of the No. 1 brake cylinder with No. 1 brake piston are positioned as shown in the illustration.

Align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston return spring sub-assembly to the No. 1 brake piston.

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

SST

09380-60011(09381-06010,09381-06040,09381-06050,09381-06070,09381-06090,09381-06100,09381-06110,09381-06120)

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

1. Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.
   
2. Be careful not to damage the automatic transmission case sub-assembly.
   

HINT:

Tape the screwdriver tip before use.

Install the No. 1 brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates to the automatic transmission case sub-assembly.

NOTICE:

Make sure that the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are installed in the correct order.

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

1. Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.
   
2. Be careful not to damage the automatic transmission case sub-assembly.
   

HINT:

Tape the screwdriver tip before use.

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

Using a feeler gauge, measure the No. 1 brake pack clearance between the No. 1 brake disc and No. 1 brake flange.

Standard clearance:

0.3 to 0.6 mm (0.0119 to 0.0236 in.)

No. 1 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	4.9 (0.193)
1	5.0 (0.197)
2	5.1 (0.201)
3	5.2 (0.205)
4	5.3 (0.209)
5	5.4 (0.213)
6	5.5 (0.217)
7	5.6 (0.220)
8	5.7 (0.224)
A	5.8 (0.228)

Install the planetary sun gear to the automatic transmission case sub-assembly.

Coat the thrust bearing race with ATF and install it to the center planetary gear assembly.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race I	53.7 (2.114)	74.0 (2.913)

Install the center planetary gear assembly to the automatic transmission case sub-assembly.

Install the center planetary ring gear to the center planetary ring gear flange

Using a screwdriver, install the snap ring to the center planetary ring gear flange with center planetary ring gear.

NOTICE:

Be careful not to damage the center planetary ring gear flange with center planetary ring gear.

HINT:

Tape the screwdriver tip before use.

Coat the 2 thrust needle roller bearings with ATF and install them to the center planetary ring gear flange with center planetary ring gear.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing H	63.3 (2.492)	78.8 (3.102)
Thrust Needle Roller Bearing I	55.7 (2.193)	76.4 (3.008)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

Install the center planetary ring gear flange with center planetary ring gear to the automatic transmission case sub-assembly.

Install the 2 No. 2 brake flanges, 4 No. 2 brake discs and 3 No. 2 brake plates to the automatic transmission case sub-assembly.

NOTICE:

1. Make sure that the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are installed in the correct order.
   
2. Install the thicker No. 2 brake flange first, and then install the thinner one.
   

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

With the No. 2 brake piston return spring sub-assembly installed to the No. 2 brake piston, align the claw of the No. 2 brake piston return spring sub-assembly with the claw of the No. 2 brake cylinder, and then install the No. 2 brake piston to the No. 2 brake cylinder.

NOTICE:

Be careful not to damage the O-rings.

Install the No. 2 brake piston return spring sub-assembly to the automatic transmission case sub-assembly while making sure that the claw of the No. 2 brake piston return spring sub-assembly is positioned as shown in the illustration.

Install the No. 2 brake cylinder with No. 2 brake piston to the automatic transmission case sub-assembly while making sure that the claw of the No. 1 brake cylinder with No. 1 brake piston is positioned as shown in the illustration.

Place SST on the No. 2 brake cylinder, and compress the No. 2 brake piston return spring sub-assembly with a press.

SST

09380-60011(09381-06010,09381-06020,09381-06040,09381-06050,09381-06060,09381-06090,09381-06100,09381-06110,09381-06120)

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

1. Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.
   
2. Be careful not to damage the automatic transmission case sub-assembly.
   

HINT:

Tape the screwdriver tip before use.

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

Using a feeler gauge, measure the No. 2 brake pack clearance between the No. 2 brake disc and No. 2 brake flange.

Standard clearance:

0.4 to 0.7 mm (0.0158 to 0.0275 in.)

No. 2 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	2.0 (0.0787)
1	2.1 (0.0827)
2	2.2 (0.0866)
3	2.3 (0.0906)
4	2.4 (0.0945)
5	2.5 (0.0984)
6	2.6 (0.102)
7	2.7 (0.106)
8	2.8 (0.110)

Set the snap ring onto the front planetary ring gear flange sub-assembly. Using needle-nose pliers, insert the snap ring into the front planetary ring gear while squeezing it, and then expand the snap ring to install it.

NOTICE:

Make sure the snap ring is securely inserted into the groove of the front planetary ring gear.

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the front planetary ring gear with front planetary ring gear flange sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing G	63.3 (2.492)	78.8 (3.102)
Thrust Bearing Race H	66.3 (2.610)	78.9 (3.106)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

Install the front planetary ring gear with front planetary ring gear flange sub-assembly to the automatic transmission case sub-assembly.

Coat the 2 thrust bearing races with ATF and install them to the front planetary gear assembly.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race F	44.0 (1.732)	62.8 (2.472)
Thrust Bearing Race G	65.8 (2.591)	86.3 (3.398)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

Install the front planetary gear assembly to the automatic transmission case sub-assembly.

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the sun gear input drum sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race E	40.83 (1.607)	52.8 (2.079)
Thrust Needle Roller Bearing F	37.1 (1.461)	61.2 (2.409)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

Install the sun gear input drum sub-assembly to the automatic transmission case sub-assembly.

Coat the 2 thrust needle roller bearings with ATF and install them to the forward clutch hub sub-assembly.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing D	33.3 (1.311)	56.6 (2.228)
Thrust Needle Roller Bearing E	39.6 (1.559)	52.8 (2.079)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

Install the forward clutch hub sub-assembly to the automatic transmission case sub-assembly.

Coat the 2 thrust bearing races with ATF and install them to the multiple disc clutch hub.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust bearing race C	22.0 (0.866)	44.8 (1.764)
Thrust bearing race D	38.4 (1.512)	56.5 (2.224)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

Install the multiple disc clutch hub to the automatic transmission case sub-assembly.

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

Install the direct clutch piston to the direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the O-rings.

Install the direct clutch return spring sub-assembly to the direct clutch piston.

Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.

Install the No. 2 clutch balancer to the direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the O-ring.

Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.

SST

09380-60011(09381-06030,09381-06040,09381-06080,09381-06100,09381-06110)

NOTICE:

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.

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

NOTICE:

Do not expand the snap ring excessively.

Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.

NOTICE:

Make sure that the No. 2 clutch discs, No. 2 clutch plates and direct clutch flange are installed in the correct order.

Using a screwdriver, install the snap ring to the direct clutch drum sub-assembly.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Using a dial indicator, measure the clearance of the No. 2 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.4 to 0.7 mm (0.0158 to 0.0275 in.)

HINT:

There are direct clutch flanges of different thicknesses.

Direct Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35675-71010	3.0 (0.118)
35675-71020	3.1 (0.122)
35675-71030	3.2 (0.126)
35675-71040	3.3 (0.130)
35675-71050	3.4 (0.134)
35675-71060	3.5 (0.138)
35675-71070	3.6 (0.142)
35675-71080	3.7 (0.146)
35675-71090	3.8 (0.150)

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

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

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

NOTICE:

Be careful not to damage the O-rings.

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

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

NOTICE:

Be careful not to damage the O-ring.

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

SST

09387-00110

NOTICE:

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.

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

NOTICE:

Do not expand the snap ring excessively.

Install the 5 No. 1 clutch plates, 5 No. 1 clutch discs and forward clutch flange to the input shaft sub-assembly.

NOTICE:

Make sure that the No. 1 clutch discs, No. 1 clutch plates and forward clutch flange are installed in the correct order.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the input shaft sub-assembly.

HINT:

Tape the screwdriver tip before use.

Using a dial indicator, measure the clearance of the No. 1 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.75 to 1.05 mm (0.0296 to 0.0413 in.)

HINT:

There are forward clutch flanges of different thicknesses.

Forward Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35635-71010	3.0 (0.118)
35635-71020	3.1 (0.122)
35635-71030	3.2 (0.126)
35635-71040	3.3 (0.130)
35635-71050	3.4 (0.134)
35635-71060	3.5 (0.138)
35635-71070	3.6 (0.142)
35635-71080	3.7 (0.146)
35635-71090	3.8 (0.150)
35635-71100	3.9 (0.154)
35635-71110	4.0 (0.157)
35635-71120	4.1 (0.161)
35635-71130	4.2 (0.165)

Coat 3 new clutch drum oil seal rings with ATF and install them to the input shaft sub-assembly.

NOTICE:

Do not expand the clutch drum oil seal ring ends excessively.

HINT:

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

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

Coat the 3 thrust needle roller bearings with ATF and install them to the clutch drum and input shaft assembly.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing A	71.9 (2.831)	85.6 (3.370)
Thrust Needle Roller Bearing B	34.6 (1.362)	52.0 (2.047)
Thrust Needle Roller Bearing C	21.3 (0.839)	41.1 (1.618)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

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

Coat the 2 thrust bearing races with ATF and install them to the oil pump assembly.

Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race B	40.0 (1.575)	52.8 (2.079)
Thrust Bearing Race A	74.2 (2.921)	87.74 (3.454)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

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

Set the oil pump assembly on the input shaft, and align the bolt holes of the oil pump assembly with the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the oil pump O-ring.

Temporarily install the oil pump assembly to the automatic transmission case sub-assembly.

Install the oil pump assembly with the 10 bolts.

Torque:

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

Using SST and a hammer, drive in 2 new manual valve lever shaft oil seals to the automatic transmission case sub-assembly.

SST

09350-30020(09350-07110)

Standard depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

Coat the lip of the manual valve lever shaft oil seal with MP grease.

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

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

Using a hammer, drive in a new spring pin.

Turn the spacer and manual valve lever shaft to align the smaller hole on the spacer with the indent on the manual valve lever sub-assembly.

Using a 3 mm pin punch and a hammer, stake the spacer.

Check that the spacer does not turn.

Make sure that the shaft rotates smoothly.

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

Install the parking lock pawl, parking lock pawl shaft and spring to the automatic transmission case sub-assembly.

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

Install the parking lock pawl bracket to the automatic transmission case sub-assembly with the 3 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Move the manual valve lever sub-assembly to P, and check the output shaft is locked by the parking lock pawl.

Coat 2 new brake drum gaskets with ATF and install them to the automatic transmission case sub-assembly.

Coat 2 new transmission case gaskets with ATF and install them to the automatic transmission case sub-assembly.

Insert the manual valve lever sub-assembly into the groove on the end of the manual valve and install the transmission valve body assembly to the automatic transmission case sub-assembly with the 12 bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

Bolt length:

Bolt A:

25 mm (0.984 in.)

Bolt B:

36 mm (1.42 in.)

Bolt C:

50 mm (1.97 in.)

Install the detent spring and detent spring cover to the transmission valve body assembly with the bolt.

Torque:

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

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

Install the valve body oil strainer assembly to the transmission valve body assembly with the 3 bolts.

Torque:

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

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

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

Install the transmission wire to the automatic transmission case sub-assembly with the bolt.

Torque:

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

Connect the 7 solenoid valve connectors.

Install the 2 temperature sensors and 2 temperature sensor clamps to the transmission valve body assembly with the bolt.

Torque:

for Bolt A:

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

for Bolt B:

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

Install the 4 transmission oil cleaner magnets to the automatic transmission oil pan sub-assembly as shown in the illustration.

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

Install the automatic transmission oil pan sub-assembly with automatic transmission oil pan gasket to the automatic transmission case sub-assembly with the 10 bolts.

Torque:

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

NOTICE:

1. Make sure that automatic transmission oil pan gasket seal surface and automatic transmission oil pan sub-assembly contact surface are free of oil and foreign matter.
   
2. Install the automatic transmission oil pan gasket so that there is no slack in the automatic transmission oil pan gasket, and the entire seal surface is level.
   
3. Make sure that the 8 protrusions are properly engaged to the automatic transmission oil pan sub-assembly.
   
4. When installing the automatic transmission oil pan sub-assembly, make sure that the automatic transmission oil pan gasket is not pinched between the sleeve and the seal surface of the automatic transmission case sub-assembly.
   

Install the drain plug and a new gasket to the automatic transmission oil pan sub-assembly.

Torque:

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

Using a 5 mm hexagon socket wrench, install a new gasket and overflow plug to the automatic transmission oil pan sub-assembly.

Torque:

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

Clean and degrease the bolts and bolt holes with non-residue solvent.

Install the automatic transmission housing to the automatic transmission case sub-assembly with the 8 bolts.

Torque:

34 N*m{346 kgf*cm, 25 ft.*lbf}

Apply adhesive to 2 or 3 threads on the end of the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install 4 bolts to the automatic transmission housing.

Torque:

for Bolt A (M10 bolt):

34 N*m{346 kgf*cm, 25 ft.*lbf}

for Bolt B (M12 bolt):

57 N*m{579 kgf*cm, 42 ft.*lbf}

Install the rear transfer case adapter oil receiver to the transfer adapter sub-assembly.

Using snap ring pliers, install the snap ring to the transfer adapter sub-assembly.

Using SST and a hammer, drive in a new transfer adapter oil seal to the transfer adapter sub-assembly.

SST

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

Standard depth:

0 to 0.5 mm (0 to 0.0196 in.)

Coat the lip of the transfer adapter oil seal with MP grease.

Using a plastic-faced hammer, tap 2 new straight pins into the transfer adapter sub-assembly.

Standard Protrusion Height:

5.7 to 6.3 mm (0.225 to 0.248 in.)

HINT:

It is not necessary to remove the straight pins they are being replaced.

Clean and degrease the threads of the 10 bolts, bolt holes and the contact surfaces of the automatic transmission case sub-assembly and transfer adapter sub-assembly with non-residue solvent.

Apply seal packing to the transfer adapter sub-assembly as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

1. Apply seal packing in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.
   
2. After applying seal packing, install the transfer adapter sub-assembly to the automatic transmission case sub-assembly within 3 minutes and tighten the bolts within 10 minutes.
   

Apply adhesive to 2 or 3 threads on the end of the 10 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the transfer adapter sub-assembly to the automatic transmission case sub-assembly with the 10 bolts.

Torque:

34 N*m{346 kgf*cm, 25 ft.*lbf}

HINT:

Each bolt length is indicated below.

Bolt length:

for Bolt A:

40 mm (1.57 in.)

for Bolt B:

50 mm (1.97 in.)

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

Using SST, install the 2 oil cooler tube unions to the automatic transmission case sub-assembly.

SST

09268-78010

Torque:

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

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
   (LandCruiser RM000003YMD00TX.html)
   
2. When using SST (fulcrum length of 34.5 mm (1.3583 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 25 N*m (252 kgf*cm, 18 ft.*lbf)
   

Coat 6 new O-rings with ATF, and install them to the 6 automatic transmission case plugs.

Install the 6 automatic transmission case plugs to the automatic transmission case sub-assembly.

Torque:

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

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

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}

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

Install the refill plug to the transfer adapter sub-assembly.

Torque:

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

Clean the bolt and bolt hole.

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:

Install the bolt within 3 minutes of applying adhesive.

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

Install a lock washer and nut to the park/neutral position switch assembly.

Torque:

6.9 N*m{70 kgf*cm, 61 in.*lbf}

Temporarily install the transmission control shaft lever LH to the manual valve lever shaft with the spring washer and nut.

Turn the transmission control shaft lever LH clockwise until it stops, and then return the transmission control shaft lever LH counterclockwise 2 notches to N.

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

Torque:

13 N*m{131 kgf*cm, 9 ft.*lbf}

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

NOTICE:

1. Be careful not to damage the park/neutral position switch assembly.
   
2. Bend at least 2 of the lock washer tabs.
   

HINT:

Tape the screwdriver tip before use.

Install the transmission control shaft lever LH to the manual valve lever shaft with the spring washer and nut.

Torque:

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

Coat a new O-ring with ATF, and install it to the transmission revolution sensor (NT).

Install the transmission revolution sensor (NT) to the automatic transmission case sub-assembly 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 transmission revolution sensor (SP2).

Install the transmission revolution sensor (SP2) to the automatic transmission case sub-assembly with the bolt.

Torque:

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

Install the breather plug sub-assembly and breather plug to the breather plug hose.

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

Install the breather plug hose to the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the O-rings.