Automatic Transmission Unit Reassembly

Install the transmission case in the overhaul attachment.

Coat 2 new O-rings with ATF.

Install the 2 O-rings on the No. 1 brake piston.

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

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

With the No. 1 brake piston underneath (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.

Install the O-ring on brake piston.

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

NOTICE:

Be careful not to damage the O-ring.

Place the No. 2 brake return spring onto the brake piston.

Place SST on the brake return spring, and compress the brae 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 the spring retainer claw.

SST

09350-30020(09350-07070)

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

Install the flange with the rounded edge facing upward.

Install the 7 discs and 7 plates.

Install in order:

F - D - P - D - P - D - P - D - P - D - P - D - P - D - P

HINT:

F = Flange

P = Plate

D = Disc

Coat the assembled bearing and race with petroleum jelly, and install it onto the case.

Assembled bearing and race diameter:

Item	Inside	Outside
Assembled bearing and race	39.38 mm (1.550 in.)	58.1 mm (2.287 in.)

NOTICE:

Be careful of the installation direction of the assembled bearing and race.

Align the teeth on the flange, discs and plates.

Face the snap ring upward (front side), and install the 2nd brake drum to the planetary gear.

NOTICE:

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

Align the splines of the transmission case with the assembled rear planetary gear and 1st and reverse brake with the output shaft, indicated by A.

Install the assembled output shaft.

Reset 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 2nd brake drum.

Clearance:

0.70 to 1.22 mm (0.0276 to 0.048 in.)

HINT:

1. If the clearance is not as specified, select another flange.
   
2. There are 8 different thicknesses for the flange.
   

Coat a new gasket with ATF, and install the brake drum gasket.

Install the thrust washer onto the 2nd brake piston sleeve.

Install the No. 1 one-way clutch as shown in the illustration.

Install the 1.8 mm (0.071 in.) thick plate with the rounded edge side of the plate facing the disc.

Install the flange, 5 plates and 5 discs.

Install in order:

P - D - P - D - P - D - P - D - P - D - F

HINT:

F = Flange

P = Plate

D = Disc

Using a screwdriver, install the snap ring.

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

Clearance:

0.62 to 1.98 mm (0.0244 to 0.0780 in.)

While turning the sun gear clockwise, install it into the one-way clutch.

HINT:

Confirm that the thrust washer is installed correctly.

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

Bearing and race diameter:

Item	Inside	Outside
Bearing	35.5 mm (1.398 in.)	47.7 mm (1.878 in.)
Race	33.7 mm (1.327 in.)	47.6 mm (1.874 in.)

NOTICE:

Be careful of the installation direction of the bearing and race.

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 under the output shaft.

Coat the race with petroleum jelly, and install it onto the planetary gear.

Race diameter:

Item	Inside	Outside
Race	53.4 mm (2.102 in.)	63.6 mm (2.504 in.)

NOTICE:

Be careful to the installation direction of the race.

Install the brake band to the case.

Install the E-ring to the pin.

Install the pin through the brake band.

Install the assembled bearing and race and thrust washer to the forward clutch.

Install the direct clutch to the forward clutch.

Coat the race with petroleum jelly, and install them onto the forward clutch.

Bearing and race diameter:

Item	Inside	Outside
Bearing	26.0 mm (1.024 in.)	42.8 mm (1.685 in.)
Race	26.0 mm (1.024 in.)	48.9 mm (1.925 in.)

NOTICE:

Be careful of the installation direction of the bearing and race.

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

Race diameter:

Item	Inside	Outside
Race	26.8 mm (1.055 in.)	53.67 mm (2.113 in.)

NOTICE:

Be careful of the installation direction of the race.

Align the flukes of the discs in the forward clutch.

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

Coat the bearing and race with petroleum jelly, and install them onto the ring gear.

Bearing and race diameter:

Item	Inside	Outside
Bearing	49.9 mm (1.965 in.)	64.4 mm (2.535 in.)
Race	53.4 mm (2.102 in.)	63.6 mm (2.504 in.)

NOTICE:

Be careful of the installation direction of the bearing and race.

Install the assembled direct clutch, forward clutch and front planetary ring gear into 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.

Distance:

5.3 to 7.3 mm (0.209 to 0.287 in.)

Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.

Assembled bearing and race diameter:

Item	Inside	Outside
Assembled bearing and race	33.7 mm (1.327 in.)	47.6 mm (1.874 in.)

NOTICE:

Be careful of the installation direction of the assembled bearing and race.

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

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

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Place a mark on the 2nd coast brake piston rod.

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

SST

09240-00020

Coat the assembled bearing and race and race with petroleum jelly, and install it onto the overdrive brake assembly.

Assembled bearing and race and race diameter:

Item	Inside	Outside
Race	36.8 mm (1.449 in.)	50.9 mm (2.004 in.)
Assembled bearing and race	33.8 mm (1.331 in.)	50.0 mm (1.969 in.)

NOTICE:

Be careful of the installation direction of the assembled bearing and race and race.

Confirm that the thrust washer is installed correctly.

HINT:

Make sure that the tab of the washer fits into the hole on the overdrive brake assembly.

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

SST

09350-30020(09350-07020)

Temporarily tighten the 2 bolts.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

HINT:

Install the snap ring open end 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 with hand.

End play:

0.30 to 1.04 mm (0.0118 to 0.0409 in.)

Check that the output shaft rotates smoothly.

Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the discs.

Install the 5 plates, 5 discs and flange.

Install in order:

P - D - P - D - P - D - P - D - P - D - F

HINT:

F = Flange

P = Plate

D = Disc

Using a screwdriver, install the snap ring.

Place SST and a dial indicator onto 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)).

Piston stroke:

1.75 to 2.05 mm (0.0689 to 0.0807 in.)

HINT:

1. If the piston stroke is still outside the standard, select another flange.
   
2. There are 7 different thicknesses for the flange.
   

Coat the race with petroleum jelly, and install it onto the overdrive brake assembly.

Race diameter:

Item	Inside	Outside
Race	37.2 mm (1.465 in.)	58.8 mm (2.315 in.)

NOTICE:

Be careful of the installation direction of the race.

Install the ring gear.

Coat the assembled bearing and race with petroleum jelly, and install them onto the ring gear.

Assembled bearing and race diameter:

Item	Inside	Outside
Assembled bearing and race	31.4 mm (1.236 in.)	49.4 mm (1.945 in.)

NOTICE:

Be careful of the installation direction of the assembled bearing and race.

Coat the race with petroleum jelly, and install it onto the planetary gear.

Race diameter:

Item	Inside	Outside
Race	24.7 mm (0.972 in.)	41.8 mm (1.646 in.)

NOTICE:

Be careful of the installation direction of the race.

Install the overdrive planetary gear, overdrive direct clutch and one-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 clutch drum.

Standard distance:

15.5 to 16.5 mm (0.610 to 0.650 in.)

Coat the assembled bearing and race with petroleum jelly, and install it onto the overdrive direct clutch.

Assembled bearing and race diameter:

Item	Inside	Outside
Assembled bearing and race	29.2 mm (1.150 in.)	50.2 mm (1.976 in.)

NOTICE:

Be careful of the installation direction of the assembled bearing and race.

Coat the race with petroleum jelly, and install it onto the oil pump.

Race diameter:

Item	Inside	Outside
Race	28.45 mm (1.120 in.)	47.3 mm (1.862 in.)

NOTICE:

Be careful of the installation direction of the race.

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

Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

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

NOTICE:

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

Install the 7 bolts.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Make sure the input shaft rotates smoothly.

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

Install the plug to the case with the bolt.

Torque:

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

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

HINT:

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

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

1. Overdrive direct clutch (C1)
   

2. Direct clutch (C2)
   

3. Forward clutch (C3)
   

4. Overdrive brake (B1)
   

5. 2nd coast brake (B2)
   

6. 2nd brake (B3)
   

7. 1st and reverse brake (B4)
   

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

SST

09350-30020(09350-07110)

Install a new spacer to the manual valve lever.

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

Using a hammer, tap in a new spring pin.

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

Make sure that the shaft rotates smoothly.

Install the E-ring to the shaft.

Install the parking lock pawl, shaft and spring.

Connect the parking lock rod to the manual valve lever.

Place the parking lock pawl bracket onto the transmission case and install 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 up by the 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.

C-0 accumulator spring:

Inner spring:

Free Length	Outer Diameter	Color
51.5 mm (2.028 in.)	14.02 mm (0.552 in.)	Red

Outer spring:

Free Length	Outer Diameter	Color
79.9 mm (3.146 in.)	20.9 mm (0.823 in.)	Light Blue

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

Install the spring and accumulator piston to the hole.

B-0 accumulator spring:

Free Length	Outer Diameter	Color
62.0 mm (2.441 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.

C-2 accumulator spring:

Inner spring:

Free Length	Outer Diameter	Color
42.1 mm (1.657 in.)	14.7 mm (0.579 in.)	Pink

Outer spring:

Free Length	Outer Diameter	Color
68.53 mm (2.698 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.

B-2 accumulator spring:

Free Length	Outer Diameter	Color
70.5 mm (2.776 in.)	19.9 mm (0.784 in.)	Light Grey

Install the spring and check ball body.

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

Install the 20 bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

Bolt length:

23 mm (0.91 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, and install the stopper plate with the bolt.

Torque:

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

Connect the connectors to the shift solenoid valves.

Install 3 new gaskets on 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.

Bolt length:

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 any seal packing material.

NOTICE:

Be careful not to drop oil on the contacting 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 (0.0787 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 on the output shaft.

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

Using snap ring pliers, install the snap ring.

Using SST and a hammer, install a new oil seal.

SST

09950-60010(09951-00560)
09950-70010(09951-07150)

Install the rear transfer adaptor and gasket.

Install the 8 bolts.

Torque:

34 N*m{344 kgf*cm, 25 ft.*lbf}

HINT:

Each bolt length is indicated below.

Bolt length:

50 mm (1.969 in.) for A

40 mm (1.575 in.) for B

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

Apply adhesive or equivalent to the 6 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the transmission housing with the 6 bolts.

Torque:

34 N*m{345 kgf*cm, 25 ft.*lbf}for 14 mm bolt

57 N*m{580 kgf*cm, 42 ft.*lbf}for 17 mm bolt

Coat a new O-ring with ATF.

Install a new O-ring 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.

Install a new O-ring 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 them to each tube union.

Torque:

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

Coat the O-ring with ATF.

Install the temperature sensor.

Torque:

15 N*m{150 kgf*cm, 11 ft.*lbf}

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

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

Torque:

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

Push the control shaft rearward as much as possible.

Return the control shaft lever 2 notches 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}

HINT:

Bend at least 2 of the lock washer tabs.

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:

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