Automatic Transmission Unit Reassembly

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 reaction sleeve.

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

With the No. 1brake piston1 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 the 1st and reverse brake piston.

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

NOTICE:

Be careful not to damage the O-ring.

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

Place SST on the spring retainer, and compress the return spring.

SST

09350-30020(09350-07050)

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

Install the thrust needle roller bearing.

Standard thrust needle roller bearing diameter:

Item	Inside	Outside
Thrust needle roller bearing	45.9 mm (1.807 in.)	64.0 mm (2.520 in.)

Install the thrust needle roller bearing.

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

Standard bearing and race diameter:

Item	Inside	Outside
Bearing	21.5 mm (0.847 in.)	40.8 mm (1.606 in.)
Race	48.5 mm (1.909 in.)	62.7 mm (2.469 in.)

Install the rear planetary gear assembly.

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

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

NOTICE:

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

HINT:

Length A = 36.35 to 37.09 mm (1.431 to 1.460 in.)

Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.

HINT:

Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.010 to 0.071 in.)

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

Standard pack clearance:

0.8 to 1.1 mm (0.031 to 0.043 in.)

If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

H thickness:

No.	Thickness	No.	Thickness
0	0 mm (0 in.)	8	0.8 mm (0.031 in.)
2	0.2 mm(0.008 in.)	10	1.0 mm (0.039 in.)
4	0.4 mm (0.016 in.)	12	1.2 mm (0.047 in.)
6	0.6 mm (0.024 in.)	14	1.4 mm (0.055 in.)

Install the 2 flanges, the 8 discs and the 7 plates.

Install in order:

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

HINT:

F = Flange

P = Plate

D = Disc

Install the brake stopper spring.

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

Standard bearing and race diameter:

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

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

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

Using SST, install the snap ring.

SST

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

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

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

Standard race diameter:

Item	Inside	Outside
Race	53.7 mm (2.114 in.)	74.0 m (2.913 in.)

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

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

Install the No. 2 brake piston to the case.

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

Install in order:

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

HINT:

D = Disc

P = Plate

F = Flange

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

SST

09351-40010

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

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

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

Using SST, install the brake piston return spring snap ring.

SST

09351-40010

Install the 3 plates, 3 discs and flange.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Flange

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

Using a screwdriver, install the snap ring.

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

Standard thrust needle roller bearing diameter:

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

Install the thrust needle roller bearing and the thrust washer.

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

Standard thrust needle roller bearing and race diameter:

Item	Inside	Outside
Thrust needle roller bearing	43.4 mm (1.709 in.)	58.3 mm (2.295 in.)
Race	38.0 mm (1.496 in.)	57.0 mm (2.244 in.)

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

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

Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.

Standard piston stroke:

0.42 to 0.72 mm (0.017 to 0.028 in.)

HINT:

There are 4 different thicknesses for the flange.

Standard flange thickness:

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

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

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

Using SST and press, install the snap ring.

SST

09351-40010

NOTICE:

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

Install the 2nd brake cylinder to the case.

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

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Install the cushion plate, 4 plates, 4 discs and 2 flanges on the case.

Install in order:

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

HINT:

C = Cushion

P = Plate

D = Disc

F = Flange

Using a screwdriver, install the snap ring.

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

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

Install the thrust needle roller bearing.

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

Standard thrust needle roller bearing and diameter:

Item	Inside	Outside
Thrust needle roller bearing	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
Race	73.6 mm (2.898 in.)	102.0 mm (4.016 in.)

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

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

Standard thrust bearing race diameter:

Item	Inside	Outside
Race	74.2 mm (2.921 in.)	87.74 mm (3.454 in.)

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

Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly 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 push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum.

Install the 10 bolts.

Torque:

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

Using SST, drive in 2 new oil seals.

SST

09350-30020(09350-07110)

Coat the oil seal lips with MP grease.

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

HINT:

When inspecting the O/D direct clutch, check with the C3 accumulator piston holes indicated in the illustration.

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

1. (1) No. 2 clutch (C2)
   
2. (2) No. 3 clutch (C3)
   
3. (3) No. 1 clutch (C1)
   
4. (4) No. 3 brake (B1)
   
5. (5) No. 1 brake (B1)
   
6. (6) No. 2 brake (B2)
   
7. (7) No. 4 brake (B4)
   

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 together with the punch.

Make sure 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 torque 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 spring and accumulator valve to the hole.

Standard accumulator spring:

Spring	Free length Outer diameter	Color
C-1 Inner	30.40 mm (1.197 in.) 11.40 mm (0.449 in.)	Pink
C-1 Outer	48.76 mm (1.920 in.) 16.60 mm (0.654 in.)	Light green

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

Install the spring and accumulator piston to the hole.

Standard accumulator spring:

Spring	Free length Outer diameter	Color
C-3 Inner	44.0 mm (1.732 in.) 14.0 mm (0.551 in.)	Yellow
C-3 Outer	73.35 mm (2.888 in.) 19.90 mm (0.784 in.)	Red

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

Install the spring and accumulator piston to the hole.

Standard accumulator spring:

Spring	Free length Outer diameter	Color
B-3	70.5 mm (2.776 in.) 19.7 mm (0.776 in.)	Purple

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

Install the spring and accumulator piston to the hole.

Standard accumulator spring:

Spring	Free length Outer diameter	Color
C-2	62.0 mm (2.441 in.) 15.9 mm (03626 in.)	White

Install the check ball body and the spring.

Install the 3 brake drum gaskets.

Install the 3 transaxle case gaskets.

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

Install the 19 bolts.

Torque:

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

HINT:

1. Each bolt length is indicated below.
   
2. Bolt length:
   25 mm (0.98 in.) for bolt A
   36 mm (1.42 in.) for bolt B
   

Install a new O-ring to the transmission wire.

Install the transmission wire harness.

Install the bolt.

Torque:

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

Connect the solenoid connector.

Connect the 7 solenoid connectors.

Install the ATF temperature sensor.

Install the clamp and the 2 bolts.

Torque:

10 N*m{100 kgf*cm, 7 ft.*lbf} for bolt A

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

HINT:

1. Each bolt length is indicated below.
   
2. Bolt length:
   12 mm (0.47 in.) for bolt A
   36 mm (1.42 in.) for bolt B
   

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

Install the oil strainer with the 4 bolts.

Torque:

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

Install the 4 transmission oil cleaner magnets.

Install a new gasket on the oil pan.

Install the 20 bolts.

Torque:

4.4 N*m{45 kgf*cm, 39 in.*lbf}

Install the drain plug.

Torque:

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

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

SST

09710-30050
09950-70010(09951-07100)

Using SST and a hammer, tap in a new extension housing dust deflector.

SST

09223-15020
09950-70010(09951-07100)

Install the thrust needle roller bearing and the 2 bearing races.

Using a snap ring expander, install the snap ring.

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

Standard clearance:

0.05 to 0.33 mm (0.0020 to 0.0130 in.)

1. If the clearance is still standard, select another race.
   

HINT:

There are 6 different thicknesses for the race.

Standard race thickness:

No.	Thickness	No.	Thickness
1	3.7 mm (0.146 in.)	4	4.0 mm (0.158 in.)
2	3.8 mm (0.150 in.)	5	4.1 mm (0.161 in.)
3	3.9 mm (0.154in.)	5	4.2 mm (0.165 in.)

Install the gasket to the extension housing.

HINT:

Take care not to drop the gasket.

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

Apply FIPG to the extension housing.

Seal packing:

Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent

Install the extension housing with 6 new bolts.

Torque:

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

HINT:

Each bolt length is indicated below.

Bolt length:

45 mm (1.72 in.) for bolt A
35 mm (1.38 in.) for bolt B

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

Install the transmission housing with the 10 bolts.

Torque:

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

57 N*m{581 kgf*cm, 42 ft.*lbf} for bolt B (17mm head)

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

Install a new O-ring to the breather tube.

Install the breather tube with the 3 bolts.

Torque:

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

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

Install the 2 transmission revolution sensor.

Install the 2 bolts.

Torque:

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

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

Install the oil cooler tube union.

Torque:

29 N*m{296 kgf*cm, 21 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 and 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{133 kgf*cm, 10 ft.*lbf}

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

HINT:

Bend at least 2 of the lock washer tabs.

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

Torque:

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