Automatic Transmission Unit Reassembly

Coat 3 new O-rings with ATF and install them to the 1st and reverse brake piston.

Install the 1st and reverse brake piston to the transmission case.

NOTICE:

1. Be careful not to damage the O-ring.
   
2. Make sure that the parking hole of the brake piston is on the bottom by engaging the brake piston protrusion and the transmission case spline grooves.
   

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

Place SST on the 1st and reverse brake return spring and compress the 1st and reverse brake return spring.

SST

09380-60010(09381-06030,09381-06040,09381-06080,09381-06120,09381-06130,09381-05040,09381-05050)

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

Measure distance A (from the tip of the 1st and reverse brake piston to the step in the transmission case) in the illustration.*1

HINT:

Standard distance A: 27.82 to 28.42 mm (1.09 to 1.12 in.)

Assemble the flange, No. 4 brake flange, 7 No. 4 brake discs and 6 plates, and measure distance B in the illustration.*2

HINT:

Standard distance B: 25.98 to 27.01 mm (1.02 to 1.06 in.)

Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 4 brake flange indicated by the graph point.

Measure length H of the selected No. 4 brake flange as shown in the illustration.

HINT:

Make sure that when the B measurement and the H dimension of the selected No. 4 brake flange are subtracted from the A measurement, the value is 0.961 to 1.261 mm (0.0378 to 0.0495 in.).

Selected No. 4 Brake Flange Length H:

Mark	Length H
0	0 mm (0 in.)
2	0.15 to 0.25 mm (0.00590 to 0.00984 in.)
4	0.35 to 0.45 mm (0.0138 to 0.0177 in.)
6	0.55 to 0.65 mm (0.0217 to 0.0256 in.)
8	0.75 to 0.85 mm (0.0295 to 0.0335 in.)
10	0.95 to 1.05 mm (0.0374 to 0.0413 in.)

Install the thrust bearing race.

HINT:

Use a small amount of MP grease to make the thrust bearing race stay securely in place.

Bearing Race Diameter:

Item	Inside	Outside
Race J	47.15 to 47.4 mm (1.86 to 1.87 in.)	66.9 to 67.1 mm (2.63 to 2.64 in.)

Install the 2 thrust needle roller bearings to the rear planetary gear assembly.

Bearing Diameter:

Item	Inside	Outside
Bearing I	23.2 to 23.4 mm (0.913 to 0.921 in.)	43.9 to 44.15 mm (1.73 to 1.74 in.)
Bearing J	43.6 to 43.85 mm (1.72 to 1.73 in.)	62.3 to 62.8 mm (2.45 to 2.47 in.)

HINT:

Use a small amount of MP grease to make the thrust needle roller bearings stay securely in place.

Install the rear planetary gear assembly.

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

Using a screwdriver, install the snap ring.

Install the 3 thrust bearing races, thrust needle roller bearing and rear planetary ring gear together with the rear planetary ring gear flange to the intermediate shaft.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearings and races stay securely in place.

Bearing and Race Diameter:

Item	Inside	Outside
Front race H	39.67 to 39.87 mm (1.56 to 1.57 in.)	56.5 to 57.0 mm (2.22 to 2.24 in.)
Bearing H	36.45 to 36.61 mm (1.437 to 1.441 in.)	56.62 to 56.92 mm (2.23 to 2.24 in.)
Rear race H	36.45 to 36.7 mm (1.435 to 1.445 in.)	56.5 to 57.0 mm (2.22 to 2.24 in.)
Race I	21.05 to 21.3 mm (0.829 to 0.839 in.)	39.5 to 39.8 mm (1.56 to 1.57 in.)

Install the intermediate shaft together with the rear planetary ring gear flange and rear planetary ring gear to the transmission case.

Install the flange, 7 discs, 6 plates and selected No. 4 brake flange.

Install in order:

F - D - P - D - P - D - P - D - P - D - P - D - P - D - S/F

HINT:

F = Flange

D = Disc

P = Plate

S/F = Selected No. 4 brake flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

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

NOTICE:

Be sure to install the 1-way clutch inner race so that it is facing in the proper direction.

Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

Install the No. 3 1-way clutch assembly to the transmission case.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

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

Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.

NOTICE:

Be careful not to damage the O-rings.

Install the No. 2 brake cylinder with No. 2 brake piston to the transmission case.

NOTICE:

1. 
   
2. When installing the No. 2 brake cylinder with No. 2 brake piston to the transmission case, align the cylinder claw with the groove in the top of the case.
   
3. Make sure the No. 2 brake cylinder with No. 2 brake piston is securely inserted into the transmission case.
   

Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.

Place SST on the No. 2 brake flange and compress the No. 2 brake piston return spring.

SST

09380-60010(09381-06010,09381-06020,09381-06050,09381-06070,09381-06090,09381-06120)

Using a screwdriver, install the snap ring to the transmission case.

Measure distance A (from the top surface of the snap ring to the top surface of the No. 2 brake piston return spring) in the illustration.*1

HINT:

Standard distance A: 21.00 to 21.76 mm (0.834 to 0.857 in.)

Assemble the 4 discs, 3 plates and flange as shown in the illustration. Then, with a fixture of 165.2 mm (6.50 in.) or less placed on the flange, measure distance B.*2

HINT:

Standard distance B: 16.54 to 17.15 mm (0.651 to 0.675 in.)

Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 2 brake flange indicated by the graph point.

HINT:

Make sure that when the B measurement and selected No. 2 brake flange thickness are subtracted from the A measurement, the value is 2.20 to 2.50 mm (0.0866 to 0.0984 in.).

Flange Thickness:

Mark	Thickness
0	1.95 to 2.05 mm (0.0768 to 0.0807 in.)
1	2.05 to 2.15 mm (0.0807 to 0.0846 in.)
2	2.15 to 2.25 mm (0.0846 to 0.0886 in.)
3	2.25 to 2.35 mm (0.0886 to 0.0925 in.)
4	2.35 to 2.45 mm (0.0925 to 0.0965 in.)
5	2.45 to 2.55 mm (0.0965 to 0.100 in.)
6	2.55 to 2.65 mm (0.100 to 0.104 in.)
7	2.65 to 2.75 mm (0.104 to 0.108 in.)

Remove the snap ring, flange and No. 2 brake piston return spring from the transmission case.

Install the No. 2 brake piston return spring, selected No. 2 brake flange, 4 No. 2 brake discs, 3 plates and flange.

Install in order:

S/F - D - P - D - P - D - P - D - F

HINT:

S/F = Selected flange

D = No. 2 brake disc

P = Plate

F = Flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Place SST on the flange and compress the No. 2 brake piston return spring.

SST

09380-60010(09381-06010,09381-06020,09381-06050,09381-06070,09381-06090,09381-06120)

Using a screwdriver, install the snap ring to the transmission case.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

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

NOTICE:

Make sure to install the center planetary sun gear with the groove facing the transmission case.

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

Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.

NOTICE:

Be careful not to damage the O-rings.

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

NOTICE:

1. 
   
2. When installing the No. 1 brake cylinder with No. 1 brake piston to the transmission case, align the cylinder claw with the groove in the top of the case
   
3. Make sure the No. 1 brake cylinder with No. 1 brake piston is securely inserted into the transmission case.
   

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

SST

09380-60010(09381-06010,09381-06020,09381-06050,09381-06060,09381-06090,09381-06100,09381-06110,09381-06120)

Using a screwdriver, install the snap ring to the transmission case.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Measure distance A (from the step in the transmission case to the tip of the No. 1 brake piston) in the illustration.*1

HINT:

Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)

Assemble the 4 plates and 4 discs and measure distance B in the illustration.*2

HINT:

Standard distance B: 16.72 to 17.19 mm (0.658 to 0.677 in.)

Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 1 brake flange indicated by the graph point.

HINT:

Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 0.56 to 0.86 mm (0.0220 to 0.0339 in.).

Flange Thickness:

Mark	Thickness
0	1.95 to 2.05 mm (0.0768 to 0.0807 in.)
1	2.15 to 2.25 mm (0.0846 to 0.0886 in.)
2	2.35 to 2.45 mm (0.0925 to 0.0965 in.)
3	2.55 to 2.65 mm (0.100 to 0.104 in.)

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

Using a screwdriver, install the snap ring.

Install the front planetary ring gear to the center planetary ring gear.

Install the thrust bearing race and thrust needle roller bearing.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

Bearing and Race Diameter:

Item	Inside	Outside
Race	62.85 to 63.1 mm (2.47 to 2.48 in.)	82.3 to 82.6 mm (3.24 to 3.25 in.)
Bearing	65.35 to 65.6 mm (2.57 to 2.58 in.)	85.6 to 85.95 mm (3.37 to 3.38 in.)

Install the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear to the transmission case.

Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.

HINT:

Use a small amount of MP grease to make the No. 2 planetary carrier thrust washer stay securely in place.

Install the thrust needle roller bearing, thrust bearing race, front planetary sun gear and front planetary gear assembly.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.

Bearing Diameter:

Item	Inside	Outside
Bearing	54.55 to 54.8 mm (2.15 to 2.16 in.)	70.0 to 70.5 mm (2.76 to 2.78 in.)
Race	55.0 to 55.2 mm (2.165 to 2.173 in.)	68.8 to 69.3 mm (2.71 to 2.73 in.)

Install the No. 1 planetary carrier thrust washer to the 1-way clutch inner race, and then install them to the 1-way clutch assembly.

HINT:

Use a small amount of MP grease to make the No. 1 planetary carrier thrust washer stay securely in place.

Install the 1-way clutch to the 1-way clutch inner race.

Hold the 1-way clutch inner race and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

Remove the 1-way clutch from the 1-way clutch inner race.

Install the 1-way clutch assembly with the 1-way clutch inner race to the transmission case.

Install the 4 plates, 4 discs and No. 1 brake flange.

Install in order:

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

HINT:

P = Plate

D = Disc

F = No. 1 brake flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.

Press the No. 3 brake piston into the No. 3 brake cylinder with both hands.

NOTICE:

Be careful not to damage the O-rings.

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

SST

09380-60010(09381-06020,09381-06040,09381-06060,09381-06100,09381-06110)

NOTICE:

Be sure the end gap of the snap ring is not aligned with the No. 3 brake piston return spring claw.

Install the No. 3 brake cylinder together with the No. 3 brake piston and No. 3 brake piston return spring to the transmission case.

NOTICE:

1. Align the oil holes of the No. 3 brake cylinder and transmission case as shown in the illustration.
   
2. Make sure the No. 3 brake piston and cylinder are securely inserted into the transmission case.
   

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Install the ''O'' mark flange, 4 discs, 3 plates and ''A'' mark flange to the transmission case.

Install in order:

OF - D - P - D - P - D - P - D - AF

HINT:

OF = ''O'' mark flange

P = Plate

D = Disc

AF = ''A'' mark flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

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

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

Press the direct clutch piston together with the direct clutch return spring and No. 2 clutch balancer into the clutch drum with both hands.

NOTICE:

Be careful not to damage the O-ring.

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

SST

09380-60010(09381-06030,09381-06040,09381-06080)

NOTICE:

Stop pressing when the spring sheet is lowered to a position 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.

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

NOTICE:

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

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

for 1VD-FTV:
Install the 6 plates, 6 discs and direct clutch flange to the clutch drum.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Direct clutch flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

for 1UR-FE, 3UR-FE:
Install the 5 plates, 5 discs and direct clutch flange to the clutch drum.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Direct clutch flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Using a screwdriver, install the snap ring to the clutch drum.

NOTICE:

Be careful not to damage the clutch drum.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Using a dial indicator, measure the moving distance (A) of the direct clutch flange at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm², 57 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.

Standard moving distance (A):

0.58 to 0.88 mm (0.0228 to 0.0346 in.)

Flange Thickness (for 1VD-FTV):

Mark	Thickness
0	3.45 to 3.55 mm (0.136 to 0.140 in.)
1	3.55 to 3.65 mm (0.140 to 0.144 in.)
2	3.65 to 3.75 mm (0.144 to 0.148 in.)
3	3.75 to 3.85 mm (0.148 to 0.152 in.)
4	3.85 to 3.95 mm (0.152 to 0.156 in.)
5	3.95 to 4.05 mm (0.156 to 0.159 in.)
6	4.05 to 4.15 mm (0.159 to 0.163 in.)
7	4.15 to 4.25 mm (0.163 to 0.167 in.)
8	4.25 to 4.35 mm (0.167 to 0.171 in.)
A	4.35 to 4.45 mm (0.171 to 0.175 in.)

Flange Thickness (for 1UR-FE, 3UR-FE):

Mark	Thickness
0	3.45 to 3.55 mm (0.136 to 0.140 in.)
1	3.55 to 3.65 mm (0.140 to 0.144 in.)
2	3.65 to 3.75 mm (0.144 to 0.148 in.)
3	3.75 to 3.85 mm (0.148 to 0.152 in.)
4	3.85 to 3.95 mm (0.152 to 0.156 in.)
5	3.95 to 4.05 mm (0.156 to 0.159 in.)
6	4.05 to 4.15 mm (0.159 to 0.163 in.)
7	4.15 to 4.25 mm (0.163 to 0.167 in.)
8	4.25 to 4.35 mm (0.167 to 0.171 in.)

Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

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

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

Insert the clutch drum into the reverse clutch piston with both hands.

NOTICE:

1. Be careful not to damage the O-ring.
   
2. Make sure to align the holes of the reverse clutch piston with those of the clutch drum as shown in the illustration.
   
3. Make sure to align the protrusions of the reverse clutch piston with the cutout of the clutch drum.
   

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

Install the reverse clutch return spring and No. 3 balancer to the reverse clutch piston.

Place SST on the clutch balancer and compress the clutch balancer with a press.

SST

09380-60010(09381-06020,09381-06030,09381-06040,09381-06050,09381-06070,09381-06080)

NOTICE:

Stop pressing when the spring sheet is lowered to a position 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.

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

NOTICE:

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

Using a screwdriver, install the snap ring to the clutch drum.

NOTICE:

1. Be careful not to damage the clutch drum.
   
2. Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.
   

HINT:

Wrap the tip of the screwdriver with protective tape before use.

for 1VD-FTV:
Install the flange, 4 discs, 3 plates, selected reverse clutch flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - S/F - C

HINT:

F = Flange

D = Disc

P = Plate

S/F = Selected reverse clutch flange

C = Cushion plate

for 1UR-FE, 3UR-FE:
Install the flange, 5 discs, 4 plates, selected reverse clutch flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P -D - S/F - C

HINT:

F = Flange

D = Disc

P = Plate

S/F = Selected reverse clutch flange

C = Cushion plate

Using a screwdriver, install the snap ring.

Using a dial indicator, measure the moving distance (A minus B) of the top surface of the reverse clutch piston (A) and cushion plate (B) at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm², 57 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard range.

Standard moving distance (A minus B):

for 1VD-FTV:

0.46 to 0.76 mm (0.0181 to 0.0299 in.)

for 1UR-FE, 3UR-FE:

0.59 to 0.89 mm (0.0232 to 0.0350 in.)

Flange Thickness:

Mark	Thickness
0	2.35 to 2.45 mm (0.0925 to 0.0965 in.)
1	2.45 to 2.55 mm (0.0965 to 0.100 in.)
2	2.55 to 2.65 mm (0.100 to 0.104 in.)
3	2.65 to 2.75 mm (0.104 to 0.108 in.)
4	2.75 to 2.85 mm (0.108 to 0.112 in.)
5	2.85 to 2.95 mm (0.112 to 0.116 in.)
6	2.95 to 3.05 mm (0.116 to 0.120 in.)
7	3.05 to 3.15 mm (0.120 to 0.124 in.)
8	3.15 to 3.25 mm (0.124 to 0.128 in.)
A	3.25 to 3.35 mm (0.128 to 0.132 in.)
B	3.35 to 3.45 mm (0.132 to 0.136 in.)
C	3.45 to 3.55 mm (0.136 to 0.140 in.)

Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.

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

Install the forward clutch piston to the input shaft.

Install the coast clutch piston to the input shaft.

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

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

NOTICE:

Be careful not to damage the O-rings.

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

SST

09350-30020(09350-07040)

NOTICE:

Stop pressing when the spring sheet is lowered to a position 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.

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

NOTICE:

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

for 1VD-FTV:
Install the 5 plates, 5 discs and coast clutch flange.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

for 1UR-FE, 3UR-FE:
Install the 4 plates, 4 discs and coast clutch flange.

Install in order:

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

HINT:

P = Plate

D = Disc

F = Flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Temporarily install the snap ring.

NOTICE:

Be careful not to damage the forward clutch piston.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Using a dial indicator, measure the moving distance (A) of the coast clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm², 28 psi) into the oil hole as shown in the illustration. Then choose from the 11 flange thicknesses in the table so that the measured value is within the standard range.

Standard moving distance (A):

for 1VD-FTV:

0.51 to 0.81 mm (0.0201 to 0.0319 in.)

for UR Engine Series:

0.41 to 0.71 mm (0.0161 to 0.0280 in.)

Flange Thickness:

Mark	Thickness
0	2.95 to 3.05 mm (0.116 to 0.120 in.)
1	3.05 to 3.15 mm (0.120 to 0.124 in.)
2	3.15 to 3.25 mm (0.124 to 0.128 in.)
3	3.25 to 3.35 mm (0.128 to 0.132 in.)
4	3.35 to 3.45 mm (0.132 to 0.136 in.)
5	3.45 to 3.55 mm (0.136 to 0.140 in.)
6	3.55 to 3.65 mm (0.140 to 0.144 in.)
7	3.65 to 3.75 mm (0.144 to 0.148 in.)
8	3.75 to 3.85 mm (0.148 to 0.152 in.)
A	3.85 to 3.95 mm (0.152 to 0.156 in.)
B	3.95 to 4.05 mm (0.156 to 0.159 in.)

Temporarily remove the snap ring, install the selected coast clutch flange and reinstall the snap ring.

NOTICE:

Be careful not to damage the forward clutch piston.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Install the cushion plate, 6 plates, 6 discs and flange to the input shaft.

Install in order:

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

HINT:

C = Cushion plate

P = Plate

D = Disc

F = Flange

NOTICE:

Before assembling new discs, soak them in ATF for at least 2 hours.

Temporarily install the snap ring.

NOTICE:

Be careful not to damage the forward clutch piston.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm², 28 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard range.

Standard moving distance (A):

0.85 to 1.15 mm (0.0335 to 0.0453 in.)

Flange Thickness:

Mark	Thickness
0	2.95 to 3.05 mm (0.116 to 0.120 in.)
1	3.05 to 3.15 mm (0.120 to 0.124 in.)
2	3.15 to 3.25 mm (0.124 to 0.128 in.)
3	3.25 to 3.35 mm (0.128 to 0.132 in.)
4	3.35 to 3.45 mm (0.132 to 0.136 in.)
5	3.45 to 3.55 mm (0.136 to 0.140 in.)
6	3.55 to 3.65 mm (0.140 to 0.144 in.)
7	3.65 to 3.75 mm (0.144 to 0.148 in.)
8	3.75 to 3.85 mm (0.148 to 0.152 in.)
A	3.85 to 3.95 mm (0.152 to 0.156 in.)
B	3.95 to 4.05 mm (0.156 to 0.159 in.)
C	4.05 to 4.15 mm (0.159 to 0.163 in.)

Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.

NOTICE:

Be careful not to damage the forward clutch piston.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

Install the No. 2 clutch hub thrust washer to the coast clutch hub.

HINT:

Use a small amount of MP grease to make the No. 2 clutch hub thrust washer stay securely in place.

Install the No. 4 1-way clutch assembly to the coast clutch hub.

Hold the coast clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

Install the 2 thrust needle roller bearings, thrust bearing race and coast clutch hub with the No. 4 1-way clutch assembly to the input shaft.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearings and thrust bearing race stay securely in place.

Bearing and Race Diameter:

Item	Inside	Outside
Bearing C	21.05 to 21.3 mm (0.829 to 0.839 in.)	39.63 to 39.88 mm (1.56 to 1.57 in.)
Race	22.8 to 23.1 mm (0.898 to 0.909 in.)	44.5 to 44.75 mm (1.75 to 1.76 in.)
Bearing D	39.45 to 39.7 mm (1.55 to 1.56 in.)	60.5 to 60.75 mm (2.38 to 2.39 in.)

Overlap the seal ring edges in the axial direction.

NOTICE:

1. Overlapping the seal ring edges in the axial direction prevents damage to the seal ring.
   
2. Do not overlap the seal ring edges in the radial direction, as this may damage the seal ring.
   

Coat 4 new oil seal rings with ATF.

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

NOTICE:

Do not excessively widen the rings.

HINT:

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

Install the input shaft to the clutch drum.

Install the No. 3 clutch hub thrust washer, forward clutch hub and thrust needle roller bearing to the clutch drum.

NOTICE:

Before installing the forward clutch hub, apply ATF to the sliding surfaces of the forward clutch hub bush. After the installation, check that the forward clutch hub rotates smoothly.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearing and No. 3 clutch hub thrust washer stay securely in place.

Bearing Diameter:

Item	Inside	Outside
Bearing	46.45 to 46.7 mm (1.83 to 1.84 in.)	64.3 to 64.55 mm (2.53 to 2.54 in.)

Install the reverse clutch hub to the clutch drum.

NOTICE:

Before installing of the reverse clutch hub, apply ATF to the sliding surfaces of the reverse clutch hub bush. After the installation, check that the reverse clutch rotates smoothly.

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the clutch drum.

HINT:

Wrap the tip of the screwdriver with protective tape before use.

for 1VD-FTV:
Install the flange, 4 discs, 3 plates, selected reverse clutch flange and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - S/F - C

HINT:

F = Flange

D = Disc

P = Plate

S/F = Selected reverse clutch flange

C = Cushion plate

for 1UR-FE, 3UR-FE:
Install the flange, 5 discs, 4 plates, selected reverse clutch flange and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P - D - S/F - C

HINT:

F = Flange

D = Disc

P = Plate

S/F = Selected reverse clutch flange

C = Cushion plate

Using a screwdriver, install the snap ring to the clutch drum.

Install the clutch drum thrust washer to the clutch drum.

HINT:

Use a small amount of MP grease to make the clutch drum thrust washer stay securely in place.

Install the 1-way clutch to the clutch drum.

Hold the reverse clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

Install the 2 thrust needle roller bearings.

HINT:

Use a small amount of MP grease to make the thrust needle roller bearings stay securely in place.

Bearing Diameter:

Item	Inside	Outside
Bearing A	71.96 to 72.26 mm (2.83 to 2.84 in.)	85.25 to 85.6 mm (3.36 to 3.37 in.)
Bearing B	36.45 to 36.7 mm (1.44 to 1.45 in.)	52.96 to 53.26 mm (2.09 to 2.10 in.)

Coat the clutch drum thrust washer with petroleum jelly and install it to the clutch drum and input shaft assembly.

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

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

Install the 2 thrust bearing races to the front oil pump assembly.

Thrust Bearing Race Diameter:

Item	Inside	Outside
Race A	74.26 to 74.56 mm (2.92 to 2.94 in.)	87.39 to 87.74 mm (3.44 to 3.45 in.)
Race B	38.0 to 38.3 mm (1.50 to 1.51 in.)	53.9 to 54.1 mm (2.12 to 2.13 in.)

Pass the input shaft through the center hole of the oil pump assembly, 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.

Apply seal packing to the flanges of the bolts.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

Do not allow seal packing to contact the bolt threads.

Install the 10 bolts.

Torque:

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

NOTICE:

During installation, do not allow oil to contact the bolts or the surface of the oil pump body.

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

HINT:

When inspecting the direct clutch, check with the accumulator piston holes indicated in the illustration.

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

1. No. 2 clutch (C2)
   
2. No. 3 clutch (C3)
   
3. No. 4 clutch (C4)
   
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)
   

Using SST, 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 sub-assembly.

Push the manual valve lever shaft through the transmission case and install the manual valve lever sub-assembly to the manual valve lever shaft.

Using a hammer, tap in a new spring pin.

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

Check that the shaft rotates smoothly.

Install a new E-ring to the shaft.

Install the parking lock pawl, shaft and spring.

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

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

Torque:

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

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

Install the 2 springs and accumulator valve to the hole.

Spring Diameter:

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

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

Install the spring and accumulator piston to the hole.

Spring Diameter:

Spring	Free Length Outer Diameter	Color
C-3	76.65 mm (3.02 in.) 20.1 mm (0.791 in.)	for 1VD-FTV: White
		for 1UR-FE, 3UR-FE: Natural

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

Install the spring and accumulator piston to the hole.

Spring Diameter:

Spring	Free Length Outer Diameter	Color
B-3	64.50 mm (2.54 in.) 19.5 mm (0.768 in.)	Orange

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

Install the spring and accumulator piston to the hole.

Spring Diameter:

Spring	Free Length Outer Diameter	Color
C-2	68.0 mm (2.68 in.) 16.1 mm (0.634 in.)	for 1VD-FTV: Blue
		for 1UR-FE, 3UR-FE: Light green

Install the spring and check ball body.

Install 3 new brake drum gaskets.

Install 3 new transmission case gaskets.

Align the hole 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:

Each bolt length is indicated below.

36 mm (1.42 in.) for bolt A

25 mm (0.984 in.) for bolt B

45 mm (1.77 in.) for bolt C

50 mm (1.97 in.) for bolt D

Install the detent spring and detent spring cover with the bolt.

Torque:

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

Install 2 new O-rings to the transmission wires.

Install the transmission wire harnesses.

Install the No. 1 transmission wire and No. 2 transmission wire with the 2 bolts.

Torque:

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

Connect the 9 connectors to the solenoid valves.

Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.

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}

HINT:

Each bolt length is indicated below.

12 mm (0.472 in.) for bolt A

36 mm (1.42 in.) for bolt B

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

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

Torque:

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

Install the 4 magnets.

Install a new gasket to the oil pan.

Install the oil pan with the 12 bolts.

Torque:

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

NOTICE:

1. 
   
2. Make sure that there is no oil or foreign matter on the gasket seal surface and oil pan contact surface.
   
3. Install the gasket so that there is no slack in the gasket, and make sure the entire circumference of the seal surface is level.
   
4. Make sure that the 9 gasket drop prevention protrusions are attached to the oil pan.
   
5. When tightening the bolts of the oil pan, make sure that the gasket is not pinched between the gasket tightening area sleeve and the transmission seal surface.
   

Install the drain plug.

Torque:

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

Using SST and a press, press in the bearing until it stops.

SST

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

Using a screwdriver, install the snap ring.

Coat the lip of a new oil seal with ATF.

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

Standard depth:

0 to 1 mm (0 to 0.0394 in.)

SST

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

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

Apply seal packing to the rear transfer adapter.

Seal packing:

Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent

Seal diameter:

1.0 to 1.5 mm (0.0394 to 0.0591 in.)

Install the rear transfer adapter with the 10 bolts.

Torque:

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

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

Install the transmission housing with the 14 bolts.

Torque:

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

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

Install the breather tube with the 2 bolts.

Torque:

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

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

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

Temporarily install bolt labeled A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt labeled A to the specified torque.

Torque:

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

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

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

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

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

Install the 2 speed sensors.

Install the 2 bolts.

Torque:

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

Clean the bolt and the 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

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

Install a new lock washer and the 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 RH.

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

Remove the control shaft lever RH.

Align the groove with the neutral basic line.

Hold the switch in position and tighten the bolt.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

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

Install the transmission control shaft lever RH with the washer and nut.

Torque:

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