Automatic Transmission Unit: Reassembly

1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
2. Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
3. Install the No. 4 brake piston to the reaction sleeve.
   Fig 2: Identifying Brake Piston No.4 To Reaction Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the 4 O-rings.

1. With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and the No. 4 brake piston to the transmission case.
   Fig 3: Identifying Brake Reaction Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the O-rings.

1. Coat a new O-ring with ATF.
2. Install the O-ring on the 1st and reverse brake piston.
3. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.
   Fig 4: Identifying 1St And Reverse Brake Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the O-ring.

1. Place the brake return spring onto the brake piston.
2. Place SST on the brake return spring, and compress the return spring.

   SST 09350-30020 (09350-07050) 

3. Using the SST, install the snap ring.

   SST 09350-30020 (09350-07070) 

Fig 5: Identifying 1St And Reverse Brake Return Spring Sub-Assembly

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1. Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

Fig 6: Identifying Brake Apply Tube

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1. Install the thrust needle roller bearing.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Thrust needle roller bearing	40.6 mm (1.598 in.)	58.0 mm (2.284 in.)

   Fig 7: Identifying Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the thrust needle roller bearing.
3. Coat the No. 9 thrust bearing race and thrust bearing race with petroleum jelly, and install them onto the rear planetary gear.

   Bearing and race diameter 

   BEARING AND RACE DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Bearing	20.8 mm (0.819 in.)	38.5 mm (1.516 in.)
   Thrust bearing Race	19.0 mm (0.748 in.)	35.0 mm (1.378 in.)
   No. 9 thrust bearing Race	43.3 mm (1.705 in.)	56.7 mm (2.232 in.)

   Fig 8: Identifying No 9 Thrust Bearing Race And Thrust Bearing Race

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4. Install the rear planetary gear assembly.

1. Install the 4 plates, the 5 discs and the 2 flanges.

   Install in order: 

   P = Plate, D = Disc, F = Flange 

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

Fig 10: Identifying Plates, Discs And Flanges

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1. Install the brake plate stopper spring.

Fig 11: Identifying Brake Plate Stopper Spring

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

Fig 12: Identifying No 8 Thrust Bearing Race And Thrust Needle Roller Bearing

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Bearing and race diameter 

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

Fig 13: View Of 1 Way No 3 Clutch Assembly & Intermediate Shaft Inner Race

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1. Install the intermediate shaft with the No. 3 one way clutch assembly to the case.
   Fig 14: Identifying Intermediate Shaft

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2. Using SST, install the snap ring.

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

Fig 15: Identifying Snap Ring

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1. Install the center planetary gear assembly and the planetary sun gear to the case.
2. Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

Race diameter 

Fig 16: View Of Center Planetary Gear Assembly

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1. Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.
2. Press the No. 2 brake piston into the No. 2 brake cylinder.
   Fig 17: Identifying No 2 Brake Piston

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the 2 O-rings.
3. Install the No. 2 brake piston to the case.

   HINT:

   Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.

4. Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

Fig 18: Identifying Oil Pressure Apply Hole Of Now 2 Brake Cylinder

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1. Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F -D - P - D - P - D - P - D - F 

   Fig 19: Identifying Flanges, Plates, Discs And Brake Piston Return Spring

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2. Using SST, a screwdriver and a press, install the No. 2 brake spring snap ring.

   SST 09351-40010 (09351-04010, 09351-04020, 09351-04040, 09351-04050) 

Fig 20: Identifying No 2 Brake Spring Snap Ring

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1. Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.
2. Press the No. 1 brake piston into the No. 1 brake cylinder.
   NOTE: Be careful not to damage the 2 O-rings.

Fig 21: Identifying O-Rings On No 1 Brake Piston

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1. Install the brake piston return spring and the No. 1 brake piston with the No. 1 brake cylinder to the transmission case.
   Fig 22: Identifying Brake Piston Return Spring

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   HINT:

   Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.

2. Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

Fig 23: Identifying Oil Pressure Apply Hole Of No 2 Brake Cylinder

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1. Using SST, a screwdriver and a press, install the brake piston return spring snap ring.

   SST 09351-40010 (09351-04010, 09351-04030, 09351-04040, 09351-04050) 

Fig 24: Identifying Brake Piston Return Spring Snap Ring

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1. Install the thrust needle roller bearing to the front planetary ring gear flange.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Thrust needle roller bearing	58.5 mm (2.303 in.)	73.5 mm (2.894 in.)

2. Install the center planetary ring gear flange to the center planetary ring gear.
3. Using a screwdriver, install the snap ring.
   Fig 25: Identifying Snap Ring (1 Of 2)

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4. Install the center planetary ring gear to the front planetary ring gear.
5. Using a screwdriver, install the snap ring.
   NOTE: Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.

Fig 26: Identifying Snap Ring (2 Of 2)

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1. Install the front planetary ring gear to the case.

Fig 27: Identifying Front Planetary Ring Gear

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1. Install the thrust needle roller bearing and the thrust washer.
2. Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

   Thrust needle roller bearing and race diameter 

   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Bearing	38.6 mm (1.520 in.)	53.1 mm (2.091 in.)
   Race	34.9 mm (1.374 in.)	50.8 mm (2.0 in.)

   Fig 28: Identifying Thrust Needle Roller Bearing And Thrust Washer

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3. Install the front planetary gear assembly and the one way clutch inner race to the case.

1. Install the 3 plates, the 3 discs and the flange.

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F - D - P - D - P - D - P 

Fig 30: Identifying Plates, Discs And Flange

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1. Install the 2nd brake cylinder to the case.
   Fig 31: Identifying 2Nd Brake Cylinder For Case

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2. Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.

Fig 32: Identifying Oil Pressure Apply Hole Of 2Nd Brake Cylinder

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

Fig 33: Identifying One Way Clutch Assembly And Thrust Washer

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

Fig 34: Identifying Snap Ring

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1. Install the flange, the 3 discs and the 3 plates to the case.

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F - D - P - D - P - D - P 

Fig 35: Identifying Flange, Discs And Plates With Case

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1. Using a screwdriver, install the snap ring.

   SST 09350-30020 (09350-07060) 

Fig 36: Removing/Installing Snap Ring

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1. Install the No. 2 one way clutch assembly and No. 2 washer to the clutch drum and input shaft.

1. Install the 2 thrust needle roller bearings and thrust washer.
2. Coat the race and washer with petroleum jelly and install them onto the clutch drum and input shaft assembly.
   Fig 38: Identifying Thrust Needle Roller Bearings And Thrust Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING AND DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Thrust needle roller bearing A	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
   Bearing Race	37.0 mm (1.457 in.)	51.2 mm (2.016 in.)
   Thrust needle roller bearing B	33.5 mm (1.319 in.)	48.0 mm (1.890 in.)

3. Install the clutch drum and input shaft into the transmission case.

Fig 39: Installing Clutch Drum And Input Shaft Into Transmission Case

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1. Install the No. 1 thrust bearing race to the front oil pump.
   THRUST BEARING RACE DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Race	74.2 mm (2.921 in.)	87.7 mm (3.453 in.)

   Fig 40: Identifying O-Ring And Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with ATF, and install it around the oil pump assembly.
3. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.
4. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.
5. Install the 9 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

Fig 41: Identifying Bolts

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

   SST 09350-30020 (09350-07110) 

2. Coat the oil seal lips with MP grease.

1. Install a new spacer to the manual valve lever.
2. Install the manual valve lever shaft to the transmission case through the manual valve lever.
   Fig 43: Installing Manual Valve Lever Shaft To Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hammer, drive in a new spring pin.
   Fig 44: Identifying Spring Pin

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4. Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.
5. Make sure that the shaft rotates smoothly.
   Fig 45: Aligning Manual Valve Lever Indentation With Spacer Hole And Staking With Punch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new E-ring to the shaft.
2. Install a new parking lock pawl, the shaft and the spring.

Fig 46: Identifying Parking Lock Pawl Shaft

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1. Connect the parking lock rod to the manual valve lever.

Fig 47: View Of Parking Lock Rod And Manual Valve Lever

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

   Torque: 7.3 N*m (74 kgf*cm, 65 in.*lbf) 

   Fig 48: Identifying Parking Lock Pawl Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Shift the manual valve lever to the P position, and confirm that the planetary gear is correctly locked up by the lock pawl.

Fig 49: Locking Planetary Gear By Lock Pawl

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1. Install the spring and the accumulator valve to the hole.

B-1 accumulator spring 

Fig 50: Identifying Spring And Accumulator Valve

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1. Coat 2 new O-rings with ATF, and install them to the piston.
2. Install the 2 springs and the accumulator piston to the hole.

C-3 accumulator spring 

Inner spring: 

Fig 51: Identifying C-3 Accumulator Piston

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Outer spring: 

1. Coat 2 new O-rings with ATF, and install them to the piston.
2. Install the spring and the accumulator piston to the hole.

Fig 52: Identifying B-3 Accumulator Piston

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Accumulator spring 

1. Coat 2 new O-rings with ATF, and install them to the piston.
2. Install the spring and the accumulator piston to the hole.

Fig 53: Identifying C-2 Accumulator Piston

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Accumulator spring 

1. Install the check ball body and the spring.

Fig 54: Identifying Check Ball Body

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1. Install the 3 new brake drum gaskets.

Fig 55: Identifying New Brake Drum Gaskets

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1. Install the 3 new transaxle case gaskets.

Fig 56: Identifying New Transaxle Case Gaskets

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1. Align the groove of the manual valve lever with the pin of the manual valve.
   Fig 57: Aligning Groove Of Manual Valve Lever With Pin Of Manual Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 19 bolts.

   Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 

   Fig 58: Identifying Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   25 mm (0.98 in.) 

   Bolt B: 

   36 mm (1.42 in.) 

   Bolt C: 

   45 mm (1.77 in.) 

   Bolt D: 

   50 mm (1.97 in.) 

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

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

Fig 59: Identifying Detent Spring And Detent Spring Cover

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1. Coat a new O-ring with ATF.
2. Install the O-ring to the transmission wire.
   Fig 60: Identifying O-Ring And Transmission Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transmission wire harness.
4. Install the bolt.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 61: Locating Transmission Internal Wiring Harness bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 9 solenoid connectors.
   Fig 62: Identifying Solenoid Connectors

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6. Install the ATF temperature sensor.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 63: Identifying ATF Temperature Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the clamp and the 2 bolts.

   Torque: Bolt A 

   6.4 N*m (65 kgf*cm, 57 in.*lbf) 

   Bolt B 

   10 N*m (102 kgf*cm, 7 ft.*lbf) 

Fig 64: Identifying Clamps

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1. Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.
   Fig 65: Identifying O-Ring And Valve Body Oil Strainer Assembly

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2. Install the oil strainer with the 4 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

Fig 66: Oil Strainer With mounting Bolts

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1. Install the 3 transmission oil cleaner magnets.

1. Install a new gasket on the oil pan.
   Fig 67: Identifying Transmission Oil Cleaner Magnets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install and tighten the 20 bolts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

3. Install a new gasket and the drain plug.

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

4. Install a new gasket and the overflow plug.

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

Fig 68: Identifying Bolts

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1. Coat the lip of a new oil seal with MP grease.
2. Using SST and a hammer, install a new oil seal until it fits with the extension housing.

   SST 09325-40010 

   Oil seal drive in depth: 

   5.4 to 5.8 mm (0.213 to 0.228 in.) 

Fig 69: Identifying Automatic Transmission Extension Housing Oil Seal

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1. Using SST and a press, install a new extension housing dust deflector.

   SST 09950-60020 (09951-01030) 

Fig 70: Identifying Extension Housing Dust Deflector

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1. Install the transmission case adapter radial ball bearing to the extension housing.
2. Using a snap ring plier, install the snap ring.
   Fig 71: Identifying Snap Ring (1 Of 2)

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3. Install the thrust needle roller bearing and the 2 bearing races.
4. Using a snap ring expander, install the snap ring.
   Fig 72: Identifying Snap Ring (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the snap ring and the race.

   Clearance: 

   0.02 to 0.12 mm (0.0008 to 0.0047 in.) 

   Fig 73: Checking Clearance Between Snap Ring And Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   If the clearance is outside the specified range, select another race that brings the clearance within the specified range.

   HINT:

   There are 12 different thicknesses for the race.

   Flange thickness 

   FLANGE THICKNESS SPECIFICATION
   
   

   NO.	Thickness	NO.	Thickness
   1	3.80 mm (0.1496 in.)	7	4.10 mm (0.1614 in.)
   2	3.85 mm (0.1516 in.)	8	4.15 mm (0.1634 in.)
   3	3.90 mm (0.1535 in.)	9	4.20 mm (0.1653 in.)
   4	3.95 mm (0.1555 in.)	10	4.25 mm (0.1673 in.)
   5	4.00 mm (0.1575 in.)	11	4.30 mm (0.1693 in.)
   6	4.05 mm (0.1594 in.)	12	4.35 mm (0.1713 in.)

6. Clean the threads of the bolts and the case with white gasoline.
7. Apply FIPG to the extension housing as shown in the illustration.

   FIPG: 

   Seal Packing 1281, THREE BOND 1281 or equivalent 

   Fig 74: Applying FIPG To Extension Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 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: 

   Bolt A: 

   45 mm (1.772 in.) 

   Bolt B: 

   35 mm (1.378 in.) 

   Fig 75: Identifying Extension Housing

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1. Clean the threads of the bolts and the case with white gasoline.
2. Install the transmission housing with the 10 bolts.
   Fig 76: Identifying Automatic Transmission Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: A {14 mm (0.551 in.) bolt} 

   34 N*m (347 kgf*cm, 25 ft.*lbf) 

   B {17 mm (0.669 in.) bolt} 

   57 N*m (581 kgf*cm, 42 ft.*lbf) 

1. Install the breather tube.
2. Install the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 77: Identifying Automatic Transmission Breather Tube

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1. Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.
2. Install the 2 transmission revolution sensors.
3. Install the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 78: Identifying Transmission Revolution Sensor

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1. Coat 2 new O-rings with ATF, and install them to the transmission oil cooler.
   Fig 79: Identifying O-Rings And Transmission Oil Cooler

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2. Install the transmission oil cooler with the 3 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

Fig 80: Identifying Transmission Oil Cooler

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1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.
2. Install a new lock washer. Install and tighten the nut.

   Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

   Fig 81: Identifying Park/Neutral Position Switch Assembly

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3. Using the control shaft lever, turn the manual lever shaft back all the way and then forward 2 notches. It is now in neutral.
   Fig 82: Positioning Manual Lever Shaft In Neutral Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. 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) 

   Fig 83: Aligning Neutral Basic Line With Switch Groove

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

   HINT:

   Bend at least 2 of the lock washer tabs.

Fig 84: Bending Tabs Of Lock Washer

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1. Install the control shaft lever RH, washer and the nut.

   Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

Fig 85: Identifying Control Shaft Lever RH

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1. Install the transmission case cover with the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 86: Locating Transaxle Case Cover Bolts

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