Reassembly [08/2015 - ]: Procedure
- BEARING POSITION
Bearing and Race Diameter
Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside A 74.3 to 74.6 mm (2.93 to 2.94 in.)/87.4 to 87.7 mm (3.44 to 3.45 in.) 72.0 to 72.3 mm (2.83 to 2.85 in.)/85.3 to 85.6 mm (3.36 to 3.37 in.) - B 37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.) 34.7 to 34.9 mm (1.366 to 1.374 in.)/51.6 to 51.9 mm (2.03 to 2.04 in.) - C - 21.4 to 21.6 mm (0.841 to 0.850 in.)/40.8 to 41.0 mm (1.606 to 1.614 in.) 22.7 to 22.9 mm (0.892 to 0.902 in.)/60.0 to 60.4 mm (2.36 to 2.38 in.) D 33.3 to 33.5 mm (1.31 to 1.32 in.)/56.3 to 56.6 mm (2.22 to 2.23 in.) 38.5 to 38.7 mm (1.515 to 1.524 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) - E - 42.6 to 42.8 mm (1.68 to 1.69 in.)/60.8 to 61.1 mm (2.39 to 2.41 in.) - F 38.0 to 38.2 mm (1.496 to 1.504 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.) 43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.4 mm (2.28 to 2.30 in.) - G - 55.8 to 56.0 mm (2.197 to 2.204 in.)/76.1 to 76.4 mm (2.996 to 3.008 in.) 53.8 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.) H 33.4 to 33.6 mm (1.31 to 1.32 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.) 32.2 to 32.3 mm (1.268 to 1.272 in.)/49.0 to 49.2 mm (1.93 to 1.94 in.) 32.2 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.) I - 21.5 to 21.8 mm (0.846 to 0.858 in.)/40.5 to 40.8 mm (1.59 to 1.61 in.) - J - 43.6 to 43.9 mm (1.72 to 1.73 in.)/60.6 to 60.9 mm (2.39 to 2.40 in.) 47.2 to 47.4 mm (1.86 to 1.87 in.)/66.9 to 67.1 mm (2.63 to 2.64 in.) K 36.9 to 37.2 mm (1.45 to 1.46 in.)/49.4 to 50.0 mm (1.94 to 1.97 in.) 36.15 to 36.31 mm (1.42 to 1.43 in.)/52.06 to 52.36 mm (2.05 to 2.06 in.) 36.15 to 36.4 mm (1.42 to 1.43 in.)/50.5 to 51.0 mm (1.99 to 2.01 in.) - ASSEMBLE NO. 4 BRAKE PISTON AND BRAKE REACTION SLEEVE
- INSTALL NO. 4 BRAKE PISTON WITH BRAKE REACTION SLEEVE
- Install the No. 4 brake piston with brake reaction sleeve to the transmission case.NOTE:
- Do not damage the O-rings.
- Make sure the No. 4 brake piston is underneath the brake reaction sleeve.
- Install the No. 4 brake piston with brake reaction sleeve to the transmission case.
- INSTALL 1ST AND REVERSE BRAKE PISTON
- Coat a new O-ring with ATF.
- Install the O-ring to the 1st and reverse brake piston.
- With the spring seat of the piston facing upwards (the front side), install the piston to the transmission case.NOTE:
Be careful not to damage the O-ring.
- INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
- INSTALL REAR PLANETARY GEAR ASSEMBLY
- Install the No. 9 thrust bearing race.
Thrust Bearing Race Diameter
Item Inside Outside Race J 47.2 to 47.4 mm (1.86 to 1.87 in.) 66.9 to 67.1 mm (2.63 to 2.64 in.) - Coat the 2 thrust needle roller bearings with petroleum jelly and install them to the rear planetary gear.
Thrust Needle Roller Bearing Diameter
Item Inside Outside Bearing J 43.6 to 43.9 mm (1.72 to 1.73 in.) 60.6 to 60.9 mm (2.39 to 2.40 in.) Bearing I 21.5 to 21.8 mm (0.846 to 0.858 in.) 40.5 to 40.8 mm (1.59 to 1.61 in.) TEXT IN ILLUSTRATION*1 Bearing I *2 Bearing J - Install the rear planetary gear assembly.
- Install the rear planetary flange thrust bearing race, thrust needle roller bearing and thrust bearing selective race.TEXT IN ILLUSTRATION
*1 Race K *2 Bearing K *2 Selective Race - Using a snap ring expander, install the snap ring.
- Using a dial indicator, measure the rear planetary gear end play.
Standard end play
0.02 to 0.12 mm (0.000787 to 0.00472 in.)
If the end play is not as specified, replace the thrust bearing race shown in the illustration with one of a different thickness so that the measured value is within the standard range.
HINT:
Use the table below to select a thrust bearing race of an appropriate thickness.
Bearing Race Thickness
Mark Thickness 3.775 to 3.825 mm (0.149 to 0.151 in.) 3.825 to 3.875 mm (0.151 to 0.153 in.) 3.875 to 3.925 mm (0.153 to 0.155 in.) 3.925 to 3.975 mm (0.155 to 0.156 in.) 3.975 to 4.025 mm (0.156 to 0.158 in.) 4.025 to 4.075 mm (0.158 to 0.160 in.) 4.075 to 4.125 mm (0.160 to 0.162 in.) 4.125 to 4.175 mm (0.162 to 0.164 in.) 4.175 to 4.225 mm (0.164 to 0.166 in.) 4.225 to 4.275 mm (0.166 to 0.168 in.) 4.275 to 4.325 mm (0.168 to 0.170 in.) 4.325 to 4.375 mm (0.170 to 0.172 in.)
- Install the No. 9 thrust bearing race.
- SELECT 1ST AND REVERSE BRAKE FLANGE
- Using a vernier caliper, measure distance A (from the top surface of the 1st and reverse brake piston to the step in the transmission case) in the illustration.NOTE:
Make sure the 1st and reverse brake piston is installed securely to the transmission case.
HINT:
Distance A = 36.35 to 37.09 mm (1.43 to 1.46 in.)
- Assemble the 2 flanges, 8 discs and 7 plates, and using a vernier caliper, measure distance B in the illustration at both ends across the diameter, and calculate the average.
HINT:
Distance B = 36.04 to 37.14 mm (1.42 to 1.46 in.)
- Select a 1st and reverse brake flange so that the value of measured distance A minus distance B is 2.85 to 3.15 mm (0.112 to 0.124 in.).
Flange H Thickness
No. Thickness 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.) 12 1.15 to 1.25 mm (0.0453 to 0.0492 in.) 14 1.35 to 1.45 mm (0.0531 to 0.0571 in.)
- Using a vernier caliper, measure distance A (from the top surface of the 1st and reverse brake piston to the step in the transmission case) in the illustration.
- INSTALL NO. 4 BRAKE DISC
- INSTALL BRAKE PLATE STOPPER SPRING
- INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
- Install the thrust bearing race, thrust needle roller bearing, thrust bearing race and planetary ring gear flange to the intermediate shaft.
Thrust Needle Roller Bearing and Race Diameter
Item Inside Outside Race H Rear 32.2 to 32.4 mm (1.27 to 1.28 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.) Bearing H 32.2 to 32.3 mm (1.268 to 1.272 in.) 49.0 to 49.2 mm (1.93 to 1.94 in.) Race H Front 33.4 to 33.6 mm (1.31 to 1.32 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.) TEXT IN ILLUSTRATION*1 Race H Rear *2 Race H Front
- Install the thrust bearing race, thrust needle roller bearing, thrust bearing race and planetary ring gear flange to the intermediate shaft.
- INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY
- Install the 1-way clutch and 1-way clutch inner race to the intermediate shaft.
- INSTALL INTERMEDIATE SHAFT
- INSTALL CENTER PLANETARY GEAR ASSEMBLY
- INSTALL NO. 2 BRAKE PISTON
- INSTALL NO. 2 BRAKE DISC
- INSTALL NO. 1 BRAKE PISTON
- INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
- Install the No. 1 brake piston with No. 1 brake cylinder and the brake piston return spring to the transmission case.
- INSTALL BRAKE PISTON RETURN SPRING SNAP RING
- Using SST and a press, compress the return spring and install the brake piston return spring snap ring.
- SST: 09351-40010
- Using SST and a press, compress the return spring and install the brake piston return spring snap ring.
- SELECT NO. 1 BRAKE FLANGE
- Using a feeler gauge, measure the distance between the snap ring and flange.
HINT:
0.42 to 0.72 mm (0.0165 to 0.0283 in.)
If the distance is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the distance is still outside the specification, select No. 1 brake flange so that the value of measured distance is 0.42 to 0.72 mm (0.0165 to 0.0283 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.)
- Using a feeler gauge, measure the distance between the snap ring and flange.
- INSTALL NO. 1 BRAKE DISC
- INSTALL CENTER PLANETARY RING GEAR
- INSTALL FRONT PLANETARY RING GEAR
- INSTALL FRONT PLANETARY GEAR ASSEMBLY
- Install the thrust washer and thrust needle roller bearing.
- Coat the No. 5 thrust race with petroleum jelly and install it to the front planetary ring gear.
Thrust Needle Roller Bearing and Race Diameter
Item Inside Outside Bearing F 43.4 to 43.6 mm (1.71 to 1.72 in.) 58.0 to 58.4 mm (2.28 to 2.30 in.) Race F 38.0 to 38.2 mm (1.496 to 1.504 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.) TEXT IN ILLUSTRATION*1 Bearing F *2 Race F - Install the front planetary gear assembly and 1-way clutch inner race to the case.
- INSTALL 2ND BRAKE PISTON
- Coat 2 new O-rings with ATF and install them to the 2nd brake piston.TEXT IN ILLUSTRATION
*1 New O-Ring - Press the 2nd brake cylinder into the 2nd brake piston with both hands.NOTE:
Be careful not to damage the O-rings.
- Install the return spring to the 2nd brake cylinder.
- Using SST and a press, compress the return spring and install the snap ring.
- SST: 09351-40010
NOTE:Make sure the end gap of the snap ring is not aligned with the spring retainer claw.
- Coat 2 new O-rings with ATF and install them to the 2nd brake piston.
- INSTALL 2ND BRAKE CYLINDER
- Install the 2nd brake cylinder to the case.
- INSTALL 1-WAY CLUTCH ASSEMBLY
- Install the thrust washer and 1-way clutch to the case.
- INSTALL 2ND BRAKE PISTON HOLE SNAP RING
- Using SST, install the snap ring.
- SST: 09350-30020
- 09350-07060
- SST: 09350-30020
- Using SST, install the snap ring.
- INSTALL NO. 3 BRAKE DISC
- INSTALL NO. 3 BRAKE SNAP RING
- Using a screwdriver, install the snap ring.
- INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
- Coat 2 new O-rings with ATF and install them to the direct clutch piston.TEXT IN ILLUSTRATION
*1 New O-Ring - Install the direct clutch return spring and No. 2 clutch balancer to the direct clutch piston.
- Press the direct clutch piston into the clutch drum with both hands.NOTE:
Be careful not to damage the O-rings.
- Place SST on the direct clutch piston and compress the return spring with a press.NOTE:
Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- SST: 09320-89010
- SST: 09350-30020
- 09350-07070
- Install the snap ring with a snap ring expander.NOTE:
Do not expand the snap ring excessively.
- Position the end gap of the snap ring as shown in the illustrationTEXT IN ILLUSTRATION
*1 Stopper NOTE:Make sure the end gap of the snap ring is not aligned with the spring retainer claw.
- Coat 2 new O-rings with ATF and install them to the direct clutch piston.
- INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY
- Coat a new O-ring with ATF and install it to the clutch drum.TEXT IN ILLUSTRATION
*1 New O-Ring - Coat a new O-ring with ATF and install it to the reverse clutch piston.TEXT IN ILLUSTRATION
*1 New O-Ring - Press the clutch drum into the reverse clutch piston with both hands.NOTE:
Be careful not to damage the O-ring.
- Coat a new O-ring with ATF and install it to the clutch drum.
- INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
- INSTALL NO. 3 CLUTCH BALANCER
- Place SST on the No. 3 clutch balancer and compress the clutch balancer with a press.
- SST: 09387-00070
- SST: 09350-30020
- 09350-07070
NOTE:Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- Install the snap ring with a snap ring expander.NOTE:
Do not expand the snap ring excessively.
- Position the end gap of the snap ring as shown in the illustration.NOTE:
Make sure the end gap of the snap ring is not aligned with the spring retainer claw.
- Place SST on the No. 3 clutch balancer and compress the clutch balancer with a press.
- INSTALL DIRECT CLUTCH DISC
- Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.
Install in order
*1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3
TEXT IN ILLUSTRATION*1 Plate *2 Disc *3 Flange - Using a screwdriver, install the snap ring to the clutch drum.
- Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air into the oil hole as shown in the illustration.
Standard moving distance (A)
0.55 to 0.85 mm (0.0217 to 0.0335 in.)
NOTE:When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.
If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.
Flange Thickness
Mark Thickness 2 2.95 to 3.05 mm (0.116 to 0.120 in.) 3 3.05 to 3.15 mm (0.120 to 0.124 in.) 4 3.15 to 3.25 mm (0.124 to 0.128 in.) 5 3.25 to 3.35 mm (0.128 to 0.132 in.) 6 3.35 to 3.45 mm (0.132 to 0.136 in.) 7 3.45 to 3.55 mm (0.136 to 0.140 in.) 8 3.55 to 3.65 mm (0.140 to 0.144 in.) 9 3.65 to 3.75 mm (0.144 to 0.148 in.) A 3.75 to 3.85 mm (0.148 to 0.152 in.) - Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.
- Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.
- SELECT REVERSE CLUTCH FLANGE
- Using a screwdriver, install the snap ring to the clutch drum.NOTE:
Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.
- Install the 2 flanges, 5 discs, 4 plates, cushion plate and reverse clutch reaction sleeve to the clutch drum.
Install in order
*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1 - *4
TEXT IN ILLUSTRATION*1 Flange *2 Disc *3 Plate *4 Cushion Plate - Using a screwdriver, install the hole 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 at both ends across the diameter (B) while applying compressed air (392 kPa, 4.0 kgf/ cm2
, 57 psi) into the oil hole as shown in the illustration. Then choose a flange of an appropriate thickness from the table so that the measured value is within the standard range.
Standard moving distance (A minus B)
0.56 to 0.86 mm (0.0220 to 0.0339 in.)
NOTE:When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position indicated by the shaded area in the illustration.
HINT:
Distance (A) = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)
Distance (B) = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)
Flange Thickness
Mark Thickness 0 2.75 to 2.85 mm (0.108 to 0.112 in.) 1 2.85 to 2.95 mm (0.112 to 0.116 in.) 2 2.95 to 3.05 mm (0.116 to 0.120 in.) 3 3.05 to 3.15 mm (0.120 to 0.124 in.) 4 3.15 to 3.25 mm (0.124 to 0.128 in.) 5 3.25 to 3.35 mm (0.128 to 0.132 in.) 6 3.35 to 3.45 mm (0.132 to 0.136 in.) 7 3.45 to 3.55 mm (0.136 to 0.140 in.) 8 3.55 to 3.65 mm (0.140 to 0.144 in.) 9 3.65 to 3.75 mm (0.144 to 0.148 in.) A 3.75 to 3.85 mm (0.148 to 0.152 in.) - Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.
- Using a screwdriver, install the snap ring to the clutch drum.
- REMOVE REVERSE CLUTCH REACTION SLEEVE
- INSTALL INPUT SHAFT OIL SEAL RING
- INSTALL FORWARD CLUTCH PISTON
- INSTALL NO. 1 CLUTCH BALANCER
- Coat a new O-ring with ATF and install it to the clutch balancer.TEXT IN ILLUSTRATION
*1 New O-Ring - Install the forward clutch return spring and clutch balancer.NOTE:
Be careful not to damage the O-ring.
- Place SST on the No. 1 clutch balancer and compress the return spring with a press.
- SST: 09350-30020
- 09350-07040
- 09350-07070
NOTE:Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
- SST: 09350-30020
- Install the snap ring with a snap ring expander.NOTE:
Do not expand the snap ring excessively.
- Position the end gap of the snap ring as shown in the illustration.NOTE:
Make sure the end gap of the snap ring is not aligned with the spring retainer claw.
- Coat a new O-ring with ATF and install it to the clutch balancer.
- INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
- Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.
Install in order
*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1
TEXT IN ILLUSTRATION*1 Flange *2 Disc *3 Plate - Using a screwdriver, temporarily install the snap ring.
- Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air into the oil hole as shown in the illustration.
Standard moving distance (A)
0.61 to 0.91 mm (0.0240 to 0.0358 in.)
NOTE:When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.
HINT:
Moving distance (A): 0.26 to 1.36 mm (0.0102 to 0.0535 in.)
If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.
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.) 9 3.85 to 3.95 mm (0.148 to 0.152 in.) A 3.95 to 4.05 mm (0.152 to 0.159 in.) - Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.
- Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.
- INSTALL INPUT SHAFT ASSEMBLY
- INSTALL MULTIPLE DISC CLUTCH HUB
- Coat the 2 thrust bearing races with petroleum jelly and install them to the multiple disc clutch hub.
Thrust Bearing Race Diameter
Item Inside Outside Race C 22.7 to 22.9 mm (0.892 to 0.902 in.) 60.0 to 60.4 mm (2.36 to 2.38 in.) Race D 33.3 to 33.5 mm (1.31 to 1.32 in.) 56.3 to 56.6 mm (2.22 to 2.23 in.) TEXT IN ILLUSTRATION*1 Race C *2 Race D - Install the multiple disc clutch hub to the clutch drum.
- Coat the 2 thrust bearing races with petroleum jelly and install them to the multiple disc clutch hub.
- INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
- Coat the 2 thrust needle roller bearings with petroleum jelly and install them to the forward clutch hub.
Thrust Needle Roller Bearing Diameter
Item Inside Outside Bearing D 38.5 to 38.7 mm (1.515 to 1.524 in.) 56.5 to 57.0 mm (2.22 to 2.24 in.) Bearing E 42.6 to 42.8 mm (1.68 to 1.69 in.) 60.8 to 61.1 mm (2.39 to 2.41 in.) TEXT IN ILLUSTRATION*1 Bearing D *2 Bearing E - Install the forward clutch hub to the clutch drum.
- Coat the 2 thrust needle roller bearings with petroleum jelly and install them to the forward clutch hub.
- INSTALL REAR CLUTCH DISC
- INSTALL REVERSE CLUTCH REACTION SLEEVE
- INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
- INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY
- INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY
- Coat the 2 thrust needle roller bearings and clutch drum thrust washer with petroleum jelly and install them to the clutch drum and input shaft assembly.
Thrust Needle Roller Bearing Diameter
Item Inside Outside Bearing A 72.0 to 72.3 mm (2.83 to 2.85 in.) 85.3 to 85.6 mm (3.36 to 3.37 in.) Bearing B 34.7 to 34.9 mm (1366 to 1.374 in.) 51.6 to 51.9 mm (2.03 to 2.04 in.) TEXT IN ILLUSTRATION*1 Bearing A *2 Bearing B - Install the clutch drum and input shaft assembly to the transmission case.
- Coat the 2 thrust needle roller bearings and clutch drum thrust washer with petroleum jelly and install them to the clutch drum and input shaft assembly.
- INSTALL OIL PUMP ASSEMBLY
- Coat the No. 1 and No. 2 thrust bearing races with petroleum jelly and install them to the front oil pump.
Thrust Bearing Race Diameter
Item Inside Outside Race A 74.3 to 74.6 mm (2.93 to 2.94 in.) 87.4 to 87.7 mm (3.44 to 3.45 in.) Race B 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.) TEXT IN ILLUSTRATION*1 Race A *2 Race B - Coat a new O-ring with ATF and install it to the oil pump assembly.TEXT IN ILLUSTRATION
*1 New O-Ring - Slide the oil pump onto the input shaft, align the bolt holes of the oil pump assembly with the bolt holes of the transmission case and install the oil pump.
- Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.NOTE:
Do not excessively push on the oil pump, as the oil seal rings will stick to the direct clutch drum.
- Install the 10 bolts.
Torque: 21 N.m (215 kgf/cm, 16 ft.lbf)
- Coat the No. 1 and No. 2 thrust bearing races with petroleum jelly and install them to the front oil pump.
- INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
- Using SST and a hammer, tap in 2 new oil seals.
- SST: 09350-30020
- 09350-07110
- SST: 09350-30020
- Coat the lips of the oil seals with MP grease.
- Using SST and a hammer, tap in 2 new oil seals.
- INSPECT INDIVIDUAL PISTON OPERATION
See step 28
- INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
- Install a new spacer to the manual valve lever.TEXT IN ILLUSTRATION
*1 Spacer *2 Manual Valve Lever - Push the manual valve lever shaft through the transmission case, and install the manual valve lever 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 spacer to the manual valve lever.
- INSTALL PARKING LOCK PAWL SHAFT
- INSTALL PARKING LOCK ROD SUB-ASSEMBLY
- Connect the parking lock rod to the manual valve lever to install it.
- INSTALL PARKING LOCK PAWL BRACKET
- Install the parking lock pawl bracket to the transmission case with the 3 bolts.
Torque: 7.4 N.m (75 kgf/cm, 65 in.lbf)
- Move the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked by the lock pawl.TEXT IN ILLUSTRATION
*1 Manual Valve Lever *2 Planetary Ring Gear *3 Parking Lock Pawl
- Install the parking lock pawl bracket to the transmission case with the 3 bolts.
- INSTALL C-1 ACCUMULATOR VALVE
- INSTALL C-3 ACCUMULATOR PISTON
- Coat 2 new O-rings with ATF and install them to the piston.TEXT IN ILLUSTRATION
*1 New O-Ring - Install the 2 springs and accumulator piston to the hole.
Accumulator Spring Diameter
Spring Free Length
Outer DiameterColor C-3 Inner 44.0 mm (1.73 in.)
14.0 mm (0.551 in.)Yellow C-3 Outer 73.35 mm (2.89 in.)
19.90 mm (0.784 in.)Red
- Coat 2 new O-rings with ATF and install them to the piston.
- INSTALL B-3 ACCUMULATOR PISTON
- INSTALL C-2 ACCUMULATOR PISTON
- INSTALL BRAKE DRUM GASKET
- Install the 3 brake drum gaskets.
- INSTALL TRANSMISSION CASE GASKET
- Install the 3 transmission case gaskets.
- INSTALL CHECK BALL BODY
- INSTALL TRANSMISSION VALVE BODY ASSEMBLY
- Insert the pin of the manual valve into the hole of the manual valve lever.TEXT IN ILLUSTRATION
*1 Pin - Install the transmission valve body assembly with 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
- Install the detent spring and detent spring cover with the bolt.
Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
- Insert the pin of the manual valve into the hole of the manual valve lever.
- INSTALL TRANSMISSION WIRE
- Coat a new O-ring with ATF and install it to the transmission wire connector.
- Install the transmission wire harness.
- Install the bolt.
Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf)
- Connect the 7 solenoid connectors.
- Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.
for bolt A
Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
for bolt B
Torque: 11 N.m (112 kgf/cm, 8 ft.lbf)
TEXT IN ILLUSTRATION*1 No. 1 Temperature Sensor *2 No. 2 Temperature Sensor HINT:
Each bolt length is indicated below.
12 mm (0.472 in.) for bolt A
36 mm (1.42 in.) for bolt B
SENSOR WIRE HARNESSWire Harness Color No. 1 temperature sensor Orange No. 2 temperature sensor Blue
- INSTALL VALVE BODY OIL STRAINER ASSEMBLY
- Coat a new O-ring with ATF and install it 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 TRANSMISSION OIL CLEANER MAGNET
- INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
- Install a new gasket to the oil pan.
- Install the oil pan with the 20 bolts.
Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf)
- Install the drain plug.
Torque: 20 N.m (204 kgf/cm, 15 ft.lbf)
- INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL
- Coat the lip of a new oil seal with ATF.
- Using SST and a hammer, tap in the oil seal.
- SST: 09710-30050
- SST: 09950-70010
- 09951-07100
Standard depth
5.4 to 5.8 mm (0.213 to 0.228 in.)
- INSTALL EXTENSION HOUSING DUST DEFLECTOR
- Using SST and a hammer, tap in a new dust deflector.
- SST: 09223-15020
- SST: 09950-70010
- 09951-07100
- Using SST and a hammer, tap in a new dust deflector.
- INSTALL EXTENSION HOUSING SUB-ASSEMBLY
- Clean the threads of the bolts and case with non residue solvent.
- Apply seal packing to the extension housing.
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.)
TEXT IN ILLUSTRATION*1 Seal Packing - Apply adhesive to the threads of the 6 bolts.
Adhesive
Toyota Genuine Adhesive 1324,
Three Bond 1324 or equivalent
- Install the extension housing with the 6 bolts.
Torque: 34 N.m (345 kgf/cm, 25 ft.lbf)
HINT:
Each bolt length is indicated below.
45 mm (1.77 in.) for bolt A
35 mm (1.38 in.) for bolt B
- INSTALL AUTOMATIC TRANSMISSION HOUSING
- Clean the threads of the bolts and case with non-residue solvent.
- Install the transmission housing with the 10 bolts.
for 14 mm head bolt A
Torque: 34 N.m (345 kgf/cm, 25 ft.lbf)
for 17 mm head bolt B
Torque: 57 N.m (579 kgf/cm, 42 ft.lbf)
for 14 mm head bolt C
Torque: 34 N.m (345 kgf/cm, 25 ft.lbf)
- INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE
- 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)
- INSTALL SPEED SENSOR
- INSTALL OIL COOLER TUBE UNION
- INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Install the park/neutral position switch to the manual valve lever shaft, and temporarily install the adjusting bolt.
- Install a new lock washer and the nut.
Torque: 6.9 N.m (70 kgf/cm, 61 in.lbf)
- Temporarily install the control shaft lever.
- Turn the control shaft lever clockwise until it stops, and then turn it counterclockwise 2 notches to set it to the N position.
- Remove the control shaft lever.
- Align the neutral basic line with the switch groove, and tighten the adjusting bolt.TEXT IN ILLUSTRATION
*1 Neutral Basic Line *2 Groove Torque: 13 N.m (130 kgf/cm, 9 ft.lbf)
- Using a screwdriver, bend the tabs of the lock washer.
HINT:
Bend at least 2 of the lock washer tabs.
- INSTALL TRANSMISSION CONTROL SHAFT LEVER LH
- Install the control shaft lever with the spring washer and nut.
Torque: 16 N.m (160 kgf/cm, 12 ft.lbf)
- Install the control shaft lever with the spring washer and nut.