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Home >> Toyota >> 2020 >> Highlander L, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 43 (Automatic Transmission System (UA81E / UA81F) - Service Information (2 Of 2)) >> Automatic Transaxle Unit >> Reassembly [10/2022 - ] >> Procedure

Reassembly [10/2022 - ]: Procedure

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  1. BEARING POSITION 

    Check bearing position and installation direction.

    GTY1113532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A w/o Stop And Start System *B w/ Stop And Start System
    GTY1062654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Thrust Needle Roller Bearing and Bearing Race Diameter

    Mark Front Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)    		 Thrust Bearing Diameter Inside / Outside
    mm (in.)    		 Rear Side Thrust Bearing Race Diameter Inside / Outside
    mm (in.)
    A 32.6 (1.28) / 54.2 (2.13) 31.7 (1.25) / 52.3 (2.06) 31.7 (1.25) / 52.3 (2.06)
    B 59.8 (2.35) / 77.0 (3.03) 58.3 (2.30) / 75.0 (2.95) -
    C - 39.2 (1.54) / 52.6 (2.07) 37.4 (1.47) / 50.2 (1.98)
    D - 39.4 (1.55) / 49.55 (1.95) 40.7 (1.60) / 50.9 (2.00)
    E 34.4 (1.35) / 48.7 (1.92) 33.2 (1.31) / 47.7 (1.88) 33.2 (1.31) / 47.7 (1.88)
    F 25.58 (1.01) / 43.7 (1.72) 24.2 (0.953) / 43.7 (1.72) 24.2 (0.953) / 43.7 (1.72)
    G - 50.5 (1.99) / 74.5 (2.93) 52.8 (2.08) / 76.4 (3.01)
  2. INSTALL AUTOMATIC TRANSMISSION CASE STRAIGHT PIN 

    HINT: 

    • Perform this procedure only when replacement of the automatic transmission case straight pins are necessary.
    • The component manufacturer (AISIN or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.
      GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Serial Number
      Serial Number Factory
      ##6######## AISIN
      ##A######## TMMWV (TOYOTA)
    1. GTY1115277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for AISIN Made *B for TMMWV Made
      1. Using a plastic hammer, tap in 2 new automatic transmission case straight pins to the specified protrusion height.

        Protrusion Height

        for AISIN Made 

        10.7 to 11.3 mm (0.421 to 0.445 in.)

        for TMMWV Made 

        7.0 to 8.0 mm (0.276 to 0.315 in.)

  3. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE) 
    1. GTY1115342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a press, install a new counter driven gear front tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.
        • SST: 09950-60011 
          1. 09951-00550
        • SST: 09950-70010 
          1. 09951-07150
        NOTE:

        Be sure to install the counter driven gear front tapered roller bearing (inner race) so that there is no clearance between the counter driven gear front tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  4. INSTALL COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (OUTER RACE) 
    1. GTY1113286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a hammer, install a new counter driven gear front tapered roller bearing (outer race) and pinion and counter driven gear shim to the transaxle housing.
        • SST: 09950-60021 
          1. 09951-00780
        • SST: 09950-70010 
          1. 09951-07150
        NOTE:

        Be sure to install the counter driven gear front tapered roller bearing (outer race) so that there is no clearance between the counter driven gear front tapered roller bearing (outer race), pinion and counter driven gear shim and the transaxle housing. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  5. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE) 
    1. GTY1111226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a press, install a new counter driven gear rear tapered roller bearing (inner race) to the pinion and counter driven gear sub-assembly.
        • SST: 09506-30012 
        • SST: 09950-60011 
          1. 09951-00420
          2. 09951-00550
        • SST: 09950-70010 
          1. 09951-07150
        NOTE:

        Be sure to install the counter driven gear rear tapered roller bearing (inner race) so that there is no clearance between the counter driven gear rear tapered roller bearing (inner race) and the pinion and counter driven gear sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  6. INSTALL COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (OUTER RACE) 
    1. GTY1119070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a hammer, install a new counter driven gear rear tapered roller bearing (outer race) to the automatic transaxle case sub-assembly.
        • SST: 09950-60021 
          1. 09951-00680
        • SST: 09950-70010 
          1. 09951-07150
        NOTE:

        Be sure to install the counter driven gear rear tapered roller bearing (outer race) so that there is no clearance between the counter driven gear rear tapered roller bearing (outer race) and the automatic transaxle case sub-assembly. If there is any clearance, the turning torque of the pinion and counter driven gear sub-assembly cannot be measured correctly.

  7. ADJUST FRONT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AISIN or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AISIN
    ##A######## TMMWV (TOYOTA)
    1. GTY1113982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove any remaining seal packing from the contact surfaces of the transaxle housing and automatic transaxle case sub-assembly.
      2. Coat the front differential case front tapered roller bearing (inner race) and the front differential case rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.
      3. Install the differential case assembly to the automatic transaxle case sub-assembly.
    2. GTY1115097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

        Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

        Bolt Length

        Bolt (A) Bolt (B)
        40 mm (1.57 in.) 35 mm (1.38 in.)
    3. GTY1111903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.
        • SST: 09564-33010 
    4. GTY1117811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a torque wrench, measure the turning torque of the front differential case tapered roller bearing while rotating SST at 10 rpm.
        • SST: 09564-33010 

        Standard Turning Torque

        for AISIN Made 

        0.69 to 1.02 N.m (8 to 10 kgf/cm, 7 to 9 in.lbf)

        for TMMWV Made 

        0.99 to 1.28 N.m (11 to 13 kgf/cm, 9 to 11 in.lbf)

        If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

        Differential Drive Pinion Shim Thickness

        Part Number Thickness (mm (in.)) Mark
        90564-75002 1.10 (0.0433) 50
        90564-75003 1.13 (0.0445) 51
        90564-75004 1.16 (0.0457) 52
        90564-75005 1.19 (0.0469) 53
        90564-75006 1.22 (0.0480) 54
        90564-75007 1.25 (0.0492) 55
        90564-75008 1.28 (0.0504) 56
        90564-75009 1.31 (0.0516) 57
        90564-75010 1.34 (0.0528) 58
        90564-75011 1.37 (0.0539) 59
        90564-75012 1.40 (0.0551) 60
        90564-75013 1.43 (0.0563) 61
        90564-75014 1.46 (0.0575) 62
        90564-75015 1.49 (0.0587) 63
        90564-75016 1.52 (0.0598) 64
        90564-75017 1.55 (0.0610) 65
        90564-75018 1.58 (0.0622) 66
        90564-75019 1.61 (0.0634) 67
        90564-75023 1.64 (0.0646) 68
        90564-75024 1.67 (0.0657) 69
        90564-75025 1.70 (0.0669) 70
        90564-75026 1.73 (0.0681) 71
        90564-75027 1.76 (0.0693) 72
        90564-75028 1.79 (0.0705) 73
        90564-75029 1.82 (0.0717) 74
        90564-75030 1.85 (0.0728) 75
        90564-75031 1.88 (0.0740) 76
        90564-75032 1.91 (0.0752) 77
        90564-75033 1.94 (0.0764) 78
        90564-75034 1.97 (0.0776) 79
        90564-75035 2.00 (0.0787) 80
    5. GTY1115095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 21 bolts and transaxle housing from the automatic transaxle case sub-assembly.
  8. ADJUST PINION AND COUNTER DRIVEN GEAR TAPERED ROLLER BEARING PRELOAD 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AISIN or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AISIN
    ##A######## TMMWV (TOYOTA)
    1. GTY1109952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the counter driven gear front tapered roller bearing (inner race) and the counter driven gear rear tapered roller bearing (inner race) with a sufficient amount of Toyota Genuine ATF WS.
      2. Install the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.
    2. GTY1118877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transaxle housing to the automatic transaxle case sub-assembly with the 21 bolts (A and B).

        Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

        Bolt Length

        Bolt (A) Bolt (B)
        40 mm (1.57 in.) 35 mm (1.38 in.)
    3. GTY1111904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST, rotate the differential case assembly 20 times or more to stabilize the bearing.
        • SST: 09564-33010 
    4. GTY1109954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a torque wrench, measure the turning torque of the pinion and counter driven gear tapered roller bearing while rotating SST at 10 rpm.
        • SST: 09564-33010 

        Standard Turning Torque

        for AISIN Made 

        Front differential case tapered roller bearing preload + 0.99 to 2.26 N.m (11 to 23 kgf/cm, 9 to 20 in.lbf)

        for TMMWV Made 

        Front differential case tapered roller bearing preload + 1.75 to 2.61 N.m (18 to 26 kgf/cm, 16 to 23 in.lbf)

        If the turning torque is not within the specified range, refer to the table below to select a shim so that the turning torque is within the specified range.

        Pinion and Counter Driven Gear Shim Thickness

        Part Number Thickness (mm (in.)) Mark
        90564-67047 1.19 (0.0469) AA
        90564-67048 1.22 (0.0480) AB
        90564-67049 1.25 (0.0492) AC
        90564-67050 1.28 (0.0504) AD
        90564-67051 1.31 (0.0516) AE
        90564-67052 1.34 (0.0528) AF
        90564-67053 1.37 (0.0539) AG
        90564-67054 1.40 (0.0551) AH
        90564-67055 1.43 (0.0563) AJ
        90564-67056 1.46 (0.0575) AK
        90564-67057 1.49 (0.0587) AL
        90564-67058 1.52 (0.0598) AM
        90564-67059 1.55 (0.0610) AN
        90564-67060 1.58 (0.0622) AP
        90564-67061 1.61 (0.0634) AR
        90564-67062 1.64 (0.0646) AS
        90564-67063 1.67 (0.0657) AT
        90564-67064 1.70 (0.0669) AU
        90564-67065 1.73 (0.0681) AV
        90564-67066 1.76 (0.0693) AW
        90564-67067 1.79 (0.0705) AX
        90564-67068 1.82 (0.0717) AY
        90564-67069 1.85 (0.0728) AZ
        90564-67071 1.88 (0.0740) BA
        90564-67072 1.91 (0.0752) BB
        90564-67073 1.94 (0.0764) BC
        90564-67074 1.97 (0.0776) BD
        90564-67075 2.00 (0.0787) BE
        90564-67076 2.03 (0.0799) BF
        90564-67077 2.06 (0.0811) BG
        90564-67078 2.09 (0.0823) BH
        90564-67079 2.12 (0.0835) BJ
        90564-67080 2.15 (0.0846) BK
        90564-67081 2.18 (0.0858) BL
        90564-67082 2.21 (0.0870) BM
    5. GTY1115095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 21 bolts and transaxle housing from the automatic transaxle case sub-assembly.
    6. GTY1109953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the pinion and counter driven gear sub-assembly from the automatic transaxle case sub-assembly.
    7. GTY1113980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the differential case assembly from the automatic transaxle case sub-assembly.
  9. INSTALL NO. 1 BREATHER PLUG (ATM) 
    1. GTY1113190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Indented Portion *b Detent Aligned
      1. Coat the O-ring portion of a new No. 1 breather plug (ATM) with Toyota Genuine ATF WS.
      2. Engage each claw to install the No. 1 breather plug (ATM) to the automatic transaxle case sub-assembly.
        NOTE:

        Securely push in the automatic transaxle case sub-assembly until the No. 1 breather plug (ATM) is engaged.

        HINT: 

        Install the No. 1 breather plug (ATM) with its detent aligned with the indented portion of the automatic transaxle case sub-assembly.

  10. INSTALL NO. 2 TRANSAXLE CASE PLUG 
    1. GTY1116774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to 2 or 3 threads on the end of the 3 No. 2 transaxle case plugs.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        NOTE:

        Make sure to install the No. 2 transaxle case plugs immediately after applying adhesive to prevent foreign matter from attaching to them.

    2. GTY1112983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the automatic transaxle case sub-assembly.

        Torque: 17 N.m (173 kgf/cm, 13 ft.lbf) 

  11. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. GTY1114686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat 4 new O-rings with Toyota Genuine ATF WS and install them to the 4 No. 1 transaxle case plugs.
    2. GTY1062420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.4 N.m (75 kgf/cm, 65 in.lbf) 

  12. INSTALL FRONT DRIVE SHAFT OIL SEAL LH 
  13. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. GTY1117312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a hammer, install a new manual valve lever shaft oil seal to the automatic transaxle case sub-assembly.
        • SST: 09950-60011 
          1. 09951-00210
        • SST: 09950-70010 
          1. 09951-07200

        Standard Depth

        4.9 to 5.6 mm (0.193 to 0.220 in.)

      2. Apply MP grease to the lip of the manual valve lever shaft oil seal.
  14. INSTALL NEEDLE ROLLER BEARING 
    1. GTY1115543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a press, install a new needle roller bearing to the automatic transaxle case sub-assembly.
        • SST: 09950-60011 
          1. 09951-00210
        • SST: 09950-70010 
          1. 09951-07150

        Standard Depth

        2.1 to 2.5 mm (0.0827 to 0.0984 in.)

        NOTE:

        Install the needle roller bearing with its supplier name mark facing the front of the automatic transaxle assembly.

  15. INSTALL NO. 2 TRANSAXLE CASE PLUG 
    1. GTY1116773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply adhesive to 2 or 3 threads on the end of the 3 No. 2 transaxle case plugs.

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        NOTE:

        Make sure to install the No. 2 transaxle case plugs immediately after applying adhesive to prevent foreign matter from attaching to them.

    2. GTY1112984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 6 mm hexagon socket wrench, install the 3 No. 2 transaxle case plugs and 3 new gaskets to the transaxle housing.

        Torque: 17 N.m (173 kgf/cm, 13 ft.lbf) 

  16. INSTALL NO. 1 TRANSAXLE CASE PLUG 
    1. GTY1114685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat 4 new O-rings with Toyota Genuine ATF WS and install them to the 4 No. 1 transaxle case plugs.
    2. GTY1062421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.4 N.m (75 kgf/cm, 65 in.lbf) 

  17. INSTALL NEEDLE ROLLER BEARING 
    1. GTY1116932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a press, install a new needle roller bearing to the transaxle housing.
        • SST: 09950-60011 
          1. 09951-00560
        • SST: 09950-70010 
          1. 09951-07200
        NOTE:

        Be careful not to damage the transaxle housing.

  18. INSTALL FRONT DRIVE SHAFT OIL SEAL RH (for UA81E) 

    Refer to PROCEDURE - Step 5

  19. INSTALL DIFFERENTIAL SIDE OIL SEAL (for UA81F) 

    Refer to PROCEDURE - Step 6 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 6 [11/2023 - ]

  20. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. GTY1111131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle housing.
        • SST: 09950-60011 
          1. 09951-00640
        • SST: 09950-70010 
          1. 09951-07200

        Standard Depth

        -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      2. Apply MP grease to the lip of the front transaxle case oil seal.
  21. INSTALL 1ST AND REVERSE BRAKE PISTON 
    1. GTY1116146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the 1st and reverse brake piston.
        NOTE:
        • Make sure to correctly distinguish between the inner side and outer side O-rings.
        • Be careful not to damage or twist the O-rings.
    2. GTY1112244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 1st and Reverse Brake Return Spring Sub-assembly *2 1st and Reverse Brake Piston
      1. Set the 1st and reverse brake return spring sub-assembly on the 1st and reverse brake piston.
    3. GTY1109899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the 1st and reverse brake piston with 1st and reverse brake return spring sub-assembly to the automatic transaxle case sub-assembly.
        NOTE:

        Make sure that the O-rings are not damaged or do not jump out of position during installation.

  22. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. GTY1110290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area - -
      1. Set the snap ring on the automatic transaxle case sub-assembly as shown in the illustration.
        NOTE:

        The opening of the snap ring should be within the area shown in the illustration (spline portion).

    2. GTY1115565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.
        • SST: 09380-60011 
          1. 09381-06020
          2. 09381-06050
          3. 09381-06060
          4. 09381-06100
          5. 09381-06110
        • SST: 09950-70010 
          1. 09951-07200
        NOTE:

        Stop the press when the 1st and reverse brake return spring sub-assembly is flush with the snap ring groove.

    3. GTY1111728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring into the snap ring groove of the automatic transaxle case sub-assembly.
        NOTE:
        • Be careful not to damage the automatic transaxle case sub-assembly.
        • Make sure that the snap ring is installed in the groove of the automatic transaxle case sub-assembly correctly.
  23. INSTALL NO. 2 1ST AND REVERSE BRAKE PISTON 
    1. GTY1062391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL 2ND BRAKE DISC 
    1. GTY1117726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 2nd Brake Flange *2 2nd Brake Disc
      *3 2nd Brake Plate - -
      *a Snap Ring Side *b 2nd Brake Disc Side
      1. Install the 5 2nd brake plates, 5 2nd brake discs and 2nd brake flange to the automatic transaxle case sub-assembly.
        NOTE:

        Assemble the 2nd brake flange with its tapered surface facing toward the 2nd brake disc.

    2. GTY1110781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area - -
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the automatic transaxle case sub-assembly.
        NOTE:

        The opening of the snap ring should be within the area shown in the illustration (spline portion).

  25. INSPECT CLEARANCE OF B-2 BRAKE 

    See step  18

  26. INSTALL DIRECT CLUTCH DRUM OIL SEAL RING 
    1. GTY1114677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a small amount of MP grease to the entire circumference of the direct clutch drum oil seal ring installation groove portion.

        HINT: 

        By applying MP grease, the wobble within the direct clutch drum oil seal ring installation groove will be eliminated, preventing damage to the direct clutch drum oil seal ring at the time of front planetary gear assembly installation.

      2. Coat 2 new direct clutch drum oil seal rings with Toyota Genuine ATF WS and install them to the automatic transaxle case sub-assembly.
        NOTE:

        While making the spread of the opening of the direct clutch drum oil seal ring as small as possible, install it to the automatic transaxle case sub-assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  27. INSTALL C-2 CLUTCH PISTON 
    1. GTY1116911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to 2 new O-rings and install them to the intermediate shaft sub-assembly.
        NOTE:

        Be careful not to damage or twist the O-rings.

    2. GTY1116822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch piston.
      2. Install the C-2 clutch piston to the intermediate shaft sub-assembly.
        NOTE:
        • Make sure the lip is not cut or folded.
        • Be careful not to damage the lip seal of the C-2 clutch piston.
  28. INSTALL CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. GTY1062385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL C-2 CLUTCH BALANCER 
    1. GTY1111544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the C-2 clutch balancer.
      2. Install the C-2 clutch balancer to the intermediate shaft sub-assembly.
        NOTE:
        • Make sure the lip is not cut or folded.
        • Be careful not to damage the lip seal of the C-2 clutch balancer.
    2. GTY1113716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.
        • SST: 09387-00020 
        NOTE:

        Stop the press when the clutch return spring sub-assembly is flush with the snap ring groove.

      2. Using SST, install the snap ring to the intermediate shaft sub-assembly.
        • SST: 09350-30020 
          1. 09350-07070
        NOTE:

        Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.

  30. INSTALL NO. 2 CLUTCH DISC 
    1. GTY1116105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Direct Clutch Flange *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate *4 Intermediate Shaft Sub-assembly
      *a Snap Ring Side *b No. 2 Clutch Disc Side
      1. Install the 4 No. 2 clutch plates, 4 No. 2 clutch discs and direct clutch flange to the intermediate shaft sub-assembly.
        NOTE:
        • Be careful during assembly because there are 2 types of No. 2 clutch plate with different thicknesses.
        • Assemble the direct clutch flange with its tapered surface facing toward the No. 2 clutch disc.
    2. GTY1111038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the intermediate shaft sub-assembly.
        NOTE:
        • Be careful not to damage the intermediate shaft sub-assembly.
        • Make sure that the snap ring is installed in the groove of the intermediate shaft sub-assembly correctly.
  31. INSTALL NO. 1 THRUST BEARING RACE 
    1. GTY1114075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 1 thrust bearing race with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.

        No. 1 Thrust Bearing Race Diameter

        Inside Outside
        52.8 mm (2.08 in.) 76.4 mm (3.01 in.)
        NOTE:

        Securely insert the claw of the No. 1 thrust bearing race into the hole of the automatic transaxle case sub-assembly.

  32. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1114986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        50.5 mm (1.99 in.) 74.5 mm (2.93 in.)
        NOTE:

        Make sure to assemble the thrust needle roller bearing in the correct direction.

        HINT: 

        When installing the C-2 clutch assembly, if the thrust needle roller bearing falls off, coat the C-2 clutch assembly installation surface with MP grease and install the parts.

  33. INSTALL C-2 CLUTCH ASSEMBLY 
    1. GTY1062986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSPECT CLEARANCE OF C-2 CLUTCH 

    See step  17

  35. INSTALL NO. 4 PLANETARY CARRIER THRUST WASHER 
    1. GTY1112647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the No. 4 planetary carrier thrust washer to the rear planetary gear assembly.

        HINT: 

        • Securely insert each protrusion of the No. 4 planetary carrier thrust washer into each indentation of the rear planetary gear assembly.
        • When installing the rear planetary gear assembly, if the No. 4 planetary carrier thrust washer falls off, coat the rear planetary gear assembly installation surface with MP grease and install the parts.
  36. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. GTY1061919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL NO. 2 THRUST BEARING RACE 
    1. GTY1112841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 2 thrust bearing race with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

        No. 2 Thrust Bearing Race Diameter

        Inside Outside
        24.2 mm (0.953 in.) 43.7 mm (1.72 in.)
  38. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1110582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-2 clutch assembly.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        24.2 mm (0.953 in.) 43.7 mm (1.72 in.)
  39. INSTALL NO. 3 THRUST BEARING RACE 
    1. GTY1112350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 3 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

        No. 3 Thrust Bearing Race Diameter

        Inside Outside
        25.58 mm (1.01 in.) 43.7 mm (1.72 in.)

        HINT: 

        When installing the rear planetary sun gear sub-assembly, if the No. 3 thrust bearing race falls off, coat the rear planetary sun gear sub-assembly installation surface with MP grease and install the parts.

  40. INSTALL REAR PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. GTY1062987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL THRUST BEARING RACE 
    1. GTY1117205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

        Thrust Bearing Race Diameter

        Inside Outside
        33.2 mm (1.31 in.) 47.7 mm (1.88 in.)
  42. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1115337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        33.2 mm (1.31 in.) 47.7 mm (1.88 in.)
  43. INSTALL NO. 4 THRUST BEARING RACE 
    1. GTY1113280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 4 thrust bearing race with Toyota Genuine ATF WS and install it to the rear planetary sun gear sub-assembly.

        No. 4 Thrust Bearing Race Diameter

        Inside Outside
        34.4 mm (1.35 in.) 48.7 mm (1.92 in.)
  44. INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. GTY1061916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL NO. 3 PLANETARY CARRIER THRUST WASHER 
    1. GTY1111259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 3 planetary carrier thrust washer with Toyota Genuine ATF WS and install it to the rear planetary gear assembly.
        NOTE:

        Securely insert the claw of the No. 3 planetary carrier thrust washer into the hole of the rear planetary gear assembly.

  46. INSTALL NO. 1 BRAKE DISC 
    1. GTY1113502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Brake Flange *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate *4 Counter Drive Gear Sub-assembly
      *a Snap Ring Side *b No. 1 Brake Disc Side
      1. Install the 4 No. 1 brake plates, 4 No. 1 brake discs and No. 1 brake flange to the counter drive gear sub-assembly.
        NOTE:
        • Be careful during assembly because there are 2 types of No. 1 brake plate with different thicknesses.
        • Assemble the No. 1 brake flange with its tapered surface facing toward the No. 1 brake disc.
    2. GTY1119050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap ring opening within this area - -
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the counter drive gear sub-assembly.
        NOTE:
        • Be careful not to damage the counter drive gear sub-assembly.
        • Make sure that the snap ring is installed in the groove of the counter drive gear sub-assembly correctly.
        • The opening of the snap ring should be within the area shown in the illustration (spline portion).
  47. INSTALL COUNTER DRIVE GEAR SUB-ASSEMBLY 
    NOTE:

    If the bolts are tightened without cleaning and degreasing the bolts and bolt holes, the tightening torque will be too high and the counter drive gear sub-assembly or automatic transaxle case sub-assembly may be damaged.

    1. GTY1112420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
    2. GTY1118756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly to the automatic transaxle case sub-assembly.
    3. GTY1116502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the 8 bolts (A and B).

        HINT: 

        Bolt (A) is a hexagon socket head cap bolt.

      2. Fully tighten the 6 bolts (B).

        Torque: 76 N.m (775 kgf/cm, 56 ft.lbf) 

      3. Using a T50 "TORX" socket wrench, fully tighten the 2 bolts (A).

        Torque: 31.8 N.m (324 kgf/cm, 23 ft.lbf) 

  48. INSPECT CLEARANCE OF B-1 BRAKE 

    See step  16

  49. INSTALL PARKING LOCK SLEEVE 
    1. GTY1109790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the parking lock sleeve with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
  50. INSTALL PARKING LOCK PAWL 
    1. GTY1111605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the parking lock pawl with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
  51. INSTALL PARKING LOCK PAWL SHAFT 
    1. GTY1113710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the parking lock pawl shaft with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
  52. INSTALL PARKING LOCK PAWL TORSION SPRING 
    1. GTY1119408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the parking lock pawl torsion spring to the automatic transaxle case sub-assembly as shown in the illustration.
        NOTE:

        Securely insert the parking lock pawl torsion spring all the way into the parking lock pawl shaft.

  53. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY 
    1. GTY1116274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the manual valve lever shaft sub-assembly to the automatic transaxle case sub-assembly.
        NOTE:

        When installing the manual valve lever shaft sub-assembly, be careful not to damage the manual valve lever shaft oil seal.

  54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. GTY1110676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Manual Valve Lever Shaft Sub-assembly *2 Parking Lock Rod Sub-assembly
      1. Move the parking lock rod sub-assembly as shown in the illustration, and install the parking lock rod sub-assembly.
        NOTE:

        Securely align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly.

  55. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. GTY1061864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL PAWL STOPPER PLATE 
    1. GTY1062983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  57. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. GTY1117021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the manual valve lever sub-assembly to the automatic transaxle case sub-assembly.
        NOTE:

        The pin portion of the manual valve lever shaft sub-assembly must be inserted into the slot of the manual valve lever sub-assembly.

  58. INSTALL MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY 
    1. GTY1116706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the manual valve lever shaft sub-assembly.
        NOTE:

        Ensure that the O-ring it not twisted.

    2. GTY1119069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and install the manual valve lever shaft sub-assembly.

        HINT: 

        Installing the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

    3. GTY1061870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  59. INSTALL NO. 5 THRUST BEARING RACE 
    1. GTY1113854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 5 thrust bearing race with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

        No. 5 Thrust Bearing Race Diameter

        Inside Outside
        40.7 mm (1.60 in.) 50.9 mm (2.00 in.)
  60. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1115880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the sun gear input hub sub-assembly.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        39.4 mm (1.55 in.) 49.55 mm (1.95 in.)
  61. INSTALL SUN GEAR INPUT HUB SUB-ASSEMBLY 
    1. GTY1061866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL FORWARD CLUTCH PISTON 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AISIN or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AISIN
    ##A######## TMMWV (TOYOTA)
    1. GTY1180280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Needle Roller Bearing - -
      *a Needle Roller Bearing Press Depth - -
      1. Using a press and SST, press a new needle roller bearing into the clutch drum sub-assembly to the position shown in the illustration. (for TMMWV Made)
        • SST: 09950-60011 
          1. 09951-00340
        • SST: 09950-70010 
          1. 09951-07100

        Needle Roller Bearing Press Depth

        31.9 to 32.3 mm (1.2559 to 1.2717 in.)

        NOTE:
        • If the needle roller bearing is pressed beyond the standard position, replace the needle roller bearing with a new one.
        • Using a press, press with 6000 N (612 kgf, 1348.9 lbf) or less.

        HINT: 

        Only perform this operation when replacing the needle roller bearing or clutch drum sub-assembly.

    2. GTY1118641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to a new D-ring and install it to the clutch drum sub-assembly.

        HINT: 

        • Be careful not to damage or twist the D-ring.
        • The rounded surface of the D-ring will be on the outer side of the ring groove.
    3. GTY1115171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to a new D-ring and install it to the forward clutch piston.
        NOTE:

        Be careful not to damage or twist the D-ring.

    4. GTY1111826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to the forward clutch piston and install it to the clutch drum sub-assembly.
        NOTE:
        • Make sure that the and D-rings are not damaged or do not jump out of position during installation.
        • Make sure the lip is not cut or folded.
  63. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. GTY1119286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the forward clutch return spring sub-assembly to the forward clutch piston.
        NOTE:

        Make sure to install in the correct direction.

  64. INSTALL NO. 1 CLUTCH BALANCER 
    1. GTY1110928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a light coat of Toyota Genuine ATF WS to the lip seal of the forward clutch piston.
      2. Install the No. 1 clutch balancer to the forward clutch piston.
        NOTE:

        Be careful not to damage the lip seal of the forward clutch piston.

    2. GTY1118423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place SST on the No. 1 clutch balancer and compress the forward clutch return spring sub-assembly with a press.
        • SST: 09387-00020 
        NOTE:

        Stop the press when the forward clutch return spring sub-assembly is flush with the snap ring groove.

      2. Using SST, install the snap ring to the clutch drum sub-assembly.
        • SST: 09350-30020 
          1. 09350-07070
        NOTE:

        Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.

  65. INSTALL FRONT CLUTCH DISC 
    1. GTY1115471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Forward Clutch Flange *2 Front Clutch Disc
      *3 Forward Multiple Disc Clutch Plate *4 Clutch Drum Sub-assembly
      *a Snap Ring Side *b Front Clutch Disc Side
      1. Install the 5 forward multiple disc clutch plates, 5 front clutch discs and forward clutch flange to the clutch drum sub-assembly.
        NOTE:
        • Be careful during assembly because there are 2 types of forward multiple disc clutch plate with different thicknesses.
        • Assemble the forward clutch flange with its tapered surface facing toward the front clutch disc.
    2. GTY1114510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the clutch drum sub-assembly.
        NOTE:
        • Be careful not to damage the clutch drum sub-assembly.
        • Make sure that the snap ring is installed in the groove of the clutch drum sub-assembly correctly.
  66. INSPECT CLEARANCE OF C-1 CLUTCH 

    See step  15

  67. INSTALL C-1 CLUTCH ASSEMBLY 
    1. GTY1061847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL NO. 6 THRUST BEARING RACE 
    1. GTY1109803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 6 thrust bearing race with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

        No. 6 Thrust Bearing Race Diameter

        Inside Outside
        37.4 mm (1.47 in.) 50.2 mm (1.98 in.)
  69. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1111574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the C-1 clutch assembly.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        39.2 mm (1.54 in.) 52.6 mm (2.07 in.)
  70. INSTALL FRONT PLANETARY RING GEAR 
    1. GTY1061842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY1113680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front planetary ring gear.
        NOTE:

        Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

    3. GTY1061835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL REAR INPUT SHAFT OIL SEAL RING 
    1. GTY1111004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a small amount of MP grease to the entire circumference of the rear input shaft oil seal ring installation groove portion.

        HINT: 

        By applying MP grease, the wobble within the rear input shaft oil seal ring installation groove will be eliminated, preventing damage to the rear input shaft oil seal ring at the time of front planetary gear assembly installation.

      2. Coat 2 new rear input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.
        NOTE:

        While making the spread of the opening of the rear input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  72. INSTALL INPUT SHAFT OIL SEAL RING 
    1. GTY1118444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a small amount of MP grease to the entire circumference of the input shaft oil seal ring installation groove portion.

        HINT: 

        By applying MP grease, the wobble within the input shaft oil seal ring installation groove will be eliminated, preventing damage to the input shaft oil seal ring at the time of front oil pump assembly and torque converter clutch assembly installation.

      2. Coat 5 new input shaft oil seal rings with Toyota Genuine ATF WS and install them to the front planetary gear assembly.
        NOTE:

        While making the spread of the opening of the input shaft oil seal ring as small as possible, install it to the front planetary gear assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  73. INSTALL NO. 7 THRUST BEARING RACE 
    1. GTY1109948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 7 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary gear assembly.

        No. 7 Thrust Bearing Race Diameter

        Inside Outside
        59.8 mm (2.35 in.) 77.0 mm (3.03 in.)
        NOTE:

        Securely insert the claw of the No. 7 thrust bearing race into the hole of the front planetary gear assembly.

        HINT: 

        When installing the front planetary gear assembly, if the No. 7 thrust bearing race falls off, coat the front planetary gear assembly installation surface with MP grease and install the parts.

  74. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1116791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        58.3 mm (2.30 in.) 75.0 mm (2.95 in.)
  75. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. GTY1061829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. INSTALL NO. 8 THRUST BEARING RACE 
    1. GTY1117903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 8 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

        No. 8 Thrust Bearing Race Diameter

        Inside Outside
        31.7 mm (1.25 in.) 52.3 mm (2.06 in.)
  77. INSTALL THRUST NEEDLE ROLLER BEARING 
    1. GTY1118306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the thrust needle roller bearing with Toyota Genuine ATF WS and install it to the front planetary ring gear.

        Thrust Needle Roller Bearing Diameter

        Inside Outside
        31.7 mm (1.25 in.) 52.3 mm (2.06 in.)
  78. INSTALL NO. 9 THRUST BEARING RACE 
    1. GTY1113837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat the No. 9 thrust bearing race with Toyota Genuine ATF WS and install it to the front planetary ring gear.

        No. 9 Thrust Bearing Race Diameter

        Inside Outside
        32.6 mm (1.28 in.) 54.2 mm (2.13 in.)
  79. INSTALL PLANETARY SUN GEAR 
    1. GTY1062969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL NO. 2 PLANETARY CARRIER THRUST WASHER 
    1. GTY1116930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the No. 2 planetary carrier thrust washer to the front planetary gear assembly.
        NOTE:

        Securely insert each protrusion of the No. 2 planetary carrier thrust washer into each indentation of the front planetary gear assembly.

  81. INSPECT CLEARANCE OF C-4 CLUTCH 

    See step  14

  82. INSPECT CLEARANCE OF C-3 CLUTCH 

    See step  13

  83. INSTALL C-3 AND C-4 CLUTCH ASSEMBLY 
    1. GTY1061811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL PLANETARY CARRIER THRUST WASHER 
    1. GTY1114669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the planetary carrier thrust washer to the C-3 and C-4 clutch assembly.
        NOTE:

        Securely insert the protrusion of the planetary carrier thrust washer into the indentation of the C-3 and C-4 clutch assembly.

  85. INSTALL FRONT OIL PUMP ASSEMBLY 
    1. GTY1115125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the front oil pump assembly to the automatic transaxle case sub-assembly with the 7 bolts.

        Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

        Bolt Length

        Bolt (A) Bolt (B)
        40 mm (1.57 in.) 30 mm (1.18 in.)
  86. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. GTY1111637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Manual Detent Spring Sub-assembly *2 Manual Valve Lever Shaft Sub-assembly
      *a Correct *b Incorrect
      1. Install the manual detent spring sub-assembly to the front oil pump assembly with the bolt.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

        NOTE:
        • Securely insert the claw of the manual detent spring sub-assembly into the hole of the front oil pump assembly.
        • Check that the roller portion of the manual detent spring sub-assembly is engaged with the manual valve lever shaft sub-assembly.
  87. INSTALL OIL PUMP SPROCKET REAR THRUST WASHER 
    1. GTY1111127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the oil pump sprocket rear thrust washer to the front oil pump assembly.
        NOTE:

        Securely insert the protrusion of the oil pump sprocket rear thrust washer into the indentation of the front oil pump assembly.

  88. INSTALL TRANSMISSION DRIVE CHAIN 
    1. GTY1109497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Drive Gear - -
      *a Correct *b Incorrect
      1. Using a screwdriver with its tip wrapped with protective tape, align the cutout of the front oil pump drive gear with the position (*a) shown in the illustration.
        NOTE:

        Do not pry with excessive force when aligning the cutout of the front oil pump drive gear.

    2. GTY1112719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly to the front oil pump assembly.
        NOTE:
        • To avoid damaging the bush of the front oil pump assembly, install the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.
        • Align the cutout of the oil pump drive shaft sub-assembly and the cutout of the front oil pump drive gear, and install the parts.
  89. INSTALL OIL PUMP SPROCKET FRONT THRUST WASHER 
    1. GTY1117328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the oil pump sprocket front thrust washer to the transmission oil pump drive sprocket.
        NOTE:

        Securely insert the long protrusion of the oil pump sprocket rear thrust washer into the slot of the oil pump sprocket front thrust washer.

  90. INSTALL CLUTCH DRUM OIL SEAL RING 
    1. GTY1114490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply a small amount of MP grease to the entire circumference of the clutch drum oil seal ring installation groove portion.

        HINT: 

        By applying MP grease, the wobble within the clutch drum oil seal ring installation groove will be eliminated, preventing damage to the clutch drum oil seal ring at the time of torque converter clutch assembly installation.

      2. Coat a new clutch drum oil seal ring with Toyota Genuine ATF WS and install it to the front oil pump assembly.
        NOTE:

        While making the spread of the opening of the clutch drum oil seal ring as small as possible, install it to the front oil pump assembly. If the ring opening is spread, briefly hold it closed with your fingers to return it to its original condition.

  91. INSTALL DIFFERENTIAL CASE ASSEMBLY 
    1. GTY1062965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL TRANSMISSION LUBE APPLY TUBE 
    1. GTY1114233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Incorrect *b Correct
      1. Install the transmission lube apply tube to the transaxle housing.
        NOTE:

        Insert the transmission lube apply tube until its spool portion is contacting the transaxle housing.

    2. GTY1061793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  93. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. GTY1112237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Incorrect *b Correct
      1. Install the differential gear lube apply tube to the transaxle housing.
        NOTE:

        Insert the differential gear lube apply tube until its spool portion is contacting the transaxle housing.

  94. INSTALL TRANSMISSION OIL CLEANER MAGNET 
    1. GTY1061790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL TRANSAXLE HOUSING OIL SEPARATOR 
    1. GTY1062963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  96. INSTALL TRANSAXLE HOUSING 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AISIN or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AISIN
    ##A######## TMMWV (TOYOTA)
    NOTE:

    When installing the transaxle housing check that the transmission drive chain rotates smoothly.

    GTY699994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. GTY1117175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Area to be cleaned - -
      1. Clean the inner chamfer of the automatic transaxle case sub-assembly shown in the illustration.
    2. GTY1118369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply seal packing to the automatic transaxle case sub-assembly as shown in the illustration.

        Seal Packing

        Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

        Standard Seal Diameter

        1.8 mm (0.0709 in.)

        NOTE:

        After applying seal packing, install the transaxle housing within 3 minutes and tighten the bolts within 20 minutes of applying the seal packing.

    3. GTY1109945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transaxle Case Gasket *2 O-ring
      1. Coat 5 new transaxle case gaskets with Toyota Genuine ATF WS and install them to the front oil pump assembly.
      2. Coat a new O-ring with Toyota Genuine ATF WS and install it to the automatic transaxle case sub-assembly.
    4. for AISIN Made:
      GTY1115096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transaxle housing to the automatic transaxle case sub-assembly with the 9 bolts (A) and 12 bolts (B).

        Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

        Bolt Length

        Bolt (A) 

        40 mm (1.57 in.)

        Bolt (B) 

        35 mm (1.38 in.)

    5. for TMMWV Made:
      GTY1110880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transaxle housing to the automatic transaxle case sub-assembly with the 6 bolts (A) and 12 bolts (B).

        Bolt (A) and (B) 

        Torque: 29.4 N.m (300 kgf/cm, 22 ft.lbf) 

        Bolt Length

        Bolt (A) 

        40 mm (1.57 in.)

        Bolt (B) 

        35 mm (1.38 in.)

      2. Apply adhesive to 2 or 3 threads on the ends of the 3 bolts (C).

        Bolt Length

        Bolt (C) 

        40 mm (1.57 in.)

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        NOTE:

        Make sure to install the bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

        HINT: 

        The 3 bolts (C) are in the locations shown in the following step.

      3. Install the 3 bolts (C).

        Bolt (C) 

        Torque: 22.7 N.m (231 kgf/cm, 17 ft.lbf) 

  97. INSPECT INPUT SHAFT END PLAY 

    See step  12

  98. INSTALL TRANSMISSION REVOLUTION SENSOR (NC) 

    Refer to PROCEDURE - Step 1

  99. INSTALL TRANSMISSION REVOLUTION SENSOR (NT) 

    Refer to PROCEDURE - Step 2

  100. INSTALL FRONT OIL PUMP COVER GASKET 

    Refer to PROCEDURE - Step 1

  101. INSTALL TRANSAXLE CASE GASKET 

    Refer to PROCEDURE - Step 2

  102. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 

    Refer to PROCEDURE - Step 3

  103. INSTALL TRANSMISSION WIRE 
  104. INSTALL TRANSMISSION CASE SIDE COVER 
  105. INSTALL NO. 1 OIL COOLER OUTLET TUBE SUB-ASSEMBLY 
    1. GTY1116857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the No. 1 oil cooler outlet tube sub-assembly.
        NOTE:

        Ensure that the O-ring is not twisted.

    2. GTY1111401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Union Nut Wrench *b Torque Wrench Fulcrum Length
      1. Using a 19 mm union nut wrench, install the No. 1 oil cooler outlet tube sub-assembly to the automatic transaxle case sub-assembly.

        Specified tightening torque 

        Torque: 31.1 N.m (317 kgf/cm, 23 ft.lbf) 

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [12/2019 - 11/2023] , or refer to PRECAUTION [11/2023 - ]

        • When using a 19 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

          26.7 N.m (272 kgf/cm, 20 ft.lbf)

  106. INSTALL OIL COOLER UNION SUB-ASSEMBLY 
    1. GTY1110552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pass the oil cooler union sub-assembly through 2 new gaskets and temporarily install it to the automatic transaxle case sub-assembly with the oil cooler union bolt.
      2. Temporarily install the oil cooler union sub-assembly bracket portion to the automatic transaxle case sub-assembly with the bolt.
      3. Fully tighten the oil cooler union bolt.

        Torque: 22.6 N.m (230 kgf/cm, 17 ft.lbf) 

      4. Fully tighten the bolt.

        Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  107. INSTALL NO. 1 TRANSMISSION OIL FILLER TUBE 
    1. GTY1117901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 6 mm hexagon socket wrench, install the No. 1 transmission oil filler tube to the transaxle housing.

        Torque: 1.7 N.m (17 kgf/cm, 15 in.lbf) 

  108. INSTALL OVERFLOW PLUG 
    1. GTY1112347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a 10 mm hexagon socket wrench, install the overflow plug and a new gasket to the transaxle housing.

        Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

        NOTE:

        To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  109. INSTALL REFILL PLUG 
    1. GTY1113816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.

        Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

        NOTE:

        To prevent the gasket from being deformed when tightening, coat the gasket with Toyota Genuine ATF WS.

  110. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. GTY1113173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a P Position *b N Position
      *c Neutral Basic Line *d Protrusion
      1. Temporarily install the park/neutral position switch assembly to the automatic transaxle case sub-assembly with the 2 bolts.
      2. Temporarily install the transmission control shaft lever to the manual valve lever shaft sub-assembly.
      3. Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.
      4. Remove the transmission control shaft lever from the manual valve lever shaft sub-assembly.
      5. Align the protrusion with the neutral basic line.
      6. Hold the park/neutral position switch assembly in that position and tighten the 2 bolts.

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

  111. INSTALL TRANSMISSION CONTROL SHAFT LEVER 
    1. GTY1113212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the transmission control shaft lever to the manual valve lever shaft sub-assembly with the washer and nut.
        NOTE:

        Be careful of the assembly direction of the transmission control shaft lever.

        Torque: 12.7 N.m (130 kgf/cm, 9 ft.lbf) 

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