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 the ATF, and install them to the brake piston No.4.
3. Install the brake piston No.4 to the reaction sleeve.
   NOTE: Be careful not to damage the O-rings.

Fig 2: Identifying O Rings

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1. Coat a new O-ring with ATF, and install it to the reaction sleeve.
2. With the brake piston No.4 underneath (the rear side), install the brake reaction sleeve and the brake piston No.4 to the transmission case.
   NOTE: Be careful not to damage the O-rings.

Fig 3: Identifying Brake Reaction Sleeve

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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.
   NOTE: Be careful not to damage the O-ring.
   Fig 4: Installing 1st And Reverse Brake Piston

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

Fig 5: Identifying Brake Return Springs

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

   SST 09350-30020 (09350-07050) 

2. Using SST, install the snap ring.

   SST 09350-30020 (09350-07070) 

   Fig 6: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.
   NOTE: Engage the 1st and reverse brake piston claw with the protrusion of the brake apply tube.

Fig 7: Installing Brake Apply Tube

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1. Install the thrust bearing race No.9.

   Race diameter 

   RACE DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Thrust bearing race	47.1 mm (1.854 in.)	67.1 mm (2.642 in.)

   Fig 8: Identifying Thrust Bearing Race

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2. Install the 2 thrust needle roller bearings.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Bearing A	21.5 mm (0.847 in.)	40.8 mm (1.606 in.)
   Bearing B	43.6 mm (1.717 in.)	61.0 mm (2.402 in.)

   Fig 9: Identifying Thrust Needle Roller Bearings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear planetary gear assembly.

1. Install the sleeve, 4 plates, the 4 discs and the flange.

   Install in order: 

   P = Plate, D = Disc, F = Flange, S = Sleeve F - D - P - D - P - D - P - D - P - S 

Fig 11: Identifying Sleeve, Plates, Discs And Flange

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1. Install the brake plate stopper spring.

Fig 12: Locating Brake Plate Stopper Spring

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Fig 13: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race

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

   Bearing and race diameter 

   BEARING AND RACE DIAMETER SPECIFICATION
   
   

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

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

Fig 14: Identifying 1 Way No 3 Clutch Assembly And 1 Way Clutch Inner Race

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1. Install the intermediate shaft with 1 way No.3 clutch assembly to the transmission case.
   Fig 15: Identifying Intermediate Shaft

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2. Using SST, install the snap ring.

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

Fig 16: Installing Snap Ring

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

   Race diameter 

   RACE DIAMETER SPECIFICATION
   
   

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

Fig 17: Identifying Center Planetary Gear Assembly And Planetary Sun Gear

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1. Coat 2 new O-rings with ATF, and install them to the brake piston No.2.
2. Being careful not to damage the O-rings, press the brake piston No.2 into the brake cylinder No.2.
3. Install the brake piston No.2 to the transmission case.

   HINT:

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

   Fig 18: Identifying O-Rings

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

Fig 19: Identifying Oil Pressure Apply Hole

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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 20: Identifying Flanges, Plates And Discs

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2. Using SST and a press, install the brake No.2 spring snap ring.
   Fig 21: Installing Brake No 2 Spring Snap Ring

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

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

Fig 22: Identifying O-Rings

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

   HINT:

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

   Fig 23: Identifying Brake Piston Return Spring

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2. Check that the oil pressure apply hole of the brake cylinder No.1 aligns with the oil pressure apply hole of the transmission case.

Fig 24: Identifying Oil Pressure Apply Hole

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

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

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	55.7 mm (2.193 in.)	76.4 mm (3.008 in.)

   Fig 25: Installing Brake Piston Return Spring Snap Ring

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2. Install the center planetary ring gear and the front planetary ring gear flange on the front planetary ring gear.
   Fig 26: Identifying Center Planetary Ring Gear And Front Planetary Ring Gear Flange

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3. 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 27: Installing Snap Ring

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

Fig 28: 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	43.4 mm (1.709 in.)	58.3 mm (2.295 in.)
   Race	38.0 mm (1.496 in.)	57.0 mm (2.244 in.)

   Fig 29: Installing Thrust Needle Roller Bearing And Thrust Bearing Race

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3. Install the front planetary gear assembly and the 1 way clutch inner race to the transmission case.
   Fig 30: Identifying Front Planetary Gear Assembly

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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 31: Identifying Plates, Discs And Flange

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1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
2. Be careful not to damage the O-rings. Press the 2nd brake piston into the 2nd brake cylinder.
   Fig 32: Identifying 2nd Brake Piston O-Rings

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3. Using SST and a press, install the return spring with the snap ring.
   NOTE: Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
   SST 09351-40010 (09351-04060, 09351-04070)

Fig 33: Installing Return Spring With Snap Ring

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1. Install the 2nd brake cylinder to the transmission case.
   Fig 34: Identifying 2nd Brake Cylinder

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

Fig 35: Identifying Oil Pressure Apply Hole Of Brake Cylinder

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

Fig 36: Identifying 1 Way Clutch Assembly And Thrust Washer

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

Fig 37: Installing 2nd Brake Piston Hole Snap Ring

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1. Install the cushion plate, flange, the 4 discs and the 4 plates to the transmission case.

   Install in order: 

   P = Plate, D = Disc, F = Flange, C = Cushion Plate 

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

Fig 38: Identifying Cushion Plate, Flange, Discs And Plates

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1. Using a screwdriver, install the snap ring.

   SST 09350-30020 (09350-07060) 

Fig 39: Installing Brake No 3 Snap Ring

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

Fig 40: Identifying 1 Way No 2 Clutch Assembly And Washer

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1. Install the thrust needle roller bearings and thrust washer.
2. Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.
   Fig 41: Identifying Thrust Needle Roller Bearings And Bearing Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Thrust needle roller bearing A	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
   Thrust needle roller bearing B	34.6 mm (1.362 in.)	52.0 mm (2.047 in.)
   Bearing Race	37.0 mm (1.457 in.)	52.3 mm (2.059 in.)

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

Fig 42: Installing Clutch Drum And Input Shaft Assembly Into Transmission Case

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

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

   Fig 43: Identifying Oil Pump And Thrust Bearing Race

   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.
   Fig 44: Identifying O-Ring

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5. Install the 10 bolts.

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

Fig 45: Installing Oil Pump Bolts

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Fig 46: Installing Manual Valve Lever Shaft Oil Seal

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1. Using SST, 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 47: 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 48: Installing Spring Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 49: Staking Manual Valve Lever And Spacer

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

Fig 50: Identifying Parking Lock Pawl And Spring

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

Fig 51: Identifying Parking Lock Rod

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

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

   Fig 52: Locating Parking Lock Pawl Bracket Bolts

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

Fig 53: Identifying Planetary Ring Gear And Manual Valve Lever

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1. Install the 2 springs and the accumulator valve to the hole.

Fig 54: Identifying Springs And B-1 Accumulator Valve

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B-1 accumulator spring 

Inner spring: 

Outer spring: 

Fig 55: Identifying B-1 Accumulator Springs

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1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 56: Identifying C-3 Accumulator Piston

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2. Install the 2 springs and the accumulator piston to the hole.

   C-3 accumulator spring 

   Inner spring: 

   C-3 ACCUMULATOR INNER SPRING LENGTH AND OUTER DIAMETER SPECIFICATION
   
   

   Free length	Outer diameter	Color
   44.0 mm (1.732 in.)	14.0 mm (0.551 in.)	Yellow

   Outer spring: 

   C-3 ACCUMULATOR OUTER SPRING LENGTH AND OUTER DIAMETER SPECIFICATION
   
   

   Free length	Outer diameter	Color
   76.65 mm (3.0178 in.)	20.10 mm (0.7913 in.)	Natural

Fig 57: Identifying C-3 Accumulator Piston And Springs

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1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 58: Identifying B-3 Accumulator Piston

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2. Install the spring and the accumulator piston to the hole.

   Accumulator spring 

   B-3 ACCUMULATOR SPRING LENGTH AND OUTER DIAMETER SPECIFICATION
   
   

   Free length	Outer diameter	Color
   64.5 mm (2.539 in.)	19.5 mm (0.768 in.)	Orange

Fig 59: Identifying B-3 Accumulator And Spring

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1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 60: Identifying C-2 Accumulator Piston

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2. Install the spring and the accumulator piston to the hole.

   Accumulator spring 

   C-2 ACCUMULATOR SPRING LENGTH AND OUTER DIAMETER SPECIFICATION
   
   

   Free length	Outer diameter	Color
   63.14 mm (2.4858 in.)	16.0 mm (0.6299 in.)	Light Gray

Fig 61: Identifying C-2 Accumulator Piston And Spring

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1. Install the check ball body and the spring.

Fig 62: Identifying Check Ball Body And Spring

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1. Install the 3 brake drum gaskets.

Fig 63: Identifying Brake Drum Gasket

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1. Install the 3 transaxle case gaskets.

Fig 64: Identifying Transaxle Case Gaskets

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1. Align the groove of the manual valve lever with the pin of the manual valve.
   Fig 65: Identifying Pin Of Manual Valve

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2. Install the 20 bolts.

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

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 

   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.) 

   Fig 66: Identifying Transmission Valve Body Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the detent spring and the detent spring cover with the bolt.

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

Fig 67: Locating Detent Spring Cover Bolt

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1. Install a new O-ring to the transmission wire.
2. Install the transmission wire.
3. Install the bolt.

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

   Fig 68: Locating Transmission Wire Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 9 solenoid connectors.
5. Install the ATF temperature sensor and clamp with the bolt.

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

6. Install the clamps with 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 69: Locating Shift Solenoid Connectors

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1. Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.
2. Install the oil strainer with the 4 bolts.

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

Fig 70: Locating Oil Strainer Bolts

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1. Install the 3 transmission oil cleaner magnets.

1. Install a new gasket on the oil pan.
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 over flow plug.

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

Fig 71: Identifying Magnets

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1. Using SST and a hammer, install a new oil seal.

   SST 09309-37010 

1. Install the 2 washers and RR cover sleeve to the output shaft.

Fig 73: Identifying Washers And RR Cover Sleeve

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1. Install the thrust needle roller bearing and the 2 bearing races.
2. Using a snap ring expander, install a new snap ring.
   Fig 74: Installing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. 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.) 

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

   HINT:

   There are 12 different thickness for the race.

   Flange thickness 

   Fig 75: Measuring Clearance Between Snap Ring And Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   BEARING RACE 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.)

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

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   Fig 76: Identifying FIPG Applying Area Of Extension Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the extension housing with 6 new bolts.

   Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 

   45 mm (1.772 mm) 

   Bolt B: 

   35 mm (1.378 mm) 

Fig 77: Locating Extension (ATM) Housing Bolts

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1. Using SST, install a new oil seal to the automatic transmission flange yoke.

   SST 09950-60010 (09951-00350), 09950-70010 (09951-07100) 

2. Install the automatic transmission flange yoke to the output shaft with a new nut.

   Torque: 126 N*m (1,285 kgf*cm, 93 ft.*lbf) 

3. Using a hammer and chisel, stake the nut.

Fig 78: Identifying Oil Seal

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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.

   Torque: A (14 mm bolt) 

   34 N*m (347 kgf cm, 25 ft.*lbf) 

   B (17 mm bolt) 

   57 N*m (581 kgf*cm, 42 ft.*lbf) 

Fig 79: Locating Automatic Transmission Housing Bolts

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

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

Fig 80: Locating Automatic Transmission Breather Tube Bolts

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

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

Fig 81: Locating Speed Sensors Bolts

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1. Coat 2 new O-rings with ATF, and install them to oil cooler tube unions.
2. Install the oil cooler tube unions as shown in the illustration.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

Fig 82: Identifying Oil Cooler Tube Unions

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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 83: Identifying Park/Neutral Position Switch Bolts

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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 84: Turning Manual Lever Shaft

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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 85: Identifying Neutral Basic Line And Park/Neutral Position Switch Groove

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a screwdriver, bend the tabs of the lock washer.

   HINT:

   Bend at least 2 of the lock washer tabs.

Fig 86: Bending Tabs Of Lock Washer

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

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

1. Install the transaxle case cover upper with the 2 bolts.

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

Fig 87: Locating Transmission Control Shaft Lever Nut (RH)

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