Automatic Transmission Unit: Reassembly

BEARING POSITION

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

BEARING POSITION

Mark	Front Race Diameter Inside/Outside	Thrust Bearing Diameter Inside/Outside	Rear Race Diameter Inside/Outside
A	74.2 mm (2.921 in.) /87.74 mm (3.454 in.)	71.9 mm (2.831 in.) /85.6 mm (3.370 in.)	-
B	38.0 mm (1.496 in.) /57.0 mm (2.244 in.)	43.4 mm (1.709 in.) /58.3 mm (2.295 in.)	-
C	-	55.7 mm (2.193 in.) /76.4 mm (3.008 in.)	-
D	-	-	53.7 mm (2.114 in.) /74.0 mm (2.913 in.)
E	33.4 mm (1.315 in.) /49.0 mm (1.929 in.)	32.1 mm (1.264 in.) 49.35 mm (1.943 in.)	32.1 mm (1.264 in.)/49.0 mm (1.929 in.)
F	-	21.5 mm (0.847 in.) /40.8 mm (1.606 in.)	-
G	-	43.6 mm (1.717 in.)/61.0 mm (2.402 in.)	47.1 mm (1.854 in.)/67.1 mm (2.642 in.)
H	37 mm (1.45 in.) /52.3 mm (2.059 in.)	34.6 mm (1.362 in.) /52.0 mm (2.047 in.)	-
I	36.9 mm (1.453 in.) /49.7 mm (1.957 in.)	36.1 mm (1.421 in.)/52.5 mm (2.067 in.)	36.1 mm (1.421 in.)/51.0 mm (2.007 in.)

INSTALL NO. 4 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
2. Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
3. Install the No. 4 brake piston to the reaction sleeve.
  NOTE: Be careful not to damage the 4 O-rings.
  
  Fig 2: Identifying No. 4 Brake Piston O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE REACTION SLEEVE
1. Coat a new O-ring with ATF, and install it to the reaction sleeve.
2. With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and the No. 4 brake piston to the transmission case.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 3: Identifying Brake Reaction Sleeve And No. 4 Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE PISTON
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: Identifying 1St And Reverse Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the brake return spring onto the No. 4 brake piston.
  
  Fig 5: Identifying Brake Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
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: Identifying Return Spring
  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: Identifying Brake Apply Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY GEAR ASSEMBLY

Install the No. 9 thrust bearing race.

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 No. 9 Thrust Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Install the rear planetary gear assembly.

Fig 10: Identifying Rear Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE PISTON (See INSPECTION )
INSTALL NO. 4 BRAKE DISC
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PLATE STOPPER SPRING
1. Install the brake plate stopper spring.
  
  Fig 12: Locating Brake Plate Stopper Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

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

Fig 13: Identifying No. 8 Thrust Bearing Race And Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bearing and race diameter

BEARING AND RACE DIAMETER SPECIFICATION

	Inside	Outside
No. 7 thrust bearing race	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.)
No. 8 thrust bearing race	32.1 mm (1.264 in.)	49.0 mm (1.929 in.)

INSTALL NO. 3 ONE WAY CLUTCH ASSEMBLY
1. Install the No. 3 one way clutch assembly and the one way clutch inner race to the intermediate shaft.
  
  Fig 14: Identifying No. 3 One Way Clutch Assembly And One Way Clutch Inner Race
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTERMEDIATE SHAFT
1. Install the intermediate shaft with the No. 3 one way clutch assembly to the transmission case.
  
  Fig 15: Identifying Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the snap ring.
  SST 09350-30020 (09350-07050, 09350-07060)
  
  Fig 16: Identifying Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CENTER PLANETARY GEAR ASSEMBLY

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.
2. Press the No. 2 brake piston into the No. 2 brake cylinder.
  NOTE: Be careful not to damage the 2 O-rings.
3. Install the No. 2 brake piston to the transmission case.
  HINT:
  
  Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.
  
  Fig 18: Identifying No. 2 Brake Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.
  
  Fig 19: Identifying Oil Pressure Apply Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 BRAKE DISC
1. Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.
  Install in order:
  
  P a Plate, D = Disc, F = Flange
  
  F - D - P - D - P - D - P - D - F
  
  Fig 20: Identifying Flanges, Plates, Discs And Brake Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, a screwdriver and a press, install the No. 2 brake spring snap ring.
  SST 09351 -40010 (09351 -04010, 09351 -04020, 09351-04040, 09351-04050)
  
  Fig 21: Identifying No. 2 Brake Spring Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON (See INSPECTION )
INSTALL NO. 1 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.
2. Press the No. 1 brake piston into the No. 1 brake cylinder.
  NOTE: Be careful not to damage the 2 O-rings.
  
  Fig 22: Identifying No. 1 Brake Piston O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Install the brake piston return spring and the No. 1 brake piston with the No. 1 brake cylinder to the transmission case.
  HINT:
  
  Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.
  
  Fig 23: Identifying Brake Piston Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that the oil pressure apply hole of the No. 1 brake cylinder aligns with the oil pressure apply hole of the transmission case.
  
  Fig 24: Identifying Oil Pressure Apply Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PISTON RETURN SPRING SNAP RING
1. Using SST, a screwdriver and a press, install the brake piston return spring snap ring.
  SST 09351 -40010 (09351 -04010, 09351 -04030, 09351-04040, 09351-04050)

INSTALL CENTER PLANETARY RING GEAR

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

Fig 25: Identifying Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.)

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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT PLANETARY RING GEAR
1. Install the front planetary ring gear to the transmission case.
  
  Fig 28: Identifying Front Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT PLANETARY GEAR ASSEMBLY

Install the thrust needle roller bearing and the thrust washer.

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: Identifying Thrust Needle Roller Bearing And Thrust Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON (See INSPECTION )

Fig 30: Identifying Front Planetary Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 BRAKE DISC
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
2. Press the 2nd brake piston into the 2nd brake cylinder.
  NOTE: Be careful not to damage the 2 O-rings.
  
  Fig 32: Identifying 2nd Brake Piston O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, a screwdriver and a press, install the return spring with the snap ring.
  SST 09351 -40010 (09351 -04060, 09351 -04070)
  
  NOTE: Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 33: Identifying 2nd Brake Piston Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE CYLINDER
1. Install the 2nd brake cylinder to the transmission case.
  
  Fig 34: Identifying 2nd Brake Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ONE WAY CLUTCH ASSEMBLY
1. Install the one way clutch assembly and the thrust washer to the transmission case.
  
  Fig 36: Identifying One Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON HOLE SNAP RING
1. Using SST, install the snap ring.
  SST 09350-30020 (09350-07060)
  
  Fig 37: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE DISC SET
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 BRAKE SNAP RING
1. Using a screwdriver, install the snap ring.
  SST 09350-30020 (09350-07060)
  
  Fig 39: Installing No. 3 Brake Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ONE WAY CLUTCH ASSEMBLY
1. Install the No. 2 one way clutch assembly and No. 2 washer to the clutch drum and input shaft.
  
  Fig 40: Identifying No. 2 One Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CLUTCH DRUM AND INPUT SHAFT

Install the thrust needle roller bearings and thrust washer.

Coat the race with petroleum jelly and install them onto the clutch drum and input shaft assembly.

Thrust needle roller bearing and diameter

THRUST NEEDLE ROLLER BEARING AND DIAMETER SPECIFICATION

	Inside	Outside
Thrust needle roller bearing A	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
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.)

Fig 41: Identifying Thrust Needle Roller Bearings And Thrust Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 42: Installing Clutch Drum And Input Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL PUMP ASSEMBLY

Install the No. 1 thrust bearing race to the front oil pump.

THRUST BEARING RACE SPECIFICATION

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

Fig 43: Identifying No. 1 Thrust Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat a new O-ring with ATF, and install it around the oil pump assembly.
Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.
Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

Fig 44: Identifying Oil Pump Assembly O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 10 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

Fig 45: Installing Oil Pump Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Using SST and a hammer, drive in 2 new oil seals.
  SST 09350-30020(09350-07110)
2. Coat the oil seal lips with MP grease.
INSPECT INDIVIDUAL PISTON OPERATION (See INSPECTION )
INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
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 Spacer To Manual Valve Lever
  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: Aligning Manual Valve Lever Indentation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL SHAFT
1. Install a new E-ring to the shaft.
2. Install the parking lock pawl, the shaft and the spring.
  
  Fig 50: Identifying Parking Lock Pawl Shaft, E-Ring And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Connect the parking lock rod to the manual valve lever.
  
  Fig 51: Identifying Parking Lock Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL BRACKET
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 And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Shift the manual valve lever to the P position, and confirm that the planetary gear is correctly locked up by the lock pawl.
  
  Fig 53: Shifting Manual Valve Lever To P Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL B-1 ACCUMULATOR VALVE

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

Fig 54: Identifying Springs And Accumulator Valve

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

B-1 accumulator spring

Inner spring:

INNER SPRING SPECIFICATION

Free length	Outer diameter	Color
44.98 mm (1.7709 in.)	11.30 mm (0.445 in.)	Natural

Outer spring:

OUTTER SPRING SPECIFICATION

Free length	Outer diameter	Color
46.36 mm (1.8252 In.)	17.10 mm (0.6732 in.)	Natural

Fig 55: Identifying B-1 Accumulator Spring

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL C-3 ACCUMULATOR PISTON

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

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

C-3 accumulator spring

Inner spring:

INNER SPRING SPECIFICATION

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

Fig 56: Identifying C-3 Accumulator Piston, Spring And O-Ring

Outer spring:

OUTTER SPRING SPECIFICATION

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

INSTALL B-3 ACCUMULATOR PISTON

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

Install the spring and the accumulator piston to the hole.

Accumulator spring

ACCUMULATOR SPRING SPECIFICATION

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

Fig 57: Identifying B-3 Accumulator Piston, Spring And O-Ring

INSTALL C-2 ACCUMULATOR PISTON

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

Install the spring and the accumulator piston to the hole.

Accumulator spring

ACCUMULATOR SPRING SPECIFICATION

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

Fig 58: Identifying C-2 Accumulator Piston, Spring And O-Ring

INSTALL CHECK BALL BODY
1. Install the check ball body and the spring.
  
  Fig 59: Identifying Check Ball Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Install the 3 new brake drum gaskets.
  
  Fig 60: Identifying Brake Drum Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE GASKET
1. Install the 3 new transaxle case gaskets.
  
  Fig 61: Identifying Transaxle Case Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve lever with the pin of the manual valve.
  
  Fig 62: Aligning Groove Of Manual Valve Lever With Pin Of Manual Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.)
  
  Fig 63: Identifying Transmission Valve Body Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt D:
  
  50 mm (1.97 in.)
3. Install the detent spring and the detent spring cover with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 64: Identifying Detent Spring Cover And Detent Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION WIRE
1. Coat a new O-ring with ATF.
2. Install the O-ring to the transmission wire.
  
  Fig 65: Identifying Transmission Wire O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the transmission wire.
4. Install the bolt.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 66: Locating Transmission Wire Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 9 solenoid connectors.
  
  Fig 67: Locating Solenoid Valves Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the ATF temperature sensor and clamp with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 68: Locating ATF Temperature Sensor Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. 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 Clamps And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.
  
  Fig 70: Identifying Valve Body Oil Strainer O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil strainer with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 71: Locating Valve Body Oil Strainer Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION OIL CLEANER MAGNET
1. Install the 3 transmission oil cleaner magnets.
INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
1. Install a new gasket on the oil pan.
  
  Fig 72: Identifying Transmission Oil Cleaner Magnets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install and tighten the 20 bolts.
  Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf)
3. Install a new gasket and the drain plug.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
4. Install a new gasket and the overflow plug.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL
1. Coat the lip of a new oil seal with MP grease.
  
  Fig 73: Locating Automatic Transmission Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, install a new oil seal.
  SST 09316-60011 (09316-00011, 09316-00051)
  
  Oil seal drive in depth:
  
  1.8 to 2.2 mm (0.071 to 0.087 in.)
  
  Fig 74: Installing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE ADAPTOR RADIAL BALL BEARING
1. Install the transmission case adaptor radial ball bearing to the extension housing sub-assembly.
  
  Fig 75: Identifying Transmission Case Adaptor Radial Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR COVER SLEEVE
1. Install the 2 washers and rear cover sleeve to the output shaft.
  
  Fig 76: Identifying Washers And Rear Cover Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL ALL EXTENSION (ATM) HOUSING SUB-ASSEMBLY

Install the thrust needle roller bearing and the 2 bearing races.
Using a snap ring expander, install the snap ring.

Fig 77: Installing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

There are 12 different thicknesses for the race.

Fig 78: Measuring Clearance Between Snap Ring And Race

Flange thickness

FLANGE THICKNESS SPECIFICATION

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

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

Seal Packing 1281, THREE BOND 1281 or equivalent

Fig 79: Identifying FIPG Applying Area
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 in.)

Bolt B:

35 mm (1.378 in.)

Fig 80: Locating Extension Housing With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY
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 81: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSMISSION HOUSING
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 82: Locating Transmission Housing With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE
1. Install the breather tube.
2. Install the 2 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 83: Locating Breather Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION REVOLUTION SENSOR
1. Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.
2. Install the 2 transmission revolution sensors.
3. Install the 2 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 84: Locating Transmission Revolution Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION OIL COOLER
1. Coat 2 new O-rings with ATF, and install them to the transmission oil cooler.
2. Coat 2 new O-rings with ATF, and install them to the spacer.
  
  Fig 85: Identifying Spacer O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the spacer and the transmission oil cooler with the 3 bolts.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 86: Identifying Bolts, Transmission Oil Cooler And Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
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 87: Locating Park/Neutral Position Switch Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 88: Turning Manual Lever Shaft Back In N Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 89: Aligning Neutral Basic Line With 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 90: Bending Tabs Of Lock Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CONTROL SHAFT LEVER RH
1. Install the control shaft lever RH, spring washer and the nut.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 91: Identifying Nut, Spring Washer And Transmission Control Shaft Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE COVER
1. Install the transmission case cover with the 2 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 92: Locating Transmission Case Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002