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Automatic Transmission Unit: Reassembly

  1. BEARING POSITION 
    Fig 1: Identifying Bearing Position
    G04948708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Bearing Position 

    BEARING POSITION CHART

    Position Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
    A - 36.2 mm (1.425 in.) / 58.2 mm (2.291 in.) 44.0 mm (1.732 in.) / 62.0 mm (2.441 in.)
    B - 34.5 mm (1.358 in.) / 49.4 mm (1.945 in.) 36.6 mm (1.441 in.) / 51.9 mm (2.043 in.)
    C 46.5 mm (1.831 in.) / 60.1 mm (2.366 in.) 47.0 mm (1.850 in.) / 61.9 mm (2.437 in.) -
    D - 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) 72.7 mm (2.858 in.) / 89.2 mm (3.512 in.)
    E 30.0 mm (1.181 in.) / 49.9 mm (1.965 in.) 31.0 mm (1.221 in.) / 53.1 mm (2.091 in.) -
    F 31.5 mm (1.240 in.) / 53.0 mm (2.0866 in.) 28.7 mm (1.130 in.) / 52.3 mm (2.059 in.) 28.7 mm (1.130 in.) / 50.4 mm (1.984 in.)
    G - 30.5 mm (1.201 in.) / 55.7 mm (2.189 in.) 33.5 mm (1.319 in.) / 59.0 mm (2.323 in.)
    H - 58.9 mm (2.319 in.) / 77.3 mm (3.043 in.) 62.0 mm (2.441 in.) / 82.5 mm (3.248 in.)
  2. INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST, tap in the bearing to the transmission case.

      SST 09316-60011 (09316-00011,09316-00021) 

    2. Using needle-nose pliers, install the snap ring.
      Fig 2: Tapping Rear Radial Ball Bearing Into Transmission Case
      G04948709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL AUTOMATIC TRANSMISSION REAR OIL SEAL 
    1. Coat the lip of a new oil seal with MP grease.
      Fig 3: Tapping Oil Seal With Transmission Case
      G04948710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap in the oil seal until it fits with the transmission case.

      SST 09214-76011 

      Standard oil seal depth: 

      3.5 +/-0.2 mm (0.138 +/- 0.008 in.) 

  4. INSTALL NO. 2 BRAKE PISTON 
    1. Coat 3 new O-rings with ATF, and install them to the brake piston.
    2. Install the brake piston to the transmission case.
      Fig 4: Identifying Brake Piston To Transmission Case
      G04948711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston's 2 protrusions to the transmission case's spline grooves. (One groove is 3 places clockwise from the top, and the other is 2 places clockwise from the bottom).

    3. Install the brake return spring to the transmission case.
    4. Set SST on the brake piston return spring, tighten SST and compress the return spring.

      SST 09380-50010 

    5. Using SST, install the snap ring.

      SST 09350-30020 (09350-07070) 

      Fig 5: Identifying Snap Ring And Brake Return Spring
      G04948684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. SELECT NO. 2 BRAKE FLANGE 
    1. Measure length A (from the tip of the No. 2 brake piston to the step in the transmission case) in the illustration. *1

      Standard: 

      14.77 to 15.37 mm (0.5815 to 0.6051 in.) 

      Fig 6: Identifying No. 2 Brake Flange Length
      G04948713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Assemble the 4 No. 2 brakes discs, 3 No. 2 brake plates, and No. 2 brake flange as shown in the illustration. Then with a weight fixture of 500 g (17.64 oz) or less placed on the flange, measure length B. *2
      Fig 7: Identifying No. 2 Brake Flange Length
      G04948714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      14.11 to 14.69 mm (0.5555 to 0.5783 in.) 

    3. Choose a No. 2 brake flange so that the value of measured length A minus length B (from steps *1 and *2) is 0.52 to 0.82 mm (0.0204 to 0.0323 in.).

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      1 2.05 to 2.15 mm (0.0807 to 0.0846 in.)
      2 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
      3 2.25 to 2.35 mm (0.0886 to 0.0925 in.)
      4 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      5 2.45 to 2.55 mm (0.0965 to 0.1004 in.)
      6 2.55 to 2.65 mm (0.1004 to 0.1043 in.)
      7 2.65 to 2.75 mm (0.1043 to 0.1083 in.)
      8 2.75 to 2.85 mm (0.1083 to 0.1122 in.)
  6. INSTALL DIRECT CLUTCH PISTON 
    1. Coat a new O-ring with ATF, and install it to the rear clutch drum sub-assembly.
    2. Coat a new O-ring with ATF, and install it to the clutch piston.
    3. Install the clutch piston to the rear clutch drum sub-assembly.
      Fig 8: Identifying Rear Clutch Drum Sub-Assembly
      G04948715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.
    5. Install the direct clutch piston return spring sub-assembly and balancer to the rear clutch drum sub-assembly.
      Fig 9: Identifying No. 2 Clutch Balancer And Direct Clutch Piston Return Spring Sub-Assembly
      G04948682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place SST on the clutch balancer and compress the return spring with a press.

      SST 09387-00020 

    7. Using SST, install the snap ring.

      SST 09350-30020 (09350-07070) 

      Fig 10: Removing/Installing Snap Ring
      G04948681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 2 CLUTCH DISC SET 
    1. Install the 6 plates, 6 discs and flange to the rear clutch drum.

      Install in order: 

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

      HINT:

      P = Plate

      D = Disc

      F = Flange

      NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.
      Fig 11: Identifying Plates, Discs And Flange
      G04948718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the snap ring.
      Fig 12: Installing Snap Ring
      G04948719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2 cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard value.
      Fig 13: Measuring Moving Distance Of Clutch Flange
      G04948720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      0.90 to 1.20 mm (0.0354 to 0.0472 in.) 

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      40 3.95 to 4.05 mm (0.1555 to 0.1594 in.)
      41 4.05 to 4.15 mm (0.1594 to 0.1634 in.)
      42 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      43 4.25 to 4.35 mm (0.1673 to 0.1713 in.)
      44 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      45 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      46 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      47 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      48 4.75 to 4.85 mm (0.1870 to 0.1909 in.)
    4. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
  8. CONNECT DIRECT CLUTCH ASSEMBLY 
    1. Coat 2 new oil seal rings with ATF, and install them to the direct clutch drum sub-assembly.
      NOTE: Do not expand the ring ends excessively.
      Fig 14: Identifying Direct Clutch Drum Sub-Assembly Oil Seal Rings
      G04948721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat 3 new oil seal rings with ATF, and install them to the output shaft.
      NOTE: Do not expand the ring ends excessively.
      Fig 15: Identifying Output Shaft Oil Seal Rings
      G04948722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the thrust needle roller bearing and thrust bearing race.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Bearing 30.5 mm (1.201 in.) 55.7 mm (2.189 in.)
      Race 33.5 mm (1.319 in.) 59.0 mm (2.323 in.)
      NOTE: Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
    4. Connect the direct clutch assembly to the output shaft.
      Fig 16: Identifying Direct Clutch Assembly
      G04948677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR PLANETARY RING GEAR 
    1. Install the snap ring to the groove of the output shaft.
    2. Using needle-nose pliers, attach the snap ring to install the ring gear to the output shaft.
      Fig 17: Installing Rear Planetary Ring Gear
      G04948724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY 
    1. Install the 2 thrust needle bearings, 2 thrust bearing races, direct clutch with rear planetary ring gear and output shaft to the transmission case.
      Fig 18: Identifying Thrust Needle Bearings And Thrust Bearing Races
      G04948725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Race A 62.0 mm (2.441 in.) 82.5 mm (3.248 in.)
      Bearing A 58.9 mm (2.319 in.) 77.3 mm (3.043 in.)
      Race B 28.7 mm (1.130 in.) 50.4 mm (1.984 in.)
      Bearing B 28.7 mm (1.130 in.) 52.3 mm (2.059 in.)
      NOTE: Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
  11. INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY 
    1. Using SST, install a new oil seal to the automatic transmission flange yoke.

      SST 09950-60010 (09951-00410), 09950-70010 (09951-07100) 

    2. Install the rear cover sleeve and 2 output shaft rear bearing No. 1 spacers.
    3. Install the automatic transmission flange yoke.
      Fig 19: Installing Oil Seal
      G04948402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set SST.

      SST 09330-00021, 09950-30012 (09955-03040) 

    5. Using SST and a 30 mm socket wrench, temporarily install and tighten a new nut.

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

      Fig 20: Installing Yoke Nut
      G04948727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. SELECT REAR COVER SLEEVE 
    1. Using a dial indicator, measure the output shaft end play. Then choose from the 15 sleeve thicknesses in the table so that the measured value is within the standard value.

      Standard end play: 

      0.21 to 0.36 mm (0.0083 to 0.0142 in.) 

      Sleeve thickness 

      Fig 21: Identifying Rear Cover Sleeve
      G05847884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      SLEEVE THICKNESS CHART

      Mark Thickness
      02 1.725 to 1.775 (0.0679 to 0.0699 in.)
      03 1.775 to 1.825 (0.0699 to 0.0719 in.)
      04 1.825 to 1.875 (0.0719 to 0.0738 in.)
      05 1.875 to 1.925 (0.0738 to 0.0758 in.)
      06 1.925 to 1.975 (0.0758 to 0.0778 in.)
      07 1.975 to 2.025 (0.0778 to 0.0797 in.)
      08 2.025 to 2.025 (0.0778 to 0.0797 in.)
      09 2.075 to 2.125 (0.0817 to 0.0837 in.)
      10 2.125 to 2.175 (0.0837 to 0.0856 in.)
      11 2.175 to 2.225 (0.0778 to 0.0797 in.)
      12 2.225 to 2.275 (0.0876 to 0.0896 in.)
      13 2.275 to 2.325 (0.0896 to 0.0915 in.)
      14 2.325 to 2.375 (0.0915 to 0.0935 in.)
      15 2.375 to 2.425 (0.0935 to 0.0955 in.)
      16 2.425 to 2.475 (0.0955 to 0.0974 in.)
    2. Temporarily remove the lock nut, flange yoke, 2 spacers and sleeve, attach the selected sleeve and restore the flange yoke.
    3. Using a chisel and hammer, securely stake the nut.
  13. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    1. Install the thrust bearing race, rear planetary gear assembly and thrust needle roller bearing to the transmission case.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Race 31.5 mm (1.240 in.) 53.0 mm (2.0866 in.)
      Bearing 31.0 mm (1.221 in.) 53.1 mm (2.091 in.)
      Fig 22: Identifying Rear Planetary Gear Assembly
      G04948672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the rear planetary gear, apply ATF to rear planetary gear bush's sliding surfaces. After the installation, check that the rear planetary gear rotates smoothly.
      • Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
  14. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Install the thrust bearing race and sun gear to the transmission case.

      Standard bearing race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Race 30.0 mm (1.181 in.) 49.9 mm (1.965 in.)
      Fig 23: Identifying Sun Gear And Thrust Bearing Race
      G04948671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the sun gear, apply ATF to sun gear bush's sliding surfaces. After the installation, check that the sun gear rotates smoothly.
      • Use a small amount of MP grease to make the thrust bearing race stay securely in place.
  15. INSTALL NO. 2 BRAKE DISC SET 
    1. Install the selected flange, 4 discs, 3 No. 2 plates and No. 1 plate.

      Install in order: 

      F - D - No. 2 P - D - No. 2 P - D - No. 2 P - D - No. 1 P 

      HINT:

      F = Flange

      D = Disc

      P = Plate

      HINT:

      Assemble the transmission case, flanges and plates by aligning their grooves as shown in the illustration.

      Fig 24: Identifying No. 2 Brake Disc Set
      G04948731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 25: Brake Disc Set Chart
      G04948732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.
  16. INSTALL NO. 1 1-WAY CLUTCH 
    1. Install the 1-way clutch to the outer race with the 2 snap rings.
      NOTE: Do not mistake the direction of the 1-way clutch.
      Fig 26: Identifying No. 1 1-Way Clutch
      G05847889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT NO. 1 1-WAY CLUTCH  (See INSPECTION  )
  18. INSTALL 1-WAY CLUTCH OUTER RACE WITH NO.1 1-WAY CLUTCH 
    1. Install the 1-way clutch outer race with 1-way clutch to the transmission case.
      Fig 27: Identifying 1-Way Clutch Outer Race With No.1 1-Way Clutch
      G04948670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the snap ring to the transmission case.

      SST 09350-30020 (09350-07060) 

      Fig 28: Removing/Installing Snap Ring
      G04948669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Install the snap ring so that its tapered face is facing the front side of the transmission case.
      • Install the snap ring so that its gap end is within the range shown in the illustration.
        Fig 29: Identifying Correct Snap Ring Position
        G05847892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY 
    1. Install the thrust bearing race, thrust needle roller bearing and sun gear input drum.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Race 72.7 mm (2.858 in.) 89.2 mm (3.512 in.)
      Bearing 71.9 mm (2.831 in.) 85.6 mm (3.370 in.)
      NOTE:
      • Before installing the sun gear input drum, apply ATF to the sun gear input drum bush's sliding surfaces. After the installation, check that the sun gear input drum rotates smoothly.
      • Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
        Fig 30: Identifying Sun Gear Input Drum Sub-Assembly
        G04948668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FORWARD CLUTCH PISTON 
    1. Coat 2 new O-rings with ATF, and install it to the clutch piston.
    2. Install the clutch piston to the forward clutch drum.
      Fig 31: Identifying Clutch Piston And Forward Clutch Drum
      G04948738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat a new O-ring with ATF, and install it to the No. 1 clutch balancer.
    4. Install the forward clutch return spring sub-assembly and clutch balancer to the forward clutch drum.
      Fig 32: Identifying Clutch Return Spring Sub-Assembly
      G04948665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Place SST on the clutch balancer, and compress the clutch balancer with a press.

      SST 09380-50010 

    6. Using SST, install the snap ring.

      SST 09350-30020 (09350-07070) 

      NOTE:
      • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
      • Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
      • Do not expand the snap ring excessively.
        Fig 33: Removing/Installing Forward Clutch Piston
        G04948664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FORWARD MULTIPLE CLUTCH DISC SET 
    1. Install the cushion plate, 4 plates, 4 discs and flange to the forward clutch drum.

      Install in order: 

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

      HINT:

      C = Cushion

      P = Plate

      D = Disc

      F = Flange

      Fig 34: Identifying Forward Multiple Clutch Disc Set
      G04948741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Assemble the cushion plate by facing its marked side towards the plates.
      • Before assembling new discs, soak them in ATF for at least 2 hours.
    2. Temporarily install the snap ring.
    3. Temporarily assemble the front planetary gear assembly to the forward clutch assembly.
      Fig 35: Identifying Front Planetary Gear Assembly
      G04948742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2 cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard value.

      Standard: 

      0.90 to 1.20 mm (0.0354 to 0.0472 in.) 

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      0 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      1 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      2 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      3 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      4 4.75 to 4.85 mm (0.1870 to 0.1909 in.)
      5 4.85 to 4.95 mm (0.1909 to 0.1949 in.)
      6 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      7 5.05 to 5.15 mm (0.1988 to 0.2029 in.)
      8 5.15 to 5.25 mm (0.2029 to 0.2067 in.)
    5. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
    6. Remove the front planetary gear assembly.
      Fig 36: Measuring Moving Distance Of Clutch Flange
      G04948743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT PLANETARY RING GEAR 
    1. Install the snap ring to the groove of forward clutch drum.
      Fig 37: Installing Snap Ring
      G04948744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using needle-nose pliers, attach the snap ring to install the ring gear to the forward multiple disc clutch assembly.
      NOTE: Check that the snap ring is securely fit into the groove by looking through the ring gear slots on both sides.
      Fig 38: Checking Snap Ring Is Securely Fit
      G05847901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL MULTIPLE DISC CLUTCH HUB 
    1. Install the thrust needle bearing, thrust bearing race and multiple disc clutch hub to the forward clutch assembly.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Bearing 34.5 mm (1.358 in.) 49.4 mm (1.945 in.)
      Race 36.6 mm (1.441 in.) 51.9 mm (2.043 in.)
      NOTE: Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
      Fig 39: Identifying Multiple Disc Clutch Hub
      G04948746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FORWARD CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR AND MULTIPLE DISC CLUTCH HUB 
    1. Install the thrust bearing race, thrust needle bearing and forward clutch assembly with front planetary ring gear and multiple disc clutch hub to the transmission case.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Bearing 47.0 mm (1.850 in.) 61.9 mm (2.437 in.)
      Race 46.5 mm (1.831 in.) 60.1 mm (2.366 in.)
      Fig 40: Identifying Thrust Needle Bearing And Forward Clutch Assembly
      G04948747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the forward clutch drum, apply ATF to forward clutch drum bush's sliding surfaces. After the installation, check that the forward clutch drum rotates smoothly.
      • Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
  25. INSTALL NO. 3 CLUTCH PISTON 
    1. Coat a new O-ring with ATF, and install it to the overdrive direct clutch drum sub-assembly.
    2. Coat a new O-ring with ATF, and install it to the piston.
    3. Install the piston to the direct clutch drum.
    4. Coat a new O-ring with ATF, and install it to the No. 3 clutch balancer.
      Fig 41: Installing Piston To Direct Clutch Drum
      G04948748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the overdrive clutch return spring and balancer to the direct clutch drum.
      Fig 42: Identifying Overdrive Clutch Return Spring And Direct Clutch Drum
      G04948658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Place SST on the clutch balancer, and compress the clutch balancer with a press.

      SST 09380-50010 

    7. Using SST, install the snap ring.

      SST 09350-30020 (09350-07070) 

      NOTE:
      • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
      • Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
      • Do not expand the snap ring excessively.
        Fig 43: Removing/Installing Snap Ring
        G04948657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REVERSE CLUTCH DRUM SUB-ASSEMBLY 
    1. Coat 3 new O-rings with ATF, and install them to the drum.
    2. Install the drum to the overdrive direct clutch drum sub-assembly.
      Fig 44: Identifying Reverse Clutch Drum Sub-Assembly
      G04948751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REVERSE CLUTCH PISTON 
    1. Coat a new O-ring with ATF, and install it to the piston.
      Fig 45: Identifying Reverse Clutch Piston
      G04948752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the piston, reverse clutch piston return spring and reverse clutch balancer.
      Fig 46: Identifying Piston, Reverse Clutch Piston Return Spring And Reverse Clutch Balancer
      G04948654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place SST on the clutch balancer, and compress the clutch balancer with a press.

      SST 09380-50010 

    4. Using SST, install the snap ring.

      SST 09350-30020 (09350-07070) 

      NOTE:
      • Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
      • Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
      • Do not expand the snap ring excessively.
        Fig 47: Removing/Installing Reverse Clutch Piston
        G04948653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REVERSE CLUTCH DISC SET 
    1. Install the cushion plate, 5 plates, 5 discs and flange to the No. 2 reverse clutch drum.

      Install in order: 

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

      HINT:

      C = Cushion Plate

      P = Plate

      D = Disc

      F = Flange

      Fig 48: Identifying Reverse Clutch Disc Set
      G04948755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Assemble the cushion plate by facing its marked side towards the plates.
      • Before assembling new discs, soak them in ATF for at least 2 hours.
    2. Temporarily install the snap ring.
      Fig 49: Identifying Snap Ring
      G04948756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft onto the oil pump.
    4. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2 cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard value.
      Fig 50: Measuring Moving Distance Of Clutch Flange
      G04948757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      0.75 to 1.05 mm (0.0295 to 0.0354 in.) 

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      0 2.95 to 3.05 mm (0.1161 to 0.1201 in.)
      1 3.05 to 3.15 mm (0.1201 to 0.1240 in.)
      2 3.15 to 3.25 mm (0.1240 to 0.1280 in.)
      3 3.25 to 3.35 mm (0.1280 to 0.1319 in.)
      4 3.35 to 3.45 mm (0.1319 to 0.1358 in.)
      5 3.45 to 3.55 mm (0.1358 to 0.1398 in.)
      6 3.55 to 3.65 mm (0.1398 to 0.1437 in.)
      7 3.65 to 3.75 mm (0.1437 to 0.1476 in.)
      8 3.75 to 3.85 mm (0.1476 to 0.1516 in.)
    5. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
  29. INSTALL NO. 3 CLUTCH DISC SET 
    1. Install the 4 plates, 4 discs and flange to the overdrive direct clutch drum.

      Install in order: 

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

      HINT:

      P = Plate

      D = Disc

      F = Flange

      NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.
      Fig 51: Identifying No. 3 Clutch Disc Set
      G04948758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the snap ring.
      Fig 52: Identifying Snap Ring
      G04948759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2 cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 7 flange thicknesses in the table so that the measured value is within the standard value.
      Fig 53: Measuring Moving Distance Of Clutch Flange
      G04948760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard: 

      0.6 to 0.9 mm (0.0236 to 0.0354 in.) 

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      0 3.95 to 4.05 mm (0.1555 to 0.1594 in.)
      1 4.05 to 4.15 mm (0.1594 to 0.1634 in.)
      2 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      3 4.25 to 4.35 mm (0.1673 to 0.1713 in.)
      4 4.35 to 4.45 mm (0.1713 to 0.1752 in.)
      5 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      6 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
    4. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
  30. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the front planetary sun gear.
      Fig 54: Identifying Front Planetary Sun Gear
      G04948648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat 2 new oil seal rings with ATF, and install them to the planetary gear.
      NOTE: Do not expand the ring ends excessively.
      Fig 55: Identifying Oil Seal Rings
      G04948762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat 3 new oil seal rings with ATF, and install them to the planetary gear.
      NOTE: Do not expand the ring ends excessively.
      Fig 56: Identifying Oil Seal Rings
      G04948763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the planetary carrier thrust washer to the planetary gear.
      NOTE: Use a small amount of MP grease to make the thrust washer stay securely in place.
      Fig 57: Identifying Planetary Carrier Thrust Washer To Planetary Gear
      G04948646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Assemble the front planetary gear assembly with the front planetary sun gear to the overdrive and reverse multiple disc clutch assembly.
      Fig 58: Identifying Front Planetary Gear Assembly
      G05847921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SELECT NO. 1 BRAKE FLANGE 
    1. Measure length A (from the step of the oil pump installation surface of the transmission case to the step of the No. 1 brake flange installation surface) in the illustration. *1

      Standard: 

      59.77 to 60.03 mm (2.3531 to 2.3634 in.) 

      Fig 59: Identifying No. 1 Brake Flange Surface Length
      G04948766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Measure length B (from the flange face of the oil pump assembly to the tip of the No. 1 brake piston) in the illustration. *2

      Standard: 

      34.636 to 34.964 mm (1.3636 to 1.3765 in.) 

      Fig 60: Identifying Oil Pump Length
      G04948767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Assemble the 5 brake plates, 5 brake discs, and brake flange, and measure length C in the illustration. *3

      Standard: 

      23.84 to 24.36 mm (0.9386 to 0.9591 in.) 

      Fig 61: Identifying Brake Flange Length
      G04948768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Choose a No. 1 brake flange so that the value of measured length A minus lengths B and C (from steps *1, *2, *3) is 0.75 to 1.05 mm (0.0295 to 0.0413 in.).

      Flange thickness 

      FLANGE THICKNESS CHART

      Mark Thickness
      0 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      1 4.55 to 4.65 mm (0.1791 to 0.1831 in.)
      2 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      3 4.75 to 4.85 mm (0.1870 to 0.1909 in.)
      4 4.85 to 4.95 mm (0.1909 to 0.1949 in.)
      5 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      6 5.05 to 5.15 mm (0.1988 to 0.2028 in.)
      7 5.15 to 5.25 mm (0.2028 to 0.2067 in.)
      8 5.25 to 5.35 mm (0.2067 to 0.2106 in.)
  32. INSTALL OVERDRIVE AND REVERSE MULTIPLE DISC CLUTCH ASSEMBLY WITH FRONT PLANETARY GEAR ASSEMBLY 
    1. Install the thrust bearing race, thrust needle bearing, overdrive and reverse multiple disc clutch assembly with front planetary gear assembly to the transmission case.

      Standard bearing and race diameter 

      ITEM SPECIFICATION

      Item Inside Outside
      Race 44.0 mm (1.732 in.) 62.0 mm (2.441 in.)
      Bearing 36.2 mm (1.425 in.) 58.2 mm (2.291 in.)
      Fig 62: Identifying Thrust Needle Bearing And Multiple Disc Clutch Assembly
      G04948769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the overdrive and reverse multiple clutch, apply ATF to the No. 3 clutch drum bush's sliding surfaces. After the installation, check that the No. 3 clutch drum rotates smoothly.
      • Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
  33. INSTALL NO. 1 BRAKE DISC SET 
    1. Install the selected flange, 5 discs and 5 plates to the transmission case.

      Install in order: 

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

      HINT:

      F = Flange

      D = Disc

      P = Plate

      NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.
      Fig 63: Identifying No. 1 Brake Disc Set
      G04948770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL OIL PUMP ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the oil pump.
    2. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transmission case.
    3. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the No. 3 clutch drum.
      Fig 64: Identifying Oil Pump O-Ring
      G04948771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 11 bolts.

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

      NOTE:
      • Make sure to apply seal packing to the flanges of the bolts.

        Seal packing:

        Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      • Do not allow seal packing to contact the bolts' threads.
      • During installation, do not allow oil to contact the bolts or the surface of the oil pump body.
        Fig 65: Locating Transmission Oil Pump Assembly Bolts
        G04948639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSPECT INDIVIDUAL PISTON OPERATION 
    1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

      HINT:

      C1 = Forward multiple clutch

      C2 = No. 2 clutch

      C3 = No. 3 clutch

      C4 = Reverse clutch

      B1 = No. 1 brake

      B2 = No. 2 brake

      Fig 66: Identifying Clutch And Brake Ports
      G04948773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using SST and a hammer, tap in a new oil seal.

      SST 09350-30020 (09350-07110) 

      Standard depth: 

      0 +/-0.3 mm (0 +/-0.012 in.) 

    2. Coat the lip of the oil seal with MP grease.
      Fig 67: Tapping In Oil Seal
      G04948774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. 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 68: Installing Manual Valve Lever
      G04948775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a hammer, tap in a new spring pin.
      Fig 69: Tapping Spring Pin
      G04948776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the manual valve lever indentation with the spacer hole, and stake them together with a punch.
    5. Make sure that the shaft rotates smoothly.
      Fig 70: Aligning Manual Valve Lever
      G04948777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL PARKING LOCK PAWL SHAFT 
    1. Install the E-ring to the shaft.
    2. Install the parking lock pawl, shaft and spring.
      Fig 71: Installing Parking Lock Pawl Shaft
      G04948778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    1. Connect the parking lock rod to the manual valve lever.
      Fig 72: Installing Parking Lock Rod Sub-Assembly
      G05847935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL PARKING LOCK PAWL BRACKET 
    1. Place the parking lock pawl bracket onto the transmission case. Loosely install the 3 bolts, and then tighten them in the order shown in the illustration.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 73: Locating Parking Lock Pawl Bracket Bolts
      G05847936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Shift the manual valve lever to the P position, and confirm that the output shaft is correctly locked up by the lock pawl.
      Fig 74: Identifying Manual Valve Lever
      G04948781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL AUTOMATIC TRANSMISSION CASE PLUG 
    1. Coat a new O-ring with ATF, and install it to the case plug.
    2. Install the case plug to the transmission case.

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      Fig 75: Locating Automatic Transmission Case Plug
      G04948632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL SPEED SENSOR 
    1. Coat a new O-ring with ATF and install it to the speed sensor NT.
    2. Using a T30 "TORX" wrench, install the sensor NT with the bolt.

      Torque: 6.8 N*m (69 kgf*cm, 60 in.*lbf) 

    3. Install the speed sensor SP2 and NC3 with the 2 bolts.

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

      Fig 76: Locating Speed Sensor Bolts
      G04948631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL TRANSMISSION WIRE 
    1. Coat a new O-ring with ATF and install it to the transmission wire connector.
    2. Install the transmission wire.
    3. Install the bolt.

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

      Fig 77: Locating Transmission Wire Connector And Bolt
      G04948441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 3 speed sensor connectors.
      Fig 78: Locating Speed Sensor Connectors
      G04948439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CHECK BALL BODY 
    1. Install the spring and check ball body.
      Fig 79: Identifying Check Ball Body And Spring
      G04948413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    1. Align the groove of the manual valve lever with the pin of the manual valve and install the pin.
      Fig 80: Aligning Groove Of Manual Valve With Lever Pin
      G04948421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 17 bolts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      HINT:

      Each bolt length is indicated below.

      Bolt length: 

      21 mm (0.83 in.) for bolt A 

      31 mm (1.22 in.) for bolt B 

      64 mm (2.52 in.) for bolt C 

      Fig 81: Locating Transmission Case Bolt Location
      G04948422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the detent spring and detent cover with the bolt.

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

      NOTE: Make sure to install the detent spring so that its roller is perpendicularly at the center of the manual valve lever.
      Fig 82: Locating Detent Spring And Bolt
      G04948411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 8 connectors to the solenoid valves.
    5. Coat a new O-ring with ATF and install it to the ATF temperature sensor.
    6. Install the ATF temperature sensor and lock plate with the bolt.

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

      Fig 83: Locating ATF Temperature Sensor, Oil Pressure Switch And Solenoid Valves Connectors
      G04948410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    1. Coat a new O-ring with ATF and install it to the oil strainer.
      NOTE: Ensure that the O-ring is not twisted or pinched.
      Fig 84: Identifying O-Ring And Oil Strainer
      G04948425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil strainer to the valve body with the 4 bolts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 85: Locating Valve Body Oil Strainer And Bolts
      G04948408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    1. Install the 3 magnets to the oil pan.
    2. Install a new gasket and the oil pan to the transmission case with the 9 bolts.

      Torque: 7.3 N*m (74 kgf*cm, 64 in.*lbf) 

      Fig 86: Identifying Oil Pan And Oil Pan Magnets
      G04948793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that there is no oil or foreign matter on the gasket seal surface and oil pan contact surface.
      • Install the gasket so that there is no slack in the gasket, and that the seal surface's entire circumference is level.
      • Make sure that the 9 gasket drop prevention protrusions are set on the oil pan.
      • When tightening the oil pan, make sure that the gasket is not pinched between the gasket tightening area's sleeve and the transmission's seal surface.
        Fig 87: Identifying Oil Pan Gasket Correct And Incorrect Installation
        G04948429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 88: Identifying Automatic Transmission Oil Pan Bolts
        G04948406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL NO. 1 BREATHER PLUG 
    Fig 89: Locating No. 1 Breather Plug
    G04948617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL OIL COOLER TUBE UNION 
    1. Coat 2 new O-rings with ATF, and install them to the unions.
    2. Install the unions as shown in the illustration.

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

      Fig 90: Installing Oil Cooler Tube Union
      G04948797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the bolt.
    2. Install a new lock washer with the nut.

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

      Fig 91: Identifying Park/Neutral Position Switch Assembly
      G04948615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the control shaft lever.
      Fig 92: Locating Control Shaft Lever
      G04948799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the control shaft lever counterclockwise until it stops, and turn it clockwise 2 notches to set it to the N position.
    5. Remove the control shaft lever.
      Fig 93: Turning Control Shaft Lever
      G04948800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Align the groove with the neutral basic line.
    7. Hold the switch in this position and tighten the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

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

      HINT:

      Bend at least 2 washer tabs.

      Fig 94: Identifying Neutral Basic Line And Groove
      G04948462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH 
    1. Install the transmission control shaft lever with the nut.

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

      Fig 95: Locating Control Shaft Lever
      G04948799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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