Automatic Transmission Unit: Reassembly

Fig 1: Identifying Bearing Position

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Bearing Position 

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 brake piston.
3. Install the brake piston to the reaction sleeve.
   NOTE: Do not damage the O-rings.
   Fig 2: Identifying No. 4 Brake Piston O-Rings

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1. Coat a new O-ring with ATF, and install it to the reaction sleeve.
2. Install the brake reaction sleeve and the No. 4 brake piston to the transmission case.
   NOTE:

   • Do not damage the O-rings.
   • Make sure the No. 4 brake piston is underneath the brake reaction sleeve.
     Fig 3: Identifying No. 4 Brake Piston

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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: Do not damage the O-ring.
   Fig 4: Identifying 1st And Reverse Brake Piston

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4. Place the brake return spring onto the No. 4 brake piston.
   Fig 5: Identifying Piston Return Spring

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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: Compressing Return Spring

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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

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1. Install the No. 9 thrust bearing race.

   Standard race diameter 

   RACE DIAMETER SPECIFICATION
   
   

   Item	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

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2. Install the 2 thrust needle roller bearings.

   Standard thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   Item	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

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3. Install the rear planetary gear assembly.

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

   Install in order: 

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

   HINT:

   S = Sleeve

   P = Plate

   D = Disc

   F = Flange

   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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1. 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.

   Standard bearing and race diameter 

   Fig 13: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing, No. 7 Thrust Bearing Race

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   THRUST BEARING RACE SPECIFICATION
   
   

   Item	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.)

1. Install the 1-way clutch assembly and the 1-way clutch inner race to the intermediate shaft.
   Fig 14: Identifying No. 3 1-Way Clutch Assembly

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1. Install the intermediate shaft with the No. 3 1-way 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 (09350-07060) 

   Fig 16: Installing Snap Ring

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1. Install the center planetary gear and 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.

   Standard race diameter 

   RACE DIAMETER SPECIFICATION
   
   

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

   Fig 17: Identifying Center Planetary Gear, Planetary Sun Gear And No. 4 Thrust Bearing Race

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1. Coat 2 new O-rings with ATF, and install them to the brake piston.
2. Being careful not to damage the O-rings, press the brake piston into the brake cylinder.
3. Install the brake piston to the transmission case.

   HINT:

   Install the brake cylinder so that the projection protrudes from the upper side of the transmission case.

   Fig 18: Identifying No. 2 Brake Piston O-Rings

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4. Check that the oil pressure apply hole of the brake cylinder 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 brake piston return spring, 2 flanges, 4 discs and 3 plates.

   Install in order: 

   F - D - P - D - P - D - P - D - F 

   HINT:

   F = Flange

   P = Plate

   D = Disc

   Fig 20: Identifying Brake Piston Return Spring, Flanges, Discs And Plates

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2. Using SST and a press, compress the spring and install the No. 2 brake spring snap ring.

   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.
2. Being careful not to damage the O-rings, press the brake piston into the brake cylinder.
   Fig 22: Identifying No. 1 Brake Piston O-Rings

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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 upper side 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 No. 1 brake cylinder 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, compress the spring and install the brake piston return spring snap ring.

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

   Fig 25: Installing Brake Piston Return Spring Snap Ring

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

   Standard thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	55.7 mm (2.193 in.)	76.4 mm (3.008 in.)

2. Install the center planetary ring gear and 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 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 thrust washer.
2. Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

   Standard thrust needle roller bearing and race diameter 

   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATION
   
   

   Item	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.)

3. Install the front planetary gear assembly and the 1-way clutch inner race to the transmission case.
   Fig 29: Identifying Thrust Needle Roller Bearing, Thrust Bearing Race And Planetary Carrier Thrust Washer

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1. Install the flange, 3 discs and 3 plates.

   Install in order: 

   F - D - P - D - P - D - P 

   HINT:

   F = Flange

   P = Plate

   D = Disc

   Fig 31: Identifying Flange, Discs And Plates

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

   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: Installing Brake Piston 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

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1. Install the 1-way clutch and thrust washer to the transmission case.
   Fig 36: Identifying 1-Way Clutch And Thrust Washer

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 37: Installing Snap Ring

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

   Install in order: 

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

   HINT:

   C = Cushion plate

   P = Plate

   D = Disc

   F = Flange

   Fig 38: Identifying Flanges, Discs, Plates & Cushion Plate

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1. Using a screwdriver, install the snap ring.
   Fig 39: Installing No. 3 Brake Snap Ring

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1. Install the 1-way clutch and washer to the clutch drum and input shaft.
   Fig 40: Identifying No. 2 1 -Way Clutch 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.

   Standard thrust needle roller bearing and race diameter 

   Fig 41: Identifying Clutch Drum Thrust Washer, Thrust Needle Roller Bearings And Bearing Race

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   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATION
   
   

   Item	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 Sub-Assembly

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

   Standard thrust bearing race diameter 

   THRUST BEARING RACE DIAMETER SPECIFICATION
   
   

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

   Fig 43: Identifying Oil Pump No. 1 Thrust Bearing Race

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2. Coat a new O-ring with ATF, and install it around the oil pump.
3. Place the oil pump through the input shaft, and align the bolt holes of the oil pump 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 Oil Pump O-Ring

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5. Install the 10 bolts.

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

   Fig 45: Removing Oil Pump Assembly Bolts

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1. Using SST and a hammer, tap in 2 new oil seals.

   SST 09350-30020 (09350-07110) 

2. Coat the lip of the oil seals 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: Identifying Spacer And Manual Valve Lever

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3. Using a hammer, drive in a new spring pin.
   Fig 48: Tapping In Spring Pin

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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 49: Aligning Manual Valve Lever Indentation With Spacer Hole

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1. Install the E-ring to the shaft.
2. Install the parking lock pawl, shaft and spring.
   Fig 50: Identifying Parking Lock Pawl Shaft E-Ring

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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

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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: Identifying Shift Manual Valve Lever And Planetary Ring Gear

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1. Install the 2 springs and accumulator valve to the hole.
   Fig 54: Identifying Springs And Accumulator Valve

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   Standard B-1 accumulator spring Inner spring: 

   B-1 ACCUMULATOR SPRING INNER SPRING SPECIFICATION
   
   

   Free Length	Outer Diameter	Color
   44.98 mm (1.7709 in.)	11.30 mm (0.445 in.)	Not colored

   Outer spring: 

   OUTER SPRING SPECIFICATION
   
   

   Free Length	Outer Diameter	Color
   46.36 mm (1.8252 in.)	17.10 mm (0.6732 in.)	Not colored

   Fig 55: Identifying Spring And Accumulator Valve

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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 And Spring

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

   Standard C-3 accumulator spring Inner spring; 

   STANDARD C-3 ACCUMULATOR SPRING INNER SPRING SPECIFICATION
   
   

   Free Length	Outer Diameter	Color
   44.0 mm (1.732 in.)	14.0 mm (0.551 in.)	Yellow

   Outer spring: 

   OUTER SPRING SPECIFICATION
   
   

   Free Length	Outer Diameter	Color
   76.65 mm (3.0178 in.)	20.10 mm (0.7913 in.)	Not colored

   Fig 57: Identifying Springs And Accumulator Piston

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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 And O-Ring

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

   Standard accumulator spring 

   ACCUMULATOR SPRING SPECIFICATION
   
   

   Free Length	Outer Diameter	Color
   64.5 mm (2.539 in.)	19.5 mm (0.768 in.)	Orange

   Fig 59: Identifying Spring And Accumulator Piston

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

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

   Standard 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 61: Identifying Spring And Accumulator Piston

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1. Install the check ball body and 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 Gaskets

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1. Install the 3 transmission 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 and install the pin.
   Fig 65: Aligning Groove Of Manual Valve Lever With 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: 

   25 mm (0.98 in.) for bolt A 

   36 mm (1.42 in.) for bolt B 

   45 mm (1.77 in.) for bolt C 

   50 mm (1.97 in.) for bolt D 

   Fig 66: Identifying Transmission Valve Body Bolts

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3. Install the detent spring and detent spring cover with the bolt.

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

   Fig 67: Identifying Detent Spring Cover And Detent Spring With Bolt

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

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

   Fig 68: Locating Transmission Wire Bolt

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4. Connect the 9 solenoid connectors to the solenoid valves.
   Fig 69: Locating Solenoid Valves Connectors

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5. Install the 2 clamps with the 2 bolts.

   Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) for bolt A 

   10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt B 

   Fig 70: Locating Transmission Wire Clamps Bolt

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6. Install the ATF temperature sensor and lock plate with the bolt.

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

   Fig 71: Locating ATF Temperature Sensor

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

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

   Fig 72: Locating Valve Body 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 overflow plug.

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

   Fig 73: Identifying Transmission Oil Cleaner Magnets

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1. Using SST and a hammer, tap in a new oil seal to the extension housing.

   SST 09309-37010 

   Standard oil seal depth: 

   1.8 to 2.2 mm (0.07 to 0.09 in.) 

   Fig 74: Installing Automatic Transmission Extension Housing Oil Seal

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1. Install the 2 washers and rear cover sleeve to the output shaft.
   Fig 75: Identifying Washers And Cover Sleeve

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1. Install the thrust needle roller bearing and 2 bearing races.
2. Using a snap ring expander, install a new snap ring.
   Fig 76: Installing Snap Ring

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3. Using a feeler gauge, measure the clearance between the snap ring and race.

   Standard clearance: 

   0.02 to 0.12 mm (0.0008 to 0.0047 in.) 

   If the clearance is not as specified, select another race that brings the clearance within the standard.

   HINT:

   There are 12 different thicknesses for the race.

   Fig 77: Measuring Clearance Between Snap Ring And Race

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   Standard 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.)

4. Clean the threads of the bolts and the case with non-residue solvent.
5. Apply seal packing to the extension housing as shown in the illustration.

   Seal packing: 

   Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent 

   Fig 78: Identifying Seal Packing Applying Area

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6. Install the extension housing with the 6 bolts.

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

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   45 mm (1.772 mm) for bolt A 

   35 mm (1.378 mm) for bolt B 

   Fig 79: Locating Extension Housing With Bolts

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

   SST 09517-36010 

   Fig 80: Installing Oil Seal

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

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

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

3. Using a chisel and hammer, securely stake the nut.
   Fig 81: Tightening Nut

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1. Clean the threads of the bolts and the case with non-residue solvent.
2. Install the transmission housing with the 10 bolts.

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

   (14 mm head) 

   57 N*m (581 kgf*cm, 42 ft.*lbf) for bolt B 

   (17 mm head) 

   Fig 82: Identifying Transmission Housing With Bolts

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1. Install the breather tube with the 2 bolts.

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

   Fig 83: Locating Breather Tube With Bolts

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

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

   Fig 84: Locating Transmission Revolution Sensors And Bolts

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1. Coat 2 new O-ring with ATF, and install them to the 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 85: 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 bolt.
2. Install a new lock washer with the nut.

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

   Fig 86: Locating Nut, Lock Washer And Bolt

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3. Using the control shaft lever, move the manual lever shaft back all the way and then forward 2 notches. it is now in neutral.
   Fig 87: Moving Manual Lever Shaft N Position

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4. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the bolt.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

   Fig 88: Identifying Park/Neutral Position Switch Groove And Neutral Basic Line

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

   HINT:

   Bend at least 2 washer tabs.

   Fig 89: Bending Tabs Of Lock Washer

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

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

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

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

   Fig 90: Locating Transmission Control Shaft Lever Nut

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