Automatic Transmission Unit: Reassembly

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 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 And O-Rings

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1. 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: Installing Brake Reaction Sleeve

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1. Coat a new O-ring with ATF.
2. Install the O-ring on the 1st and reverse brake piston.
3. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.
   NOTE: Be careful not to damage the O-ring.
   Fig 4: Installing 1st And Reverse Brake Piston

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

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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.

   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

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2. Install the 2 thrust needle roller bearings.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

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

   Fig 9: Identifying Thrust Needle Roller Bearings

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3. Install the rear planetary gear assembly.

1. Install the sleeve, the 4 plates, the 4 discs and the 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.
   Fig 13: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing And No. 7 Thrust Bearing Race

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   Bearing and race diameter 

   BEARING AND RACE DIAMETER 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 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

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1. Install the intermediate shaft with the No. 3 one 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 (09350-07050, 09350-07060) 

   Fig 16: Installing Snap Ring

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

   Race diameter 

   RACE DIAMETER SPECIFICATION
   
   

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

   Fig 17: Identifying Center Planetary Gear Assembly

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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 And O-Rings

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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

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1. Install the 2 flanges, 4 discs, 3 plates and brake piston return spring.

   Install in order: 

   F - D - P - D - P - D - P - D - F 

   HINT:

   F = Flange

   P = Plate

   D = Disc

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

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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) 

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 And 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 upside of the transmission case.

   Fig 23: Identifying Brake Piston Return Spring

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2. Check that the oil pressure apply hole of the 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, a screwdriver and a press, install the brake piston return spring snap ring.

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

1. Install the thrust needle roller bearing to the front planetary ring gear flange.
   Fig 25: Installing Thrust Needle Roller Bearing

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   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.)

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

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3. Using a screwdriver, install the snap ring.
   NOTE: Install the snap ring to the ring gear so that both ends of the snap ring come to the center of a protrusion on the ring gear.
   Fig 27: Installing Snap Ring

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1. Install the front planetary ring gear to the transmission case.
   Fig 28: Identifying Front Planetary Ring Gear

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

   Thrust needle roller bearing and race diameter 

   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATION
   
   

   	Inside	Outside
   Bearing	43.4 mm (1.709 In.)	58.3 mm (2.295 in.)
   Race	38.0 mm (1.496 in.)	57.0 mm (2.244 in.)

   Fig 29: Identifying Thrust Needle Roller Bearing And Thrust Washer

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

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

   Install in order: 

   F - D - P - D - P - D - P 

   HINT:

   F = Flange

   D = Disc

   P = Plate

   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. 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 And O-Rings

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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: Installing Return Spring With Snap Ring

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

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2. Check that the oil pressure apply hole of the brake cylinder aligns with the oil pressure apply hole of the transmission case.
   Fig 35: Identifying Oil Pressure Apply Hole

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

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 37: Installing 2nd Brake Piston Hole Snap Ring

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1. Install the cushion plate, 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 Cushion Plate, Plates, Discs And Flange

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1. Using a screwdriver, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 39: Installing No. 3 Brake Snap Ring

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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 And Clutch Drum Thrust Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the thrust needle roller bearings and thrust washer.
2. Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.

   Thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING AND 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.)

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

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3. Install the clutch drum and input shaft into the transmission case.
   Fig 42: Installing Clutch Drum And Input Shaft Into Transmission Case

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1. Install the No. 1 thrust bearing race to the front oil pump.
   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
2. Coat a new O-ring with ATF, and install it around the oil pump assembly.
3. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.
4. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.
   Fig 44: Identifying Front 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: Installing 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 lips of the oil seal with MP grease.

1. Install a new spacer to the manual valve lever.
2. Install the manual valve lever shaft to the transmission case through the manual valve lever.
   Fig 47: Installing Spacer To Manual Valve Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hammer, drive in a new spring pin.
   Fig 48: Driving In Spring Pin

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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 With Spacer Hole

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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 And 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 Manual Valve Lever To P Position

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

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   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: 

   OUTER 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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Outer spring: 

   OUTER SPRING SPECIFICATION
   
   

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

1. Coat 2 new O-rings with ATF, and install them to the piston.
2. 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 C-3 Accumulator Piston And Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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1. Install the check ball body and the spring.
   Fig 59: Identifying Check Ball Body And Spring

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1. Install 3 new brake drum gaskets.
   Fig 60: Identifying Brake Drum Gaskets

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1. Install 3 new transaxle case gaskets.
   Fig 61: Identifying Transaxle Case Gaskets

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1. Align the groove of the manual valve lever with the pin of the manual valve.
   Fig 62: Aligning Groove Of Manual Valve Lever With Pin Of Manual Valve

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2. Install the 20 bolts.

   Torque: 11 N*m (112 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 Bolts Sequence

   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 Bolt, Detent Spring Cover And Detent Spring

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1. Coat a new O-ring with ATF.
2. Install the O-ring to the transmission wire.
   Fig 65: Identifying Transmission Wire O-Ring

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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

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5. Connect the 9 solenoid connectors.
   Fig 67: Locating Solenoid Valves Connectors

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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 And Clamp

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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 Bolts

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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

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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

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1. Install the 3 transmission oil cleaner magnets.

1. Install a new gasket on the oil pan.
   Fig 72: Identifying Transmission Oil Cleaner Magnets

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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) 

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 the oil seal.

   SST 09316-60011 (09316-00011,09316-00051) 

   Standard depth: 

   1.8 to 2.2 mm (0.071 to 0.087 in.) 

   Fig 74: Installing Oil Seal

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1. Install the transmission case adaptor radial ball bearing to the extension housing sub-assembly.
   Fig 75: Identifying Transmission Case Adaptor Radial Ball Bearing

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1. Install the 2 washers and rear cover sleeve to the output shaft.
   Fig 76: Identifying Washers And Rear Cover Sleeve

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1. Install the thrust needle roller bearing and the 2 bearing races.
2. Using a snap ring expander, install the snap ring.
   Fig 77: Installing Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a feeler gauge, measure the clearance between the snap ring and the race.

   Standard 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

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   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 FIPG to the extension housing as shown in the illustration.

   Seal packing: 

   Toyota Genuine Seal Packing 1281. 

   Three Bond 1281 or equivalent 

   Fig 79: Identifying Seal Packing Applying Area

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6. Install the extension housing with 6 new bolts.

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

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 

   45 mm (1.772 in.) 

   Bolt B: 

   35 mm (1.378 in.) 

   Fig 80: Locating Extension Housing With Bolts

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

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

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

   Torque: 126 N*m (1285 kgf*cm, 93 ft.*lbf) 

3. Using a hammer and chisel, stake the nut.
   Fig 81: Identifying Oil Seal

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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: Bolt A (14 mm head) 

   34 N*m (347 kgf*cm, 25 ft.*lbf) 

   Bolt B (17 mm head) 

   57 N*m (581 kgf*cm, 42 ft.*lbf) 

   Fig 82: Locating Automatic Transmission Housing Bolts

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

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

   Fig 83: Locating Automatic Transmission Breather Tube Bolts

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

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

   Fig 84: Locating Speed Sensor Bolts

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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 And O-Rings

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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: Locating Transmission Oil Cooler Bolts

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1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.
2. Install a new lock washer. Install and tighten the nut.

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

   Fig 87: Identifying Bolt And Park/Neutral Position Switch

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3. Using the control shaft lever, turn the manual lever shaft back all the way and then forward 2 notches. It is now in neutral.
   Fig 88: Turning Manual Lever Shaft

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

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

   Fig 89: Aligning Neutral Basic Line With Switch Groove

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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

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

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

   Fig 91: Identifying Nut, Spring Washer And Transmission Control Shaft Lever

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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

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