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Automatic Transmission Unit: Reassembly: Reassembly

  1. BEARING POSITION 
    1. Check the bearing positions.
      Fig 1: Identifying Bearing Positions
      GTY270697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bearing Diameter

      Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside
      A 74.26 to 74.56 mm (2.92 to 2.94 in.)/87.39 to 87.74 mm (3.44 to 3.45 in.) 71.96 to 72.26 mm (2.83 to 2.84 in.)/85.25 to 85.60 mm (3.36 to 3.37 in.) -
      B 37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.) 34.65 to 34.85 mm (81.36 to 1.37 in.)/51.56 to 51.86 mm (2.03 to 2.04 in.) -
      C - 21.35 to 21.60 mm (0.841 to 0.850 in.)/40.72 to 40.92 mm (1.60 to 1.61 in.) 22.65 to 22.90 mm (0.892 to 0.902 in.)/44.50 to 44.75 mm (1.75 to 1.76 in.)
      D - 35.65 to 35.9 mm (1.40 to 1.41 in.)/56.3 to 56.55 mm (2.22 to 2.23 in.) -
      E - 42.55 to 42.80 mm (1.68 to 1.69 in.)/60.84 to 61.14 mm (2.40 to 2.41 in.) -
      F 38.0 to 38.2 mm (1.49 to 1.50 in.)/56.50 to 57.0 mm (2.22 to 2.24 in.) 43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.25 mm (2.28 to 2.29 in.) -
      G - 55.76 to 55.95 mm (2.19 to 2.20 in.)/76.1 to 76.35 mm (3.00 to 3.01 in.) 53.75 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.)
      H 33.18 to 33.53 mm (1.31 to 1.32 in.)/48.8 to 49.0 mm (1.89 to 1.93 in.) 32.15 to 32.31 mm (1.26 to 1.27 in.)/48.97 to 49.22 mm (1.93 to 1.94 in.) 32.15 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)
      I - 43.60 to 43.85 mm (1.72 to 1.73 in.)/60.56 to 60.86 mm (2.38 to 2.40 in.) 47.15 to 47.40 mm (81.86 to 1.87 in.)/67.07 to 67.40 mm (2.64 to 2.65 in.)
  2. ASSEMBLE NO. 4 BRAKE PISTON AND BRAKE REACTION SLEEVE 
    Fig 2: Identifying No. 4 Brake Piston & Brake Reaction Sleeve
    GTY283073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    3. Install the No. 4 brake piston to the reaction sleeve.
  3. INSTALL NO. 4 BRAKE PISTON WITH BRAKE REACTION SLEEVE 
    Fig 3: Identifying Brake Reaction Sleeve
    GTY125284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 4 brake piston with brake reaction sleeve to the transmission case
      NOTE:
      • Do not damage the O-rings.
      • Make sure the No. 4 brake piston is underneath the brake reaction sleeve.
  4. INSTALL 1ST AND REVERSE BRAKE PISTON 
    Fig 4: Identifying 1st & Reverse Brake Piston
    GTY142751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF.
    2. Install the O-ring to the 1st and reverse brake piston.
    3. With the spring seat of the piston facing upwards (the front side), install the piston to the transmission case.
      NOTE:

      Be careful not to damage the O-ring.

  5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    Fig 5: Identifying Piston Return Spring Sub-Assembly
    GTY102081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place the brake return spring onto the 1st and reverse brake piston.
    2. Place SST on the spring retainer and compress the return spring.
      Fig 6: Identifying SST & Snap Ring
      GTY270655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        1. 09350-07050
    3. Using SST, install the snap ring.
      • SST: 09350-30020 
        1. 09350-07070
      TEXT IN ILLUSTRATION

      *1 Snap Ring
      NOTE:

      Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

    4. Make sure the No. 4 brake piston moves smoothly when applying and releasing compressed air into and from the transmission case.
      Fig 7: Applying Compressed Air Into Transmission Case
      GTY107755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL REAR PLANETARY GEAR ASSEMBLY 
    Fig 8: Identifying Thrust Needle Roller Bearing Race
    GTY167817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the thrust bearing race.

      Bearing Race Diameter

      Item Inside Outside
      Race I 47.15 to 47.40 mm (81.86 to 1.87 in.) 67.07 to 67.40 mm (2.64 to 2.65 in.)
    2. Install the thrust needle roller bearing to the rear planetary gear.
      Fig 9: Identifying Thrust Needle Roller Bearing & Rear Planetary Gear
      GTY189763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bearing Diameter

      Item Inside Outside
      Bearing I 43.60 to 43.85 mm (1.72 to 1.73 in.) 60.56 to 60.86 mm (2.38 to 2.40 in.)
    3. Install the rear planetary gear assembly.
      Fig 10: Identifying Rear Planetary Gear Assembly
      GTY149519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SELECT NO. 4 BRAKE FLANGE 
    1. Using a vernier caliper, measure distance A (from the top surface of the 1st and reverse brake piston to the step in the transmission case) in the illustration.
      Fig 11: Identifying Level Difference Between Upper Surface Of 1st & Reverse Brake Piston
      GTY149653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The 1st and reverse brake piston must be installed securely to the end face of the transmission case.

      HINT: 

      Distance A = 36.35 to 37.09 mm (1.43 to 1.46 in.)

    2. Assemble the flange, 8 discs and 7 plates, and then, using a vernier caliper, measure distance B in the illustration at both ends across the diameter and calculate the average.
      Fig 12: Identifying Measurement Of Flange, Discs & Plates
      GTY268404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Flange
      *2 Plate
      *3 Disc
      *4 Selected Flange

      HINT: 

      Distance B = 33.94 to 35.04 mm (1.34 to 1.38 in.)

    3. Select a No. 4 brake flange so that the value of measured distance A minus distance B minus thickness H is 1.35 to 1.65 mm (0.0531 to 0.0650 in.).

      Thickness H

      No. Thickness
      0 0 mm (0 in.)
      2 0.15 to 0.25 mm (0.00590 to 0.00984 in.)
      4 0.35 to 0.45 mm (0.0138 to 0.0177 in.)
      6 0.55 to 0.65 mm (0.0217 to 0.0256 in.)
      8 0.75 to 0.85 mm (0.0295 to 0.0335 in.)
      10 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      12 1.15 to 1.25 mm (0.0453 to 0.0492 in.)
      14 1.35 to 1.45 mm (0.0531 to 0.0571 in.)
  8. INSTALL NO. 4 BRAKE DISC 
    Fig 13: Identifying No. 4 Brake Discs, Flange & Plates
    GTY285566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the flange, 8 discs, 7 plates and selected flange.

      Install in order

      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      TEXT IN ILLUSTRATION

      *1 Flange
      *2 Disc
      *3 Plate
  9. INSTALL BRAKE PLATE STOPPER SPRING 
    Fig 14: Identifying Brake Plate Stopper Spring
    GTY100364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    Fig 15: Identifying Snap Ring
    GTY132646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the rear planetary ring gear flange to the rear planetary ring gear.
    2. Using a screwdriver, install the snap ring.
    3. Install the thrust bearing race, thrust needle roller bearing, thrust bearing race and planetary ring gear flange together with the rear planetary ring gear to the intermediate shaft.
      Fig 16: Identifying Rear Planetary Ring Gear Flange, Rear Planetary Ring Gear & Intermediate Shaft
      GTY255211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bearing and Race Diameter

      Item Inside Outside
      Race H (Fr) 33.18 to 33.53 mm (1.31 to 1.32 in.) 48.8 to 49.0 mm (1.89 to 1.93 in.)
      Bearing H 32.15 to 32.31 mm (1.26 to 1.27 in.) 48.97 to 49.22 mm (1.93 to 1.94 in.)
      Race H (Rr) 32.15 to 32.4 mm (1.27 to 1.28 in.) 48.7 to 49.0 mm (1.92 to 1.93 in.)
  11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY 
    Fig 17: Identifying No. 3 1-Way Clutch Assembly
    GTY107751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 1-way clutch and 1-way clutch inner race to the intermediate shaft.
  12. INSTALL INTERMEDIATE SHAFT 
    Fig 18: Identifying Intermediate Shaft & No. 3 1-Way Clutch Assembly
    GTY127537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the intermediate shaft with No. 3 1-way clutch assembly to the case.
    2. Using SST, install the snap ring.
      Fig 19: Identifying Snap Ring & SST
      GTY205859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        1. 09350-07060
  13. INSTALL CENTER PLANETARY GEAR ASSEMBLY 
    Fig 20: Identifying Center Planetary Gear Assembly
    GTY140202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the planetary sun gear and center planetary gear to the case.
    2. Coat the thrust bearing race with petroleum jelly and install it to the center planetary gear.

      Race Diameter

      Item Inside Outside
      Race G 53.75 to 55.95 mm (2.12 to 2.20 in.) 73.7 to 74.0 mm (2.90 to 2.91 in.)
  14. INSTALL NO. 2 BRAKE PISTON 
    Fig 21: Identifying No. 2 Brake Piston O-Rings
    GTY277045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the brake piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Press the brake piston into the brake cylinder with both hands.
      NOTE:

      Be careful not to damage the O-rings.

    3. Install the No. 2 brake cylinder with No. 2 brake piston to the case.

      HINT: 

      Install the No. 2 brake cylinder so that the projection faces the top of the transmission case.

    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 22: Identifying Brake Cylinder Hole
      GTY107892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SELECT NO. 2 BRAKE FLANGE 
    1. Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.
    2. Place SST on the brake flange and compress the brake return spring.
      • SST: 09351-40010 
        1. 09351-04010
        2. 09351-04020
        3. 09351-04040
        4. 09351-04050
      Fig 23: Compressing Return Spring
      GTY174087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, install the snap ring to the transmission case.
    4. Measure distance A (from the top surface of the snap ring to the surface of the brake piston return spring retainer) in the illustration.
      Fig 24: Measuring Top Surface Of Snap Ring To Surface Of Brake Piston Return Spring Retainer
      GTY275262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Return Spring Retainer

      HINT: 

      Standard distance A: 20.94 to 22.12 mm (0.824 to 0.871 in.)

    5. Remove the snap ring, flange and No. 2 brake piston return spring.
    6. Assemble the flange, 4 discs, 3 plates and flange (thickness: 1.95 to 2.05 mm (0.0768 to 0.0807 in.)) as shown in the illustration, and then, using a vernier caliper, measure distance B in the illustration at both ends across the diameter and calculate the average.
      Fig 25: Identifying Measurement Of Flange, Discs & Plates
      GTY265985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Flange
      *2 Plate
      *3 Disc
      *4 Flange (Thickness: 1.95 to 2.05 mm (0.0768 to 0.0807 in.))

      HINT: 

      Standard distance B: 18.52 to 19.15 mm (0.729 to 0.754 in.)

    7. Select a No. 2 brake flange so that the value of measured distance A minus distance B is 0.6 to 0.9 mm (0.0236 to 0.0354 in.).

      Flange Thickness

      No. 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 0.100 in.)
      6 2.55 to 2.65 mm (0.100 to 0.104 in.)
      7 2.65 to 2.75 mm (0.104 to 0.108 in.)
  16. INSTALL NO. 2 BRAKE DISC SET 
    Fig 26: Identifying No. 2 Brake Discs, Flanges & Plates
    GTY254427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the brake piston return spring.
    2. Install the 2 flanges, 4 discs and 3 plates.

      Install in order

      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

      TEXT IN ILLUSTRATION

      *1 Flange
      *2 Disc
      *3 Plate
    3. Using SST and a press, compress the return spring and install the snap ring.
      Fig 27: Compressing Return Spring
      GTY174087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09351-40010 
        1. 09351-04010
        2. 09351-04030
        3. 09351-04040
        4. 09351-04050
  17. INSTALL NO. 1 BRAKE PISTON 
    Fig 28: Identifying No. 1 Brake Piston O-Rings
    GTY278583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the brake piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Press the brake piston into the brake cylinder with both hands to install it.
      NOTE:

      Be careful not to damage the O-rings.

  18. INSTALL NO. 1 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    Fig 29: Identifying No. 1 Brake Piston Return Spring
    GTY107726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 1 brake cylinder with No. 1 brake piston and the brake piston return spring to the transmission case.
    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 30: Identifying Oil Pressure Apply Hole
      GTY107890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL NO. 1 BRAKE PISTON RETURN SPRING SNAP RING 
    Fig 31: Compressing Return Spring
    GTY100429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, compress the return spring and install the No. 1 brake piston return spring snap ring.
      • SST: 09351-40010 
        1. 09351-04010
        2. 09351-04030
        3. 09351-04040
        4. 09351-04050
  20. SELECT NO. 1 BRAKE FLANGE 
    Fig 32: Identifying No. 1 Brake Flange, Discs & Plates
    GTY261887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure distance A (from the step in the transmission case to the top surface of the No. 1 brake piston) in the illustration.

      HINT: 

      Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)

    2. Assemble the 4 plates, 4 discs and flange (thickness: 2.15 to 2.25 mm (0.0846 to 0.0886 in.)) as shown in the illustration, and then, using a vernier caliper, measure distance B in the illustration at both ends across the diameter and calculate the average.
      TEXT IN ILLUSTRATION

      *1 Plate
      *2 Disc
      *3 Flange

      HINT: 

      Standard distance B: 18.93 to 19.39 mm (0.745 to 0.763 in.)

    3. Select a No. 1 brake flange so that the value of measured distance A minus distance B is 0.56 to 0.86 mm (0.0220 to 0.0339 in.).

      Flange Thickness

      No. Thickness
      0 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      1 2.15 to 2.25 mm (0.0846 to 0.0886 in.)
      2 2.35 to 2.45 mm (0.0925 to 0.0965 in.)
      3 2.55 to 2.65 mm (0.100 to 0.104 in.)
  21. INSTALL NO. 1 BRAKE DISC 
    Fig 33: Identifying No. 1 Brake Discs, Flange & Plates
    GTY282168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 4 plates, 4 discs and flange.

      Install in order

      *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3

      TEXT IN ILLUSTRATION

      *1 Plate
      *2 Disc
      *3 Flange
  22. INSTALL CENTER PLANETARY RING GEAR 
    Fig 34: Identifying Center Planetary Ring Gear & Front Planetary Ring Gear Flange
    GTY149603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the center planetary ring gear and front planetary ring gear flange to the front planetary ring gear.
    2. Using a screwdriver, install the snap ring.
      Fig 35: Identifying Snap Ring
      GTY149602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT PLANETARY RING GEAR 
    Fig 36: Identifying Front Planetary Ring Gear & Bearing
    GTY149511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the thrust needle roller bearing and front planetary ring gear to the case.

      Thrust Needle Roller Bearing Diameter

      Item Inside Outside
      Bearing G 55.76 to 55.79 mm (2.19 to 2.20 in.) 76.1 to 76.35 mm (3.00 to 3.01 in.)
  24. INSTALL FRONT PLANETARY GEAR ASSEMBLY 
    Fig 37: Identifying Front Planetary Gear Thrust Needle Roller Bearing & Race
    GTY270843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the thrust washer and thrust needle roller bearing.
    2. Coat the thrust bearing race with petroleum jelly and install it to the front planetary ring gear.

      Thrust Needle Roller Bearing and Race Diameter

      Item Inside Outside
      Bearing F 43.4 to 43.6 mm (1.71 to 1.72 in.) 58.0 to 58.25 mm (2.28 to 2.29 in.)
      Race F 38.0 to 38.2 mm (1.49 to 1.50 in.) 56.50 to 57.0 mm (2.22 to 2.24 in.)
      TEXT IN ILLUSTRATION

      *1 Bearing
      *1 Race
    3. Install the front planetary gear assembly and 1-way clutch inner race to the case.
      Fig 38: Identifying Front Planetary Gear Assembly & 1-Way Clutch Inner Race
      GTY107719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 3 BRAKE PISTON 
    Fig 39: Identifying No. 3 Brake Piston O-Rings
    GTY266014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the No. 3 brake piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Press the No. 3 brake cylinder into the No. 3 brake piston with both hands to install it.
      NOTE:

      Be careful not to damage the O-rings.

    3. Using SST and a press, compress the return spring and install the snap ring.
      Fig 40: Identifying Snap Ring
      GTY100584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09351-40010 
      NOTE:

      Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

  26. INSTALL NO. 3 BRAKE CYLINDER 
    Fig 41: Identifying No. 3 Brake Cylinder
    GTY107718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 3 brake cylinder to the case.
  27. INSTALL 1-WAY CLUTCH ASSEMBLY 
    Fig 42: Identifying 1-Way Clutch Assembly & No. 1 Planetary Carrier Thrust Washer
    GTY102664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the thrust washer and 1-way clutch to the case.
  28. INSTALL NO. 3 BRAKE PISTON HOLE SNAP RING 
    Fig 43: Identifying No. 3 Snap Ring & SST
    GTY205859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, install the snap ring.
      • SST: 09350-30020 
        1. 09350-07060
  29. INSTALL NO. 3 BRAKE DISC 
    Fig 44: Identifying No. 3 Brake Discs, Flange & Plates
    GTY260404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the cushion plate, 4 plates, 4 discs and flange to the case.

      Install in order

      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *4

      TEXT IN ILLUSTRATION

      *1 Cushion Plate
      *2 Plate
      *3 Disc
      *4 Flange
  30. INSTALL NO. 3 BRAKE SNAP RING 
    Fig 45: Identifying No. 3 Brake Snap Ring
    GTY107712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, install the snap ring.
  31. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY 
    Fig 46: Identifying Direct Clutch Piston Sub-Assembly O-Rings
    GTY283688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the direct clutch piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the direct clutch return spring and No. 2 clutch balancer to the direct clutch piston sub-assembly.
      Fig 47: Identifying No. 2 Clutch Balancer & Direct Clutch Return Spring
      GTY107783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Press the direct clutch piston with clutch return spring and the clutch balancer into the reverse clutch piston with both hands to install them.
      NOTE:

      Be careful not to damage the O-ring.

    4. Place SST on the direct clutch balancer and compress the return spring with a press.
      • SST: 09320-89010 
      Fig 48: Compressing Return Spring On Direct Clutch Balancer With Press & SST
      GTY281470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
      NOTE:

      Stop pressing when the spring seat is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.

    5. Using SST, install the snap ring.
      Fig 49: Identifying Snap Ring & Stopper
      GTY276302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        1. 09350-07070
      NOTE:

      Do not expand the snap ring excessively.

    6. Position the end gap of the snap ring in the balancer as shown in the illustration.
      NOTE:

      Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

      TEXT IN ILLUSTRATION

      *1 Stopper
  32. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY 
    Fig 50: Identifying O-Ring & Clutch Drum
    GTY270209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the clutch drum.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Coat a new O-ring with ATF and install it to the reverse clutch piston.
      Fig 51: Identifying O-Ring & Reverse Clutch Piston
      GTY283416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    3. Press the clutch drum into the reverse clutch piston with both hands.
      NOTE:

      Be careful not to damage the O-rings.

      Fig 52: Identifying Reverse Clutch Piston Sub-Assembly
      GTY289507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL NO. 3 CLUTCH BALANCER 
    Fig 53: Identifying O-Ring & No. 3 Clutch Balancer
    GTY280685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the reverse clutch piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the reverse clutch return spring and balancer to the reverse clutch piston.
    3. Place SST on the clutch balancer and compress the return spring with a press.
      Fig 54: Placing SST On No. 3 Clutch Balancer
      GTY205908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00070 
      NOTE:

      Stop pressing when the spring seat is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.

    4. Using SST, install the snap ring.
      • SST: 09350-30020 
        1. 09350-07070
      NOTE:

      Do not expand the snap ring excessively.

    5. Position the end gap of the snap ring in the piston as shown in the illustration.
      Fig 55: Identifying Snap Ring End Gap
      GTY266725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Gap
      NOTE:

      Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

  34. INSTALL DIRECT CLUTCH DISC 
    Fig 56: Identifying Direct Clutch Discs, Flange & Plates
    GTY270936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 6 plates, 6 discs and direct clutch flange to the clutch drum.

      Install in order

      *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3

      TEXT IN ILLUSTRATION

      *1 Plate
      *2 Disc
      *3 Flange
      NOTE:

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. Using a screwdriver, install the snap ring to the clutch drum.
      Fig 57: Identifying Snap Ring & Clutch Drum
      GTY142117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) into the oil hole as shown in the illustration.
      Fig 58: Applying Compressed Air Into Clutch Drum To Measure Moving Distance A
      GTY266921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Hole *2 -

      Standard moving distance (A)

      0.60 to 0.90 mm (0.0236 to 0.0354 in.)

      If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

      Flange Thickness

      Mark Thickness
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)
    4. Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.
  35. SELECT REVERSE CLUTCH FLANGE 
    Fig 59: Identifying Snap Ring To Clutch Drum
    GTY110246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, install the snap ring to the clutch drum.
      NOTE:

      Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.

    2. Install the 2 flanges, 5 discs, 4 plates, cushion plate and reverse clutch reaction sleeve to the clutch drum.
      Fig 60: Identifying Reverse Clutch Discs, Flange & Plates
      GTY273922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install in order

      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1 - *4

      TEXT IN ILLUSTRATION

      *1 Flange
      *1 Disc
      *1 Plate
      *1 Cushion Plate
    3. Using a screwdriver, install the hole snap ring.
      Fig 61: Identifying Snap Ring
      GTY127035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a dial indicator, measure the moving distance (A minus B) of the top surface of the reverse clutch piston (A) and cushion plate (B) at both ends across the diameter while applying compressed air (392 kPa, 4.0 kgf/ cm2 , 57 psi) into the oil hole as shown in the illustration. Then choose a flange of an appropriate thickness from the table so that the measured value is within the standard range.
      Fig 62: Applying Compressed Air Into Oil Hole To Measure Moving Distances A & B
      GTY259426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Hole *2 -

      Standard moving distance (A minus B)

      0.50 to 0.80 mm (0.0197 to 0.0315 in.)

      Flange Thickness

      Mark Thickness
      0 2.75 to 2.85 mm (0.108 to 0.112 in.)
      1 2.85 to 2.95 mm (0.112 to 0.116 in.)
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)
    5. Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.
      Fig 63: Identifying Reverse Clutch Reaction Sleeve, Clutch Cushion Plate
      GTY107819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY AND COAST CLUTCH PISTON 
    Fig 64: Identifying O-Ring & Input Shaft
    GTY258752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the input shaft.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the forward clutch piston and coast clutch piston to the input shaft.
      Fig 65: Identifying Forward Clutch Piston & Coast Clutch Piston
      GTY110249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat a new O-ring with ATF and install it to the No. 1 clutch balancer.
      Fig 66: Identifying O-Ring & No. 1 Clutch Balancer
      GTY273760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    4. Install the forward clutch return spring and No. 1 clutch balancer to the input shaft.
      NOTE:

      Be careful not to damage the O-rings.

    5. Place SST on the No. 1 clutch balancer and compress the return spring with a press.
      Fig 67: Identifying SST & No. 1 Clutch Balancer
      GTY110374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-30020 
        1. 09350-07040
      NOTE:

      Stop pressing when the spring seat is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.

    6. Using SST, install the snap ring.
      • SST: 09350-30020 
        1. 09350-07070
      NOTE:

      Do not expand the snap ring excessively.

    7. Position the end gap of the snap ring in the balancer as shown in the illustration.
      Fig 68: Identifying Position Of Snap Ring In Balancer
      GTY284528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the end gap of the snap ring is not aligned with the spring retainer claw.

      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
  37. INSTALL COAST CLUTCH DISC SET 
    Fig 69: Identifying Coast Clutch Discs, Flange & Plates
    GTY266056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 3 plates, 3 discs and flange.

      Install in order

      *1 - *2 - *1 - *2 - *1 - *2 - *3

      TEXT IN ILLUSTRATION

      *1 Plate
      *2 Disc
      *3 Flange
      NOTE:

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.
      Fig 70: Identifying Snap Ring
      GTY127039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) into the oil hole as shown in the illustration.
      Fig 71: Applying Compressed Air Into Oil Hole To Measure Moving Distance A
      GTY281437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Hole

      Standard moving distance (A)

      0.30 to 0.60 mm (0.0118 to 0.0236 in.)

      If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

      Flange Thickness

      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      A 3.85 to 3.95 mm (0.152 to 0.156 in.)
    4. Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.
  38. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    Fig 72: Identifying Underdrive 1-Way Clutch Assembly
    GTY138536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 2 clutch hub thrust washer to the coast clutch hub.

      HINT: 

      Use a small amount of MP grease to make the thrust washer stay securely in place.

    2. Install the 1-way clutch to the coast clutch hub.
  39. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY  See step  2
  40. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY WITH UNDERDRIVE 1-WAY CLUTCH ASSEMBLY 
    Fig 73: Identifying Coast Clutch Hub Sub-Assembly & Underdrive 1-Way Clutch Assembly
    GTY277960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 thrust needle roller bearings, thrust bearing race and coast clutch hub together with the underdrive 1-way clutch to the input shaft.

      HINT: 

      Use a small amount of MP grease to make the thrust needle roller bearings and race stay securely in place.

      Bearing and Race Diameter

      Item Inside Outside
      Bearing C 21.35 to 21.60 mm (0.841 to 0.850 in.) 40.72 to 40.92 mm (1.60 to 1.61 in.)
      Race C 22.65 to 22.90 mm (0.892 to 0.902 in.) 44.50 to 44.75 mm (1.75 to 1.76 in.)
      Bearing D 35.65 to 35.9 mm (1.40 to 1.41 in.) 56.3 to 56.55 mm (2.22 to 2.23 in.)
      TEXT IN ILLUSTRATION

      *1 Bearing C
      *2 Race C
      *3 Bearing D
  41. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC SET 
    Fig 74: Identifying Forward Multiple Disc Clutch Discs, Flange & Plates
    GTY283446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 5 plates, 5 discs and flange to the input shaft.

      Install in order

      *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3

      TEXT IN ILLUSTRATION

      *1 Plate
      *2 Disc
      *3 Flange
      NOTE:

      Before assembling new discs, soak them in ATF for at least 2 hours.

    2. Temporarily install the snap ring.
      Fig 75: Identifying Hole Snap Ring
      GTY107784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) into the oil hole as shown in the illustration.
      Fig 76: Applying Compressed Air Into Oil Hole To Measure Moving Distance A
      GTY267771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Oil Hole

      Standard moving distance (A)

      0.7 to 1.0 mm (0.0276 to 0.0394 in.)

      If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

      Flange Thickness

      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      9 3.85 to 3.95 mm (0.152 to 0.156 in.)
      A 3.95 to 4.05 mm (0.156 to 0.159 in.)
    4. Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.
  42. INSTALL INPUT SHAFT OIL SEAL RING 
    1. Coat 4 new oil seal rings with ATF.
    2. Overlap the seal ring ends in the axial direction.
      Fig 77: Identifying Correct & Incorrect Input Shaft Oil Seal Ring Overlap
      GTY272403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a CORRECT
      *b INCORRECT
      NOTE:
      • Overlapping the seal ring ends in the axial direction prevents damage to the seal ring.
      • Do not overlap the seal ring ends in the radial direction, as this may damage the seal ring.
    3. Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.
      Fig 78: Identifying Oil Rings & Input Shaft Groove
      GTY269416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 New Oil Seal Ring
      NOTE:

      Do not excessively widen the rings.

      HINT: 

      After installing the oil seal rings, check that they rotate smoothly.

  43. INSTALL INPUT SHAFT ASSEMBLY 
    Fig 79: Identifying Input Shaft Sub-Assembly
    GTY110372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the input shaft to the clutch drum.
  44. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY 
    Fig 80: Identifying Forward Clutch Hub Sub-Assembly
    GTY110368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the No. 3 clutch hub thrust washer, forward clutch hub and thrust needle roller bearing to the clutch drum.
      NOTE:

      Before installing the forward clutch hub, apply ATF to the forward clutch hub bush sliding surfaces. After the installation, check that the forward clutch hub rotates smoothly.

      HINT: 

      Use a small amount of MP grease to make the thrust needle roller bearing and thrust washer stay securely in place.

      Bearing Diameter

      Item Inside Outside
      Bearing E 42.55 to 42.80 mm (1.68 to 1.69 in.) 60.84 to 61.14 mm (2.40 to 2.41 in.)
  45. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY 
    Fig 81: Identifying Reverse Clutch Hub To Clutch Drum
    GTY127050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the reverse clutch hub to the clutch drum.
      NOTE:

      Before installing the reverse clutch hub, apply ATF to the reverse clutch hub bush sliding surfaces. After the installation, check that the reverse clutch rotates smoothly.

  46. INSTALL REAR CLUTCH DISC SET 
    Fig 82: Identifying Rear Clutch Discs, Flange & Plates
    GTY274495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the flange, 5 discs, 4 plates, selected flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

      Install in order

      *1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *4 - *5

      TEXT IN ILLUSTRATION

      *1 Flange
      *1 Disc
      *1 Plate
      *1 Selected Flange
      *1 Cushion Plate
    2. Using a screwdriver, install the snap ring to the clutch drum.
  47. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY 
    Fig 83: Identifying No. 2 1-Way Clutch & Clutch Drum Thrust Washer
    GTY289416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the clutch drum thrust washer to the clutch drum.

      HINT: 

      Use a small amount of MP grease to make the thrust washer stay securely in place.

    2. Install the 1-way clutch to the clutch drum.
  48. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY  See step  2
  49. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY 
    Fig 84: Identifying Clutch Drum & Input Shaft Bearings
    GTY270826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 thrust needle roller bearings.

      HINT: 

      Use a small amount of MP grease to make the thrust needle roller bearings stay securely in place.

      Bearing Diameter

      Item Inside Outside
      Bearing A 71.96 to 72.26 mm (2.83 to 2.84 in.) 85.25 to 85.6 mm (3.36 to 3.37 in.)
      Bearing B 34.65 to 34.85 mm (81.36 to 1.37 in.) 51.56 to 51.86 mm (2.03 to 2.04 in.)
      TEXT IN ILLUSTRATION

      *1 Bearing A
      *2 Bearing B
    2. Coat the clutch drum thrust washer with petroleum jelly and install it to the clutch drum and input shaft assembly.
    3. Install the clutch drum and input shaft assembly to the transmission case.
      Fig 85: Installing Clutch Drum & Input Shaft Drum Assembly Onto Transmission Case
      GTY125527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL OIL PUMP ASSEMBLY 
    Fig 86: Identifying O-Ring & Thrust Bearing Races
    GTY178508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the oil pump.
    2. Install the 2 thrust bearing races to the front oil pump.

      Thrust Bearing Race Diameter

      Item Inside Outside
      Race A 74.26 to 74.56 mm (2.92 to 2.94 in.) 87.39 to 87.74 mm (3.44 to 3.45 in.)
      Race B 37.0 to 37.3 mm (1.46 to 1.47 in.) 52.1 to 52.3 mm (2.05 to 2.06 in.)
    3. Pass the input shaft through the center hole of the oil pump and align the bolt holes of the oil pump assembly with the transmission case.
      Fig 87: Identifying Oil Pump Assembly Bolts
      GTY149498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Hold the input shaft and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.
    5. Apply seal packing to the flanges of the bolts.

      Seal packing

      Toyota Genuine Seal Packing 1281,

      Three Bond 1281 or equivalent

    6. Install the oil pump with the 10 bolts.

      Torque: 21 N*m (215 kgf*cm, 16 ft.*lbf) 

      NOTE:

      During installation, do not allow oil to contact the bolts or the surface of the oil pump body.

  51. INSPECT INDIVIDUAL PISTON OPERATION  See step  28
  52. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL 
    Fig 88: Using SST To Drive In New Oil Seals
    GTY138139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, tap in 2 new oil seals.
      • SST: 09350-30020 
        1. 09350-07110

      Standard depth

      -0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

    2. Coat the lips of the oil seals with MP grease.
  53. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY 
    Fig 89: Installing Spacer To Manual Valve Lever
    GTY268863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new spacer to the manual valve lever.
      TEXT IN ILLUSTRATION

      *1 Spacer
      *2 Manual Valve Lever
    2. Push the manual valve lever shaft through the transmission case and install the manual valve lever to the shaft.
    3. Using a hammer, tap in a new spring pin.
      Fig 90: Tapping In Spring Pin
      GTY101325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the manual valve lever indentation with the spacer hole and stake them together with a punch.
      Fig 91: Staking Manual Valve Lever Indentation With Punch
      GTY149623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Check that the shaft rotates smoothly.
  54. INSTALL PARKING LOCK PAWL SHAFT 
    Fig 92: Identifying Parking Lock Pawl E-Ring, Parking Lock Pawl & Spring
    GTY273865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new E-ring to the shaft.
      TEXT IN ILLUSTRATION

      *1 E-Ring
      *2 Parking Lock Pawl
      *3 Spring
    2. Install the parking lock pawl, shaft and spring.
  55. INSTALL PARKING LOCK ROD SUB-ASSEMBLY 
    Fig 93: Identifying Parking Lock Rod
    GTY136138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the parking lock rod to the manual valve lever.
  56. INSTALL PARKING LOCK PAWL BRACKET 
    Fig 94: Identifying Parking Lock Pawl Bracket Bolts
    GTY141479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the parking lock pawl bracket to the transmission case with the 3 bolts.

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

    2. Move the manual valve lever to the P position and confirm that the planetary ring gear is correctly locked by the lock pawl.
      Fig 95: Moving Manual Valve Lever To Confirm Operation Of Planetary Ring Gear
      GTY278580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Manual Valve Lever
      *2 Planetary Ring Gear
      *3 Parking Lock Pawl
  57. INSTALL B-1 ACCUMULATOR VALVE 
    Fig 96: Identifying Springs & Accumulator Valve
    GTY110252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 2 springs and accumulator valve to the hole.

      Spring Diameter

      Spring Free Length
      Outer Diameter      		 Color
      B-1 Inner 44.98 mm (1.77 in.)
      11.3 mm (0.445 in.)      		 Natural
      B-1 Outer 46.36 mm (1.83 in.)
      17.1 mm (0.673 in.)      		 Natural
  58. INSTALL C-3 ACCUMULATOR PISTON 
    Fig 97: Identifying Springs & C-3 Accumulator Piston O-Rings
    GTY282869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the 2 springs and accumulator piston to the hole.

      Spring Diameter

      Spring Free Length
      Outer Diameter      		 Color
      C-3 Inner 44.0 mm (1.73 in.)
      14.0 mm (0.551 in.)      		 Yellow
      C-3 Outer 73.35 mm (2.89 in.)
      19.9 mm (0.783 in.)      		 Red
  59. INSTALL B-3 ACCUMULATOR PISTON 
    Fig 98: Identifying Springs & B-3 Accumulator Piston O-Rings
    GTY280872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the spring and accumulator piston to the hole.

      Spring Diameter

      Spring Free Length
      Outer Diameter      		 Color
      B-3 70.5 mm (2.78 in.)
      19.7 mm (0.776 in.)      		 Purple
  60. INSTALL C-2 ACCUMULATOR PISTON 
    Fig 99: Identifying Springs & C-2 Accumulator Piston O-Rings
    GTY285534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the piston.
      TEXT IN ILLUSTRATION

      *1 New O-Ring
    2. Install the spring and accumulator piston to the hole.

      Spring Diameter

      Spring Free Length
      Outer Diameter      		 Color
      C-2 62.0 mm (2.44 in.)
      15.9 mm (0.626 in.)      		 White
  61. INSTALL CHECK BALL BODY 
    Fig 100: Identifying Check Ball Body & Springs
    GTY226272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the spring and check ball body.
      TEXT IN ILLUSTRATION

      *1 Spring
      *2 Check Ball Body
  62. INSTALL BRAKE DRUM GASKET 
    Fig 101: Identifying Brake Drum Gaskets
    GTY104076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install 3 new brake drum gaskets.
  63. INSTALL TRANSMISSION CASE GASKET 
    Fig 102: Identifying Transmission Case Gasket
    GTY269645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install 3 new transmission case gaskets.
  64. INSTALL TRANSMISSION VALVE BODY ASSEMBLY 
    Fig 103: Identifying Pin & Manual Valve Assembly
    GTY217389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Align the hole of the manual valve with the pin of the lever and connect the pin to the manual valve.
      TEXT IN ILLUSTRATION

      *1 Pin
    2. Install the valve body with the 19 bolts.
      Fig 104: Identifying Valve Body Bolts
      GTY175080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Each bolt length is indicated below.

      36 mm (1.42 in.) for bolt A

      25 mm (0.984 in.) for bolt B

      45 mm (1.77 in.) for bolt C

      50 mm (1.97 in.) for bolt D

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

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

  65. INSTALL TRANSMISSION WIRE 
    Fig 105: Identifying Transmission Wire Bolt
    GTY102899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

    4. Connect the 9 solenoid connectors.
      Fig 106: Identifying Transmission Wire Sensor Clamps, Bolts & Connectors
      GTY278740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.

      for bolt A 

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

      for bolt B 

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

      TEXT IN ILLUSTRATION

      *1 Orange
      *2 Blue

      HINT: 

      Each bolt length is indicated below.

      12 mm (0.472 in.) for bolt A

      36 mm (1.42 in.) for bolt B

    6. Attach the wire harness to the 2 clamps.
  66. INSTALL VALVE BODY OIL STRAINER ASSEMBLY 
    Fig 107: Identifying Valve Body Oil Strainer Assembly Bolts
    GTY170777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the oil strainer.
    2. Install the oil strainer with the 4 bolts.

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

  67. INSTALL TRANSMISSION OIL CLEANER MAGNET 
    Fig 108: Identifying Transmission Oil Cleaner Magnets
    GTY262784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 4 magnets.
  68. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    Fig 109: Identifying Automatic Transmission Oil Pan Sub-Assembly Bolts
    GTY172533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new gasket to the oil pan.
    2. Install the oil pan with the 20 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    3. Install a new gasket and the drain plug.

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

  69. INSTALL TRANSFER CASE REAR ADAPTER OIL RECEIVER 
    1. Install the transfer case rear adaptor oil receiver to the rear adaptor transfer.
      Fig 110: Installing Transfer Case Rear Adaptor Oil Receiver
      GTY234016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using snap ring pliers, install the snap ring.
  70. INSTALL EXTENSION HOUSING REAR OIL SEAL 
    1. Coat the lip of a new oil seal with ATF.
    2. Using SST and a hammer, tap in the oil seal.
      • SST: 09950-60010 
        1. 09951-00650
      • SST: 09950-70010 
        1. 09951-07150
      Fig 111: Tapping In Extension Housing Rear Oil Seal
      GTY278466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard depth

      0 to 0.5 mm (0 to 0.0197 in.)

  71. INSTALL REAR TRANSFER ADAPTER 
    1. Install the transfer adapter hole snap ring.
    2. Clean the threads of the bolts and transfer adapter.
    3. Apply seal packing or equivalent to the transfer adapter.
      Fig 112: Identifying Seal Packing Area Of Rear Transfer Adapter
      GTY258815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Seal packing

      Toyota Genuine Seal Packing 1281,

      Three Bond 1281 or equivalent

      Seal diameter

      1.0 to 1.5 mm (0.0394 to 0.0591 in.)

    4. Apply adhesive to the threads of the 8 bolts.

      Adhesive

      Toyota Genuine Adhesive 1324,

      Three Bond 1324 or equivalent

    5. Install the extension housing with the 6 bolts.
      Fig 113: Identifying Transmission Case Adapter & Bolts
      GTY212171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

      HINT: 

      Each bolt length is indicated below.

      50 mm (1.97 in.) for bolt A

      40 mm (1.57 in.) for bolt B

  72. INSTALL AUTOMATIC TRANSMISSION HOUSING 
    Fig 114: Identifying Automatic Transmission Housing Bolts & Case
    GTY265221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Clean the threads of the bolts and case with non-residue solvent.
    2. Apply adhesive to the threads of the 4 bolts labeled B and C.

      Adhesive

      Toyota Genuine Adhesive 1324,

      Three Bond 1324 or equivalent

    3. Install the transmission housing with the 10 bolts.

      for bolt A and C (14 mm head) 

      Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

      for bolt B (17 mm head) 

      Torque: 57 N*m (579 kgf*cm, 42 ft.*lbf) 

  73. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE 
    Fig 115: Locating Breather Tube & Bolts
    GTY263287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat a new O-ring with ATF and install it to the breather tube.
    2. Install the breather tube with the 2 bolts.

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

  74. INSTALL SPEED SENSOR 
    1. Coat 2 new O-rings with ATF and install one to each speed sensor.
      Fig 116: Identifying Speed Sensor Bolts
      GTY113550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 speed sensors.
    3. Install the 2 bolts.

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

  75. INSTALL OIL COOLER TUBE UNION 
    Fig 117: Installing Oil Cooler Tube Unions
    GTY258301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Coat 2 new O-rings with ATF and install them to the 2 oil cooler tube unions.
    2. Install the 2 oil cooler tube unions.

      Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf) 

  76. INSTALL PARK / NEUTRAL POSITION SWITCH ASSEMBLY 
    Fig 118: Identifying Nut, Lock Washer & Bolt
    GTY124988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the park / neutral position switch to the manual valve lever shaft and temporarily install the adjusting bolt.
    2. Install a new lock washer and the nut.

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

    3. Turn the control shaft lever counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position.
      Fig 119: Identifying Control Shaft Lever Operation
      GTY269235Courtesy 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.
      Fig 120: Identifying Neutral Basic Line & Switch Groove
      GTY219768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      TEXT IN ILLUSTRATION

      *1 Neutral Basic Line
      *2 Groove
    5. Using a screwdriver, bend the tabs of the lock washer.
      Fig 121: Bending Tabs Of Lock Washer
      GTY102833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Bend at least 2 of the lock washer tabs.

  77. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH 
    Fig 122: Identifying Transmission Control Shaft Lever LH
    GTY267380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the control shaft lever LH with the washer and nut.

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

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