Automatic Transmission Unit: Reassembly

1. Coat 2 new O-rings with ATF, and install them to brake reaction sleeve.
2. Coat 2 new O-rings with the ATF, and install them to the brake piston No.4.
3. Install the brake piston No.4 to the reaction sleeve.
   NOTE: Be careful not to damage the O-rings.
   Fig 2: Identifying O Rings

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1. With the brake piston No.4 underneath (the rear side), install the brake reaction sleeve with the brake piston No.4 to the transmission case.
   NOTE: Be careful not to damage the O-rings.
   Fig 3: Identifying 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: Identifying O-Ring On 1ST And Reverse Brake Piston

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4. Place the brake return spring onto the brake piston.
   Fig 5: Placing Brake Return Spring Onto 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: Identifying Snap Ring

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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 With Its Protruding Part Fitting Into Groove Of Transmission Case

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1. Install the thrust bearing race No.9.

   Race diameter 

   RACE DIAMETER
   
   

   	Inside	Outside
   Thrust bearing race	47.1 mm (1.854 in.)	67.1 mm (2.642 in.)

   Fig 8: Identifying 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
   
   

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

   Fig 9: Identifying Thrust Needle Roller Bearings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear planetary gear assembly.

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

   Install in order: 

   P = Plate, D = Disc, F = Flange, S = Sleeve 

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

   Fig 11: Identifying Brake Disc No.4

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1. Install the brake plate stopper spring.
   Fig 12: Identifying Brake Plate Stopper Spring

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

   Bearing and race diameter 

   Fig 13: Identifying Rear Planetary Ring Gear Flange Sub-Assembly

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   BEARING AND RACE DIAMETER
   
   

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

1. Install the 1 way No.3 clutch assembly and the 1 way clutch inner race to the intermediate shaft.
   Fig 14: View Of 1 Way No 3 Clutch Assembly & Intermediate Shaft Inner Race

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1. Install the intermediate shaft with 1 way No.3 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: Identifying 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
   
   

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

   Fig 17: View Of Center Planetary Gear Assembly

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1. Coat 2 new O-rings with ATF, and install them to the brake piston No.2.
2. Being careful not to damage the O-rings, press the brake piston No.2 into the brake cylinder No.2.
3. Install the brake cylinder No.2 to the transmission case.

   HINT:

   Install the brake cylinder No.2 so that the projection protrudes from the upside of the transmission case.

4. Check that the oil pressure apply hole of the brake cylinder No.2 aligns with the oil pressure apply hole of the transmission case.
   Fig 18: Coating O-Rings With ATF

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   Fig 19: Identifying Oil Pressure Apply Hole Of Brake Cylinder No.2 Alignment With Oil Pressure Apply Hole Of Transmission Case

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

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F - D- P - D - P - D - P - D - F 

   Fig 20: Identifying 2 Flanges, 3 Plates, 4 Discs And Brake Piston Return Spring

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2. Using SST and a press, install the brake No.2 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 No.1.
2. Be careful not to damage the O-rings. Press the brake piston No.1 into the brake cylinder No.1.
   Fig 22: Coating O-Rings With ATF

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1. Install the brake piston return spring and the brake piston No.1 with the brake cylinder No.1 to the transmission case.

   HINT:

   Install the brake cylinder No.1 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 brake cylinder No.1 aligns with the oil pressure apply hole of the transmission case.
   Fig 24: Identifying Oil Pressure Apply Hole Of Brake Cylinder No.1 Alignment With Oil Pressure Apply Hole Of Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST 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.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER
   
   

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

   Fig 25: Identifying Brake Piston Return Spring Snap Ring

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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 On Front Planetary Ring Gear

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

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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
   
   

   	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 And Thrust Washer

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

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F - D - P - D - P - D - P 

   Fig 31: Identifying Brake Disc No.1

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1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
2. Be careful not to damage the O-rings. Press the 2nd brake piston into the 2nd brake cylinder.
3. Place the brake piston return spring on the 2nd brake piston.
   Fig 32: Coating O-Rings With ATF

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a press, install the snap ring.
   NOTE: Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.

   SST 09351-40010 (09351-04060, 09351-04070) 

   Fig 33: Identifying Snap Ring

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

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2. Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.
   Fig 35: Identifying Oil Pressure Apply Hole Of 2Nd Brake Cylinder Alignment With Oil Pressure Apply Hole Of Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 37: Identifying 2Nd Brake Piston Hole Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Install in order: 

   P = Plate, D = Disc, F = Flange, C = Cushion 

   Plate 

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

   Fig 38: Identifying 2ND Brake Disc Set

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1. Using a screwdriver, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 39: Identifying Snap Ring

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1. Coat the thrust washer with petroleum jelly and install the 1 way No.2 clutch assembly and washer No.2.
   Fig 40: View Of 1 Way no. 2 Clutch Assembly And Clutch Drum Thrust Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Thrust needle roller bearing and diameter 

   Fig 41: Identifying Thrust Needle Roller Bearings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   THRUST NEEDLE ROLLER BEARING AND DIAMETER
   
   

   	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 assembly onto the transmission case.
   Fig 42: Identifying Clutch Drum And Input Shaft Assembly Onto Transmission Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the thrust bearing race No.1 to the front oil pump.
   THRUST BEARING RACE NO.1 DIAMETER
   
   

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

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

   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 O Ring Around Oil Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the 10 bolts.

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

   Fig 45: Identifying Oil Pump

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1. Using SST, drive in 2 new oil seals.

   SST 09350-30020 (09350-07110) 

2. Coat the oil seal lips 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 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.
5. Make sure that the shaft rotates smoothly.
   Fig 49: Staking Manual Valve Lever Indentation

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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1. Connect the parking lock rod to the manual valve lever.
   Fig 51: View Of Parking Lock Rod And Manual Valve Lever

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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: Identifying Parking Lock Pawl Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly locked up by the lock pawl.
   Fig 53: Identifying Planetary Ring Gear Locking Condition

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

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   B-1 accumulator spring 

   Inner spring: 

   B-1 ACCUMULATOR SPRING SPECIFICATIONS - INNER SPRING
   
   

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

   Outer spring: 

   B-1 ACCUMULATOR SPRING SPECIFICATIONS - OUTER SPRING
   
   

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

   Fig 55: Identifying B-1 Accumulator Springs - Inner, Outer Springs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 56: Identifying C-3 Accumulator Piston

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

   C-3 accumulator spring 

   Inner spring: 

   C-3 ACCUMULATOR SPRING - INNER SPRING SPECIFICATIONS
   
   

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

   Outer spring: 

   C-3 ACCUMULATOR SPRING - OUTER SPRING SPECIFICATIONS
   
   

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

   Fig 57: Identifying C-3 Accumulator Springs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 58: Identifying B-3 Accumulator Piston

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

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATIONS
   
   

   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 To Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the spring and the accumulator piston to the hole.

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATIONS
   
   

   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 To Hole

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1. Install the check ball body and the spring.
   Fig 62: Identifying Check Ball Body

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1. Install the 3 brake drum gaskets.
   Fig 63: Identifying Brake Drum Gasket

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1. Install the 3 transaxle case gaskets.
   Fig 64: Identifying Transaxle Case Gasket

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1. Align the groove of the manual valve with the pin of the lever.
   Fig 65: Aligning Groove Of Manual Valve With Pin Of Lever

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2. Install the transmission valve body with the 20 bolts.

   Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 

   25 mm (0.98 in.) 

   Bolt B: 

   36 mm (1.42 in.) 

   Bolt C: 

   45 mm (1.77 in.) 

   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 66: Identifying Transmission Valve Body

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

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

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

   Fig 68: Locating Transmission Internal Wiring Harness bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 9 solenoid connectors.
5. Install the ATF temperature sensor and clamp with the bolt.

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

6. Install the clamps and 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: Identifying Solenoid Connectors

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

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

   Fig 70: Oil Strainer With mounting Bolts

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1. Install the 6 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 over flow plug.

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

   Fig 71: Identifying Transmission Oil Cleaner Magnet

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Clean the threads of the bolts and the transmission case with white gasoline.
2. Install the transmission housing with the 10 bolts.

   Torque: A (14 mm bolt) 

   34 N*m (345 kgf*cm, 25 ft.*lbf) 

   B (17 mm bolt) 

   57 N*m (581 kgf*cm, 42 ft.*lbf) 

   Fig 72: Identifying Automatic Transmission Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Fig 73: Identifying Automatic Transmission Breather Tube

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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.
3. Install the 2 bolts.

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

   Fig 74: Identifying Transmission Revolution Sensor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
3. Install the spacer and transmission oil cooler with the 3 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Fig 75: Identifying Transmission Oil Cooler

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 76: Identifying Park/Neutral Position Switch Assembly

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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 77: Identifying Install Park/Neutral Position Switch Assembly Neutral Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

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

   Fig 78: 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 79: Bending Tabs Of Lock Washer

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1. Install the spring washer and the nut to the control shaft lever LH.

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

(See INSTALLATION )

Fig 80: Identifying Transmission Control Shaft Lever LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002