Automatic Transmission Unit: Reassembly

1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
2. Coat 2 new O-rings with the ATF, and install them to the No. 4 brake piston.
3. Install the No. 4 brake piston to the reaction sleeve.

Fig 2: Identifying O-Rings With No. 4 Brake Piston

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1. With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve with the No. 4 brake piston to the transmission case.

Fig 3: Installing Brake Reaction Sleeve With No. 4 Brake Piston To Transmission Case

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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.
   Fig 4: Installing O-Ring On 1st & Reverse Brake Piston

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   NOTE: Be careful not to damage the O-ring.
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 a SST, install the snap ring.

   SST 09350-30020 (09350-07070) 

   Fig 6: Installing Snap Ring

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3. Install the brake apply tube with its protruding part fitting into the groove of the transmission case.

Fig 7: Installing Brake Apply Tube With Its Protruding Part Fitting Into Groove Of Transmission Case

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1. Install the No. 9 thrust bearing race.

   Race diameter 

   REAR PLANETARY GEAR ASSEMBLY
   
   

   -	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 SPECIFICATIONS
   
   

   -	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 MOTOR SALES, U.S.A., INC.
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 Sleeve, Plates, Discs & Flange

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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 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: Installing Rear Planetary Ring Gear Flange Sub-Assembly

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Bearing and race diameter 

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 & Intermediate Shaft 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: Installing Intermediate Shaft With No. 3 One Way Clutch Assembly To Transmission Case

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Using a 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 

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.
   Fig 18: Installing O-Rings To No. 2 Brake Piston

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
   NOTE: Be careful not to damage the 2 O-rings.
3. Install the No. 2 brake cylinder to the transmission case.

   HINT:

   Install the No. 2 brake cylinder so that the projection protrudes from the upside 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 19: Identifying Oil Pressure Apply Hole Of Transmission Case

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

   Install in order: 

   P = Plate, D = Disc, F = Flange 

   F - D- P - D - P - D - F 

   Fig 20: Installing Flanges, Plates, Discs & Brake Piston Return Spring

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Using SST and a press, install the No. 2 brake 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.

Fig 22: Identifying O-Rings Of No. 1 Brake Piston

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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

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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 Of Transmission Case

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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 Brake Piston Return Spring Snap Ring

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATIONS
   
   

   -	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: Installing Center Planetary Ring Gear & Front Planetary Ring Gear Flange On Front Planetary Ring Gear

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Using a screwdriver, install the snap ring.

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.
   Fig 29: Installing Thrust Bearing Race Onto Front Planetary Ring Gear

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

   Thrust needle roller bearing and race diameter 

   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATIONS
   
   

   -	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.

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: Installing Plates, Discs & Flange

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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 O-Rings Of 2nd Brake Piston

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Place the brake piston return spring on the 2nd brake piston.
4. Using SST, a screwdriver and a press, install the snap ring.

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

Fig 33: Installing Snap Ring

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1. Install the 2nd brake cylinder to the transmission case.
   Fig 34: Installing 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 Transmission Case

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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 & Thrust Washer

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1. Using SST, install the snap ring.

SST 09350-30020 (09350-07060) 

Fig 37: Installing Snap Ring

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1. Install the flange, the 3 discs, the 3 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 - C 

Fig 38: Installing Flange, Discs, Plates & Cushion Plate To Transmission Case

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1. Using a screwdriver, install the snap ring.

Fig 39: Installing No. 3 Brake Snap Ring

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1. Coat the thrust washer with petroleum jelly and install the No. 2 one way clutch assembly and No. 2 washer.

Fig 40: Identifying No. 2 One Way Clutch Assembly & Clutch Drum Thrust Washer

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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.
   Fig 41: Installing Thrust Needle Roller Bearings

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

   Thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING AND DIAMETER SPECIFICATIONS
   
   

   -	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 into the transmission case.

Fig 42: Installing Clutch Drum & Input Shaft Assembly Into Transmission Case

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

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

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

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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 Of Oil Pump Assembly

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. Install the 10 bolts.

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

Fig 45: Identifying Oil Pump Assembly Bolts

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1. Using SST and a hammer, 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: Installing New Spacer To Manual Valve Lever

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Using a hammer, drive in a new spring pin.
   Fig 48: Driving In New Spring Pin

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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 MOTOR SALES, U.S.A., INC.

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 & Spring

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1. Connect the parking lock rod to the manual valve lever.

Fig 51: Identifying Parking Lock Rod & 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 MOTOR SALES, U.S.A., INC.
2. Shift the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked up by the lock pawl.

Fig 53: Identifying Planetary Ring Gear Is Correctly Locked Up By Lock Pawl

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1. Install the 2 springs and the accumulator valve to the hole.

Fig 54: Installing Springs & Accumulator Valve To Hole

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B-1 accumulator spring 

Inner spring: 

Outer spring: 

Fig 55: Identifying Inner Spring & Outer Spring

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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: 

Fig 56: Identifying O-Rings Of C-3 Accumulator Piston

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Outer spring: 

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.

Fig 57: Identifying O-Rings Of B-3 Accumulator Piston

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Accumulator spring 

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.

Fig 58: Identifying O-Rings Of C-2 Accumulator Piston

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Accumulator spring 

1. Install the check ball body and the spring.

Fig 59: Installing Check Ball Body & Spring

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1. Install 3 new brake drum gaskets.

Fig 60: Installing New Brake Drum Gaskets

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1. Install 3 new transaxle case gaskets.

Fig 61: Installing New Transaxle Case Gaskets

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

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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: 

   Fig 63: Identifying Transmission Valve Body Bolts

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

   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) 

1. Coat a new O-ring with ATF.
   Fig 64: Installing Detent Spring & Detent Spring Cover With Bolt

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Install the O-ring to the transmission wire.
3. Install the transmission wire.
   Fig 65: Identifying Transmission Wire Harness O-Ring

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4. Install the bolt.

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

   Fig 66: Locating Transmission Internal Wiring Harness bolt

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. Connect the 9 solenoid connectors.
   Fig 67: Connecting Solenoid Connectors

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6. Install the 2 clamp brackets with 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 68: Installing Clamp Brackets With Bolts

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. Install the ATF temperature sensor and sensor clamp with the bolt.

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

Fig 69: Installing ATF Temperature Sensor & Sensor Clamp With Bolt

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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: Installing Valve Body Oil Strainer With Bolts

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1. Install the 6 transmission oil cleaner magnets.

Fig 71: Installing Transmission Oil Cleaner Magnets

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1. Install a new gasket on the oil pan.
2. Install and tighten the 20 bolts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

3. Install a new gasket and the drain plug.

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

4. Install a new gasket and the overflow plug.

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

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

Fig 72: Installing Automatic Transmission Housing With Bolts

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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) 

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

Fig 73: Installing Automatic Transmission Breather Tube With Bolt

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

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: Installing Transmission Revolution Sensors With Bolt

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1. Coat 2 new O-rings with ATF, and install them to the spacer.
   Fig 75: Identifying O-Rings Of Spacer

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

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

Fig 76: Installing Spacer & Transmission Oil Cooler With Bolts

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

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

   Fig 77: Installing Park/Neutral Position Switch Onto Manual Valve Lever Shaft

   Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. 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 78: Positioning Control Shaft Lever In Neutral

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6. Align the neutral basic line with the switch groove and tighten the adjusting bolt.

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

   Fig 79: Aligning Neutral Basic Line With Switch Groove

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

   HINT:

   Bend at least 2 of the lock washer tabs.

   Fig 80: Bending Tabs Of Lock Washer

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

Fig 81: Installing Spring Washer & Nut To Control Shaft Lever LH

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

(See INSTALLATION )