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Home >> Toyota >> 1988 >> Land Cruiser >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A-440F >> Transmission Reassembly

Transmission Reassembly

NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces with ATF prior to reassembly. All gaskets and rubber "O" rings should be replaced. Ensure ends of snap rings are not aligned with cut-outs and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with the subassembly containing that bushing. Check thrust bearings and races for wear or damage. Use petroleum jelly to hold parts in place. Replace parts as necessary. Soak clutch plates in ATF for at least 15 minutes prior to installation.
  1. Using Seal Replacer (09350-06150), tap in NEW oil seals. Apply multipurpose grease to oil seal lip. Assemble NEW spacer to manual valve lever. Connect parking lock rod to manual valve lever.
  2. Install manual valve lever shaft to transmission case through plate, wave washer, manual valve lever and plate. Using hammer, tap in pin with slot at right angle to shaft. Align spacer hole with notch in lever and stake in position using a hammer and punch. Ensure manual valve lever shaft turns smoothly.
  3. Install NEW gasket and rear cover with 3 bolts and 6 screws. Torque bolts to 69 INCH lbs. (7.8 N.m). Install NEW "O" rings on C1 accumulator piston. Install spring and accumulator piston into bore of case. Install 2 NEW gaskets with plate in between. Install front clutch accumulator cover. Torque bolts to 69 INCH lbs. (7.8 N.m).
  4. Place transmission case on a cylinder. DO NOT  damage case. Tape top of cylinder. Install NEW "O" rings on piston and coat with ATF. Using Handle (09350-06050) and Plate (09350-06090), push in brake piston.
  5. Position return spring on brake piston. Using spring compressor, compress return spring. Using screwdriver, install snap ring.
  6. Install cushion plate with rounded edge facing inward. Install in order: plate, disc, plate, disc, plate, disc, plate, disc, plate, disc, plate, disc. Install flange with rounded edge facing outward. If flange is step edged, install flange with step edge facing inward. Install snap ring. Ensure end of snap ring is not aligned with cutout portion of transmission case.
  7. Using Spring Compressor (09350-06130) and dial indicator, measure piston stroke of 1st and reverse brake piston by applying compressed air. See Figure. Piston stroke should be .059-.118" (1.50-3.00 mm). If piston stroke is less than specified, parts may have been assembled incorrectly. Check and reassemble. If piston stroke is greater than specified, select different thickness flange. See 1ST & REVERSE BRAKE FLANGE SPECIFICATIONS  table.
    1ST & REVERSE BRAKE FLANGE SPECIFICATIONS

    Identifying Mark Thickness In. (mm)
    None .2618 (6.650)
    1 .2776 (7.050)
    2 .2933 (7.450)
  8. Install planetary gears, one-way clutch and output shaft assembly. Place case on a cylinder per step  4. Install rear planetary carrier and output shaft assembly to case.
  9. Install 2 bolts to front planetary carrier. Use 6 mm bolts. DO NOT  screw in over 5 revolutions. Align spline of one-way clutch with spline groove of case.
  10. Install front planetary carrier and one-way clutch assembly into case. Mesh front planetary carrier spline with disc tabs by rotating and pushing front planetary carrier clockwise. If front planetary carrier will not rotate clockwise, check installation of one-way clutch.
  11. Using a screwdriver, install snap ring. Ensure end of snap ring is not aligned with cutout portion of case. Coat thrust washer with petroleum jelly and install on front planetary carrier. Securely fit claws of thrust washer into grooves of front planetary gear.
  12. Install governor body on output shaft. Insert a .004" (.10 mm) feeler gauge between output shaft and governor body. Temporarily tighten bolts. Ensure clearance between output shaft and governor body is even all way around. Torque bolts to 89 INCH lbs. (10 N.m).
  13. Place NEW gasket on transmission case. Insert parking lock rod between parking lock pawl and bracket. Attach transfer adapter on case. Apply Three Bond (1324) sealant to bolt threads. Install NEW gasket and transfer adapter. Torque bolts to 27 ft. lbs. (37 N.m).
  14. Slide spacer on output shaft with cut-out part facing outward. Using Bearing Replacer (09309-36033), install output shaft rear bearing. Install transfer component parts without No. 2 transfer case cover. See appropriate TRANSFER CASE article in TRANSFER CASES for detailed information.
  15. Temporarily install center support assembly. Install thrust washer on rear side of center support. Securely fit thrust washer claws into center support grooves. Install Puller (09350-06140) to center support. Align center support and case oil and bolt holes. Install center support into case.
  16. Adjust thrust clearance of center support. Push transmission output shaft toward front of transmission by applying a force of 11-22 lbs. (5-10 kg). Push center support toward rear of transmission by applying a force of 11-22 lbs. (5-10 kg), then pull with same amount of force.
  17. Position Plate (09350-06090) on center support. Using calipers, measure distance "A" between top of plate and thrust washer on front planetary gear. Using calipers, measure thickness "B" of Plate (09350-06090). See Fig 1.
  18. Remove 3 center support set bolts. Using Puller (09350-06140), remove center support from case. Turn center support and thrust washer over. Place assembly on flat surface. Inserting calipers into thrust washer hole, measure distance "C" between thrust washer hole and flat surface. See Fig 1.
  19. Center support thrust clearance is "A" - ("B"+"C"). Standard thrust clearance should be .0118-.0276" (.300-.700 mm). Maximum thrust clearance is .0354" (.900 mm). If thrust clearance is excessive, select and install thrust washer. There are 4 different thicknesses for thrust washers: .071" (1.80 mm), .083" (2.10 mm), .094" (2.40 mm) and .102" (2.60 mm).
  20. Install 3 new "O" rings in center support oil holes. Install Puller (09350-06140) to center support. Align center support and case oil and bolt holes. Install center support into case. Apply Three Bond (1344) sealant to center support set bolt threads. Install 3 center support set bolts and torque to 18 ft. lbs. (25 N.m).
  21. Install rear clutch into case. Mesh rear clutch drum splines and disc tabs by rotating and pushing rear clutch drum clockwise or counterclockwise.
  22. Install races on rear clutch drum and front clutch hub. Install front clutch into case. Mesh front clutch hub splines and disc tabs by rotating and pushing front clutch drum clockwise or counterclockwise.
  23. Position Plate (09350-06090) on installation surface of oil pump. Using calipers, measure distance between top of plate and front clutch drum. See Fig 2. If distance corresponds to measurement taken during disassembly, front clutch assembly is installed correctly.
    Fig 1: Checking Center Support Thrust Clearance
    G93C25264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Checking Front Clutch Installation
    G93D25265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Temporarily install Overdrive (OD) case. Remove oil seal ring from input shaft. Install races, bearing and spacer on front clutch drum. Install Puller (09350-06140) on OD case. Align OD and transmission case oil and bolt holes. Install 3 OD case set bolts. Torque to 18 ft. lbs. (25 N.m).
  25. Adjust front clutch drum input shaft thrust clearance. Push transmission output shaft toward front of case by applying a force of 11-22 lbs. (5-10 kg). Push OD case toward rear of transmission by applying a force of 11-22 lbs. (5-10 kg).
  26. Using Extension Bar (09350-06130) and dial indicator, measure thrust clearance of input shaft. Standard thrust clearance should be .0118-.0276" (.300-.700 mm). Maximum thrust clearance is .0276" (.700 mm). If thrust clearance is greater than maximum, adjust with spacer.
  27. Remove 3 OD case set bolts. Using Puller (09350-06140), remove OD case. Remove races, thrust bearing and spacer from front clutch drum or OD case. Select a spacer. There are 5 different thicknesses of spacers: .035" (.90 mm), .047" (1.20 mm), .059" (1.50 mm), .071" (1.80 mm) and .083" (2.10 mm). Install spacer, races and bearing on front clutch drum. Reinstall oil seal to input shaft.
  28. Install OD case. Install new "O" rings on OD case oil holes. Install Puller (09350-06140) to OD case. Align transmission and OD case oil and bolt holes. Apply Three Bond (1344) sealant to OD case set bolt threads. Install 3 OD case set bolts and torque to 18 ft. lbs. (25 N.m). Install snap ring. Install transfer No. 2 case cover.
  29. Install race on OD case. Install bearing on ring gear flange. Install OD ring gear assembly.
  30. Install bearing and race on OD planetary gear. Install OD planetary gear, OD direct clutch and one-way clutch assembly into transmission case. Mesh OD direct clutch drum splines with disc tabs by rotating and pushing OD direct clutch drum clockwise or counterclockwise.
  31. Position Plate (09350-06090) on installation surface of oil pump. Using calipers, measure distance between top of plate and OD clutch drum. See Fig 3. If distance corresponds to measurement taken during disassembly, OD planetary gear, OD direct clutch and one-way clutch assembly is installed properly.
  32. Temporarily install oil pump. Install races and bearing on clutch drum. Position gasket on transmission case. Align pump body and case bolt holes. Install and torque bolts to 15 ft. lbs. (21 N.m).
  33. Adjust OD planetary gear input shaft clearance. Push OD input shaft toward rear of transmission by applying a force of 11-20 lbs. (5-9 kg). Measure thrust clearance of input shaft. Standard thrust clearance should be .0157-.0354" (.400-.900 mm). If maximum thrust clearance is excessive, adjust with race.
  34. Remove 11 oil pump set bolts. Using Puller (09350-06140), remove oil pump and gasket. Remove race from oil pump cover. Select a race. There are 3 different thicknesses of races: .031" (.80 mm), .039" (1.00 mm) and .055" (1.40 mm). Coat race with petroleum jelly and install on oil pump cover.
  35. Install oil pump. Position NEW gasket on case. Install "O" ring on pump body. Align pump body and case bolt holes. Using plastic hammer, lightly tap in oil pump to case. Apply Three Bond (1344) sealant to oil pump set bolt threads. Install and torque bolts to 15 ft. lbs. (21 N.m).
  36. Install rear clutch, OD brake and 2nd brake accumulator pistons and springs. See Fig 4. Install NEW "O" rings on pistons. Install pistons and springs into the transmission case bores. Refer to the specifications in the ACCUMULATOR PISTON SPECIFICATIONS  table and ACCUMULATOR SPRING SPECIFICATIONS  table.
    Fig 3: OD Planetary Gear, Direct & One-Way Clutch Installation
    G93E25266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Exploded View Of Accumulators & Springs
    G93F25267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    ACCUMULATOR PISTON SPECIFICATIONS

    Application Diameter In. (mm)
    OD Brake 1.413 (35.90)
    2nd Brake 1.728 (43.90)
    Front Clutch (1) 1.176 (29.90)
    Rear Clutch 1.571 (39.90)
    (1) For front clutch accumulator piston location, see Figure.
    ACCUMULATOR SPRING SPECIFICATIONS

    Application Color Code Free Length In. (mm) Diameter In. (mm)
    OD Brake None 2.52 (64.1) .831 (21.10)
    2nd Brake
    1991 Yellow 2.56 (65.0) .988 (25.10)
    1992 Yellow 2.48 (63.0) .854 (21.70)
    Front Clutch (1) None 3.63 (92.3) .708 (17.90)
    Rear Clutch Red 3.44 (87.3) .858 (21.80)
    (1) For front clutch accumulator spring location, see Figure.
  37. Install NEW "O" ring on throttle cable. Install throttle cable to case. Install 4 NEW center support apply gaskets with pitted side facing toward case.
  38. Install the control valve assembly. See CONTROL VALVE ASSEMBLY  under ON-VEHICLE SERVICE. Ensure proper length bolt is installed in proper location.
  39. Install NEW gasket and oil strainer with 7 wave washers and 8 mm head bolts. Install 10 mm head bolts. Torque 8 mm head bolts to 48 INCH lbs. (5.4 N.m) and 10 mm head bolts to 89 INCH lbs. (10 N.m). See Figure.
  40. Remove lock-up relay valve body plate. DO NOT  drop lock-up relay valve pins. Install NEW gasket and lock-up relay valve body plate with 4 wave washers (for short bolts) and 7 bolts. Torque 8 mm head bolts to 48 INCH lbs. (10 N.m). See Figure.
  41. Install magnets in oil pan. Install NEW gasket and oil pan. Torque bolts to 61 INCH lbs. (6.9 N.m). Install oil pan protector.
  42. Install transmission housing. Torque bolts to 47 ft. lbs. (64 N.m). Install throttle cable to case. Install new "O" ring on ATF temperature sensor. Install sensor. Torque to 25 ft. lbs. (34 N.m). Install wire clamp. Install oil cooler unions. Torque to 21 ft. lbs. (29 N.m).
  43. Install the control shaft lever. Tighten to 115 INCH lbs. (13 N.m). Temporarily install neutral start switch with 2 bolts. Install grommet, NEW lock washer and nut. Torque to 61 INCH lbs. (6.9 N.m). Fully turn control shaft lever back and return 2 notches. Lever is now in Neutral position. Align neutral basic line with switch groove. Torque bolts to 115 INCH lbs. (13 N.m). Bend tabs of lock washer. Bend at least 2 tabs.
  44. Install oil cooler pipes with 2 unions and bolt. Torque to 25 ft. lbs. (34 N.m). Install NEW "O" ring on breather plug. Install breather plug and hose. Connect 4 connectors and install transmission wire harness.
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