Automatic Transmission Unit: Reassembly

Fig 1: Exploded View Of Bearings

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Bearing diameter 

1. Coat 2 new O-rings with ATF, and install them onto the brake reaction sleeve.
2. Coat 2 new O-rings with ATF, and install them onto the No. 4 brake piston.
3. Install the No. 4 brake piston onto the reaction sleeve.
   Fig 2: Identifying No. 4 Brake Piston O-Rings

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1. Coat a new O-ring with ATF, and install it to the reaction sleeve.
2. With the No. 1 brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston onto 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 onto the 1st and reverse brake piston.
3. With the spring seat of the piston facing upward (the front side), place the piston in the transmission case.
   NOTE: Be careful not to damage the O-ring.
   Fig 4: Identifying 1st & Reverse Brake Piston

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4. Place the piston return spring onto the 1st and reverse brake piston.
   Fig 5: Locating Piston Return Spring

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1. Place SST on the spring retainer, and compress the return spring.

   SST 09350-30020 (09350-07050) 

2. Using SST, install the snap ring.

   SST 09350-30020 (09350-07070) 

   Fig 6: Using SST To Install Snap Ring

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1. Install the thrust needle roller bearing.
   Fig 7: Identifying Thrust Needle Roller Bearing

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   Thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	45.9 mm (1.807 in.)	64.0 mm (2.520 in.)

2. Install the thrust needle roller bearing.
3. Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear bearing and race diameter
   Fig 8: Identifying Thrust Needle Roller Bearing & Race

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   BEARING AND RACE DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Bearing	21.5 mm (0.847 in.)	40.8 mm (1.606 in.)
   Race	48.5 mm (1.909 in.)	62.7 mm (2.469 in.)

4. Install the rear planetary gear assembly.
   Fig 9: Identifying Rear Planetary Gear Assembly

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1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
   Fig 10: Applying Compressed Air Into Transmission Case

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2. Using vernier calipers, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.
   NOTE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.

   HINT:

   Length A = 36.35 to 37.09 mm (1.431 to 1.460 in.)

   Fig 11: Measuring Level Difference Between Upper Surface Of 1st & Reverse Brake Piston Using Vernier Calipers

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3. Using vernier calipers, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.

   HINT:

   Pack clearance = Length A - Length B - 0.25 mm - 1.8 mm

   Length B = 36.04 to 37.14 mm (1.419 to 1.462 in.)

   Pack clearance: 0.8 to 1.1 mm (0.031 to 0.043 in.) 

4. If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.
   Fig 12: Measuring Thickness Of Brake Flanges, Brake Plates & Brake Discs Using Vernier Calipers

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   H thickness 

   FLANGES THICKNESS SPECIFICATION
   
   

   No.	Thickness
   0	0 mm (0 in.)
   2	0.2 mm (0.008 in.)
   4	0.4 mm (0.016 in.)
   6	0.6 mm (0.024 in.)
   8	0.8 mm (0.032 in.)
   10	1.0 mm (0.039 in.)
   12	1.2 mm (0.047 in.)
   14	1.4 mm (0.055 in.)

1. Install the 7 plates, 8 discs and 2 flanges.

   Install in order: F - D - P - D - P - D - P - D - P - D - P - D - P - D - P - D - F 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 13: Identifying Plates, Discs & Flanges

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1. Install the brake stopper spring.
   Fig 14: Identifying Brake Plate Stopper Spring

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1. Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange onto the intermediate shaft.
   Fig 15: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing, No. 7 Thrust Bearing Race & Planetary Ring Gear Flange

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   Bearing and race diameter mm (in.) 

   BEARING AND RACE DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   No. 7 thrust bearing race	33.4(1.315)	49.0(1.929)
   Thrust needle roller bearing	32.1 (1.264)	49.35(1.943)
   No. 8 thrust bearing race	32.1 (1.264)	49.0 (1.929)

2. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY 
   1. Install the No. 3 1-way clutch assembly and the 1-way clutch inner race onto the intermediate shaft.
      Fig 16: Identifying No. 3 1-Way Clutch Assembly & 1-Way Clutch Inner Race

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3. INSTALL INTERMEDIATE SHAFT 
   1. Install the intermediate shaft with the No. 3 1-way clutch assembly onto the case.
      Fig 17: Identifying Intermediate Shaft With No. 3 1-Way Clutch Assembly

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   2. Using SST, install the snap ring.

      SST 09350-30020 (09350-07050, 09350-07060) 

      Fig 18: Using SST To Install Snap Ring

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4. INSTALL CENTER PLANETARY GEAR ASSEMBLY 
   1. Install the center planetary gear assembly and planetary sun gear into the case.
   2. Coat the No. 4 thrust bearing race and thrust needle roller bearing with petroleum jelly, and install them onto the center planetary ring gear.
      Fig 19: Identifying No. 4 Thrust Bearing Race & Thrust Needle Roller Bearing

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   Race and Bearing diameter 

   RACE AND BEARING DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Race	53.7 mm (2.114 in.)	74.0 mm (2.913 in.)
   Bearing	55.7 mm (2.192 in.)	76.4 mm (3.008 in.)

1. Coat 2 new O-rings with ATF, and install them onto the No. 2 brake piston.
2. Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.
3. Install the No. 2 brake piston onto the case.
   Fig 20: Identifying No. 2 Brake Piston O-Rings

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

   Install in order: F - D - P - D - P - D - P 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 21: Identifying Flange, Plates, Discs & Brake Piston Return Spring

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2. Using SST and press, install the No. 2 brake spring snap ring.

   SST 09351-40010 

   Fig 22: Using SST & Press To Install No. 2 Brake Spring Snap Ring

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1. Coat 2 new O-rings with ATF, and install them onto the No. 1 brake piston.
2. Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.
   Fig 23: Identifying No. 1 Brake Piston O-Rings

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1. Install the brake piston return spring and No. 1 brake piston with the No. 1 brake cylinder into the transmission case.
   Fig 24: Identifying Brake Piston Return Spring & No. 1 Brake Piston With No. 1 Brake Cylinder

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1. Using SST and a press, install the brake piston return spring snap ring.

   SST 09351-40010 

   Fig 25: Using SST & Press To Install Brake Piston Return Spring Snap Ring

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

   Install in order: F - D - P - D - P - D - P 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 26: Identifying Plates, Discs And Flange

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1. Install the center planetary ring gear and front planetary ring gear flange into the front planetary ring gear.
   Fig 27: Identifying Center Planetary Ring Gear & Front Planetary Ring Gear Flange

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2. Using a screwdriver, install the snap ring.
   Fig 28: Using Screwdriver To Install Snap Ring

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1. Install the front planetary ring gear into the case.
   Fig 29: Installing Front Planetary Ring Gear

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1. Install the thrust needle roller bearing and No. 2 planetary carrier thrust washer.
   Fig 30: Identifying Thrust Needle Roller Bearing & No. 2 Planetary Carrier Thrust Washer

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2. Coat the No. 3 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 DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller 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 1-way clutch inner race into the case.
   Fig 31: Identifying Front Planetary Gear Assembly & 1-Way Clutch Inner Race

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1. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
   Fig 32: Applying Compressed Air Into Transmission Case

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2. Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.

   Piston stroke: 0.42 to 0.72 mm (0.017 to 0.028 in.) 

   If the piston stroke is outside the specification, parts may have been assembled incorrectly.

   Perform the reassembly again.

   If the piston stroke is still outside the specification, select another flange.

   HINT:

   There are 4 different thicknesses for the flange.

   Fig 33: Measuring B3 Brake Pack Clearance Between Snap Ring & Flange Using Feeler Gauge

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   Flange thickness 

   FLANGE THICKNESS SPECIFICATION
   
   

   No.	Thickness
   0	2.0 mm (0.079 in.)
   1	2.2 mm (0.087 in.)
   2	2.4 mm (0.094 in.)
   3	2.6 mm (0.102 in.)

1. Coat 2 new O-rings with ATF, and install them onto the 2nd brake piston.
2. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands.
   Fig 34: Identifying 2nd Brake Piston O-Rings

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3. Using SST and press, install the snap ring.

   SST 09351-40010 

   NOTE: Make sure that the end gap of the snap ring is not aligned with the spring retainer claw.
   Fig 35: Using SST & Press To Install Snap Ring

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1. Install the 2nd brake cylinder into the case.
   Fig 36: Identifying 2nd Brake Cylinder

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1. Install the 1-way clutch assembly and the thrust washer into the case.
   Fig 37: Identifying 1-Way Clutch Assembly & No. 1 Planetary Carrier Thrust Washer

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 38: Using SST To Install 2ND Brake Piston Hole Snap Ring

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1. Install the flanges, 4 discs, 4 plates and the cushion plate onto the case.

   Install in order: F - D - P - D - P - D - P - D - P - C 

   HINT:

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

   Fig 39: Identifying No. 3 Brake Flanges, Discs, Plates & Cushion Plate

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1. Using a screwdriver, install the snap ring.
   Fig 40: Using Screwdriver To Remove No. 3 Brake Snap Ring

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1. Coat the race with petroleum jelly and install it onto the No. 2 clutch drum thrust washer.
2. Install the No. 2 1-way clutch assembly washer.
   Fig 41: Identifying No. 2 1-Way Clutch Assembly

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1. Install the thrust needle roller bearing.
   Fig 42: Identifying Thrust Needle Roller Bearing

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2. Coat the race with petroleum jelly and install it onto the clutch drum thrust washer.

   Thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
   Race	73.6 mm (2.898 in.)	102.0 mm (4.016 in.)

3. Install the clutch drum thrust washer and race onto the clutch drum and input shaft assembly.
4. Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.
   Fig 43: Identifying Input Shaft Sub-Assembly

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1. Install the No. 1 thrust bearing race onto the front oil pump.

   No. 1 thrust bearing race diameter 

   NO. 1 THRUST BEARING RACE DIAMETER SPECIFICATION
   
   

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

   Fig 44: Identifying No. 1 Thrust Bearing Race

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2. Coat a new O-ring with ATF, and install it onto the oil pump assembly.
3. Place the oil pump through the input shaft, and align the bolt holes; in 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.
   NOTE: Do not push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum.
   Fig 45: Identifying O-Ring

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5. Install the 10 bolts.

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

   Fig 46: Identifying Oil Pump Assembly Bolts

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

   SST 09350-30020 (09350-07110) 

2. Coat the oil seal lips with MP grease.

1. Install a new spacer onto the manual valve lever.
2. Install the manual valve lever shaft onto the transmission case through the manual valve lever.
   Fig 48: Identifying New Spacer In Manual Valve Lever

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3. Using a hammer, tap in a new spring pin.
   Fig 49: Tapping In New Spring Pin Using Hammer

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4. Align the manual valve lever indentation with the spacer hole, and stake them together with a punch and hammer.
5. Make sure the shaft rotates smoothly.
   Fig 50: Aligning Manual Valve Lever Indentation With Spacer Hole & Stake Them Together With Punch

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1. Install the E-ring onto the shaft.
2. Install the parking lock pawl, shaft and spring.
   Fig 51: Identifying Parking Lock Pawl, Shaft & Spring

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1. Connect the parking lock rod to the manual valve lever.
   Fig 52: Identifying Parking Lock Rod

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1. Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.

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

   Fig 53: Identifying Parking Lock Pawl Bracket Bolts

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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 54: Identifying Shift Manual Valve Lever And Planetary Ring Gear

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1. Coat a new O-ring with ATF, and install it onto the piston.
   Fig 55: Identifying C-1 Accumulator Valve

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2. Install the 2 springs and accumulator valve into the hole.

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length Outer diameter	Color
   C-1 Inner	30.40 mm (1.197 in.) 11.40 mm (0.449 in.)	Pink
   C-1 Outer	48.76 mm (1.920 in.) 16.60 mm (0.654 in.)	Light green

   Fig 56: Identifying Spring & C-1 Accumulator Valve

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1. Coat a new O-ring with ATF, and install it into the piston.
   Fig 57: Identifying C-3 Accumulator Piston

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

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length. Outer diameter	Color
   C-3 Inner	44.0 mm (1.732 in.) 14.0 mm (0.551 in.)	Yellow
   C-3 Outer	73.35 mm (2.888 in.) 19.90 mm (0.784 in.)	Red

   Fig 58: Identifying Spring & C-3 Accumulator Piston

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1. Coat 2 new O-rings with ATF, and install them onto the piston.
   Fig 59: Identifying B-3 Accumulator Piston

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

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length Outer diameter	Color
   B-3	70.5 mm (2.776 in.) 19.7 mm (0.776 in.)	Purple

   Fig 60: Identifying Spring & B-3 Accumulator Piston

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1. Coat 2 new O-rings with ATF, and install them onto the piston.
   Fig 61: Identifying C-2 Accumulator Piston

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

   Accumulator spring 

   ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length Outer diameter	Color
   C-2	62.0 mm (2.441 in.) 15.9 mm (0.626 in.)	White

   Fig 62: Identifying Spring & Accumulator Piston

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1. Install the check ball body and spring.
   Fig 63: Identifying Check Ball Body & Spring

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1. Install the 3 brake drum gaskets.
   Fig 64: Identifying Brake Drum Gaskets

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1. Install the 3 transaxle case gaskets.
   Fig 65: Identifying Transaxle Case Gasket

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1. Align the groove of the manual valve with the pin of the lever.
   Fig 66: Aligning Groove Of Manual Valve With Pin Of Lever

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2. Install the 19 bolts.

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

   HINT:

   Each bolt length is as indicated below.

   Bolt length: 

   25 mm (0.98 in.) for bolt A 

   36 mm (1.42 in.) for bolt B 

   Fig 67: Identifying Transmission Bolts

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

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

4. Connect the solenoid connector.
   Fig 68: Identifying Transmission Wire Bolt

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5. Connect the 7 solenoid connectors.
6. Install the ATF temperature sensor.
7. Install the 2 clamps and the 2 bolts.

   Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf) for bolt A 

   11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt B 

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   12 mm (0.47 in.) for bolt A 

   36 mm (1.42 in.) for bolt B 

   Fig 69: Identifying Transmission Wire Clamps & Bolts

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

   Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf) 

   Fig 70: Identifying Valve Body Oil Strainer Assembly Bolts

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1. Install the 4 transmission oil cleaner magnets.
   Fig 71: Identifying Transmission Oil Cleaner Magnets

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1. Install a new gasket onto the oil pan.
2. Install the 20 bolts.

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

3. Install the drain plug.

   Torque: 28 N*m (285 kgf*cm, 21 ft.*lbf) 

1. Using SST and a hammer, tap in a new oil seal.

   SST 09226-10010 

   Fig 72: Tapping In Transmission Case Adaptor Oil Seal Using SST & Hammer

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1. Apply seal packing or equivalent to the 8 bolts.

   Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent 

   Fig 73: Identifying Transmission Case Adapter Gasket

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2. Install the transmission case adapter sub-assembly with the 8 bolts.

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

   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   50 mm (1.969 in.) for bolt A 

   40 mm (1.575 in.) for bolt B 

   Fig 74: Identifying Transmission Case Adapter Bolts

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

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

   57 N*m (581 kgf*cm, 42 ft.*lbf) for bolt B 

   34 N*m (345 kgf*cm, 25 ft.*lbf) for bolt C 

   Fig 75: Identifying Transmission Housing Bolts

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   HINT:

   Each bolt length is indicated below.

   Bolt length: 

   Bolt A: 14 mm 

   Bolt B: 17 mm 

   Bolt C: 14 mm 

1. Install a new O-ring onto the breather tube.
2. Install the breather tube with the 3 bolts.

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

   Fig 76: Identifying Automatic Transaxle Breather Tube & Bolts

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1. Coat 2 new O-rings with AFT, and install one onto each transmission revolution sensor.
2. Install the 2 transmission revolution sensors.
3. Install the 2 bolts.

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

   Fig 77: Identifying Transmission Revolution Sensor Bolts

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1. Coat 2 new O-rings with ATF, and install one onto each oil cooler tube union.
2. Install the 2 oil cooler tube unions.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 78: Identifying Oil Cooler Tube Union

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

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

   Fig 79: Identifying Park/Neutral Position Switch Nut, Lock Washer & Bolt

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3. Push the control shaft rearward as much as possible.
4. Return the control shaft lever 2 notches to the N position.
   Fig 80: Identifying Control Shaft Lever N Position

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

   Torque: 13 N*m (129 kgf*cm, 9.4 ft.lbf) 

   Fig 81: Aligning Neutral Basic Line With Switch Groove

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

   HINT:

   Bend at least 2 of the lock washer tabs.

   Fig 82: Bending Tabs Of Lock Washer Using Screwdriver

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1. Install the control shaft lever LH with the washer and nut.

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

   Fig 83: Identifying Control Shaft Lever LH Washer & Nut

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