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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 cutouts and are installed correctly in groove. If a worn bushing is to be replaced, replacement must be made with 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. Clutch discs should be soaked in ATF for 15 minutes before installation.
NOTE: For thrust bearing and race identification and installation positions, refer to illustration. See Fig 3.
  1. Install rear planetary ring gear with thrust bearing. Install snap ring securing rear planetary ring gear. Install races and bearing onto rear planetary ring gear. Install output shaft with center and rear planetary gear into case. Install thrust washer. See Figure.
  2. Install spring and 2nd brake pack, starting with flange. Ensure correct number of discs and plates are installed. See CLUTCH DISC & PLATE QUANTITY  table under TRANSMISSION SPECIFICATIONS. Additional flanges in thicknesses from .083" (2.10 mm) to .122" (3.10 mm) are available, but clearance specification and measuring procedure information is not available from manufacturer.
  3. Install front and center planetary sun gear. Install front planetary gear with thrust washer. Install 2 thrust washers onto top of front planetary gear. Install multiple disc brake into case. Install No. 1 one-way clutch. Install snap ring. Install brake drum gaskets. See Figure.
  4. Install thrust washer onto top of No. 1 one-way clutch. Install sun gear input drum. Install races and thrust bearing. Install 3rd coast brake band to case. Install pin through brake band. Secure pin with "E" rings.
  5. Assemble forward clutch hub with thrust bearing and race to forward clutch. See Figure. Assemble forward clutch with thrust bearing and race to direct clutch. Place direct/forward clutch assembly into case.
  6. Measure distance between sun gear input drum and direct clutch drum. See Fig 1. Distance should be .161-.236" (4.10-6.00 mm). If distance is not with specification, check for proper installation of components. Install 3rd coast brake spring, piston assembly and cover in case. Install snap ring.
  7. Place reference mark on 3rd coast brake piston rod. Apply 57-114 psi (4.8 kg/cm2 ) of air at opening of transmission case. Using wire gauge, measure clearance between reference mark and case. See Figure and Figure . Piston stroke should be .079-.118" (2.00-3.00 mm). If stroke is not within specification, replace piston rod. Piston rod lengths available are 3.057" (77.65 mm), 3.086" (78.40 mm), 3.116" (79.15 mm), 3.146" (79.90 mm) and 3.175" (80.65 mm).
  8. Install O/D support assembly with thrust race and bearing. See Fig 3. Use 2 bolts screwed into face of support to assist in positioning support in case. Ensure oil passages face valve body side of case. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS . Install snap ring.
  9. Using dial indicator, check output shaft end play. End play should be .064-.114" (1.63-2.89 mm). If end play is not within specification, check installation of installed components. Ensure output shaft turns freely.
  10. Install a .157" (4.00 mm) thick flange with rounded edge facing disc. Install O/D brake pack discs and plates with spring, beginning with plate. Install end flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are located at cut-out areas of case.
  11. Check overdrive brake piston stroke. Install a dial indicator onto overdrive (OD) brake piston. Measure piston stroke by applying 57-114 psi (4-8 kg/cm2 ) compressed air to opening in case. See OD BRAKE PISTON STROKE SPECIFICATIONS  table. See Figure. If piston stroke is not within specification, install different thickness flange. Flanges are available in thicknesses of .130" (3.3 mm) to .157" (4.0 mm) in .008" (.20 mm) increments.
    OD BRAKE PISTON STROKE SPECIFICATIONS

    Application In. (mm)
    V8 Models .055-.067 (1.40-1.70)
    6-Cyl. Models .052-.064 (1.32-1.62)
  12. Install O/D planetary ring gear with race. Install thrust bearing and race in ring gear. Install race on end of O/D planetary gear. Install O/D planetary gear and O/D one-way clutch in case. See Figure.
  13. Install bearing/race assembly onto O/D direct clutch. Install race on rear of oil pump with raised side toward oil pump. Install "O" ring on outer diameter of oil pump. Ensure oil seal rings are installed on rear of oil pump. Align holes of oil pump and transmission case. Install oil pump while holding input shaft and lightly pressing on oil pump.
  14. Install oil pump bolts and tighten to specification. See TORQUE SPECIFICATIONS . Ensure input shaft rotates smoothly. Apply air pressure to specified oil passages to check operating components. See Figure. When air checking OD direct clutch, O/D accumulator piston hole must be plugged.
  15. Install 2 NEW case oil seals. Assemble NEW spacer to manual valve lever. Install manual lever shaft to case through manual valve lever. Install pin to shaft. Align spacer hole with lever hole and stake spacer to lever. Ensure manual valve lever shaft turns smoothly.
  16. Install "E" ring, parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl, shaft and spring. Connect parking lock rod to manual valve lever. Position parking lock pawl bracket on case and install.
  17. Install accumulator pistons with NEW "O" rings and springs. See Fig 2. Accumulator pistons and springs must be correct diameter and height. Accumulator pistons are stamped with identification codes. Determine correct spring free length. See ACCUMULATOR SPRING SPECIFICATIONS  table.
    ACCUMULATOR SPRING SPECIFICATIONS

    Component, (Code) & Color Free Length - In. (mm) Diameter - In. (mm)
    Direct Clutch (C2)
    V8
    Inner 1.409 (35.80) .551 (14.00)
    Outer 3.520 (89.41) .776 (19.70)
    6-Cyl.
    Inner White 1.409 (35.80) .551 (14.00)
    Outer White 3.223 (81.86) .776 (19.70)
    OD Brake (B0) White 2.732 (69.40) .640 (16.25)
    OD Direct Clutch (C0) 2.559 (65.00) .811 (20.59)
    3rd Brake (B2) Pink/White 3.185 (80.91) .786 (19.97)
    Fig 1: Measuring Sun Gear Input Drum-To-Direct Clutch Drum Clearance
    G99A04828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Identifying Accumulator Piston Assemblies
    G99C04810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Install check ball body and spring. See Figure. Install valve body. See VALVE BODY ASSEMBLY  under ON-VEHICLE SERVICE.
  19. Install retainer and No. 2 one-way clutch. Install snap ring. Install sensor rotor with washers on output shaft with snap ring. Install extension housing and gasket. Shorter mounting bolts go to bottom of extension housing. Install transmission output flange. Shift manual valve lever to "P" position. Tighten and stake nut. Install transmission housing.
  20. Install speed sensors. Install park/neutral position switch. Tighten nut to 61 INCH lbs. (6.9 N.m). Align neutral basic line and switch groove. Bend at least 2 lock washer tabs. Install control shaft lever. Install torque converter. Using straightedge and depth gauge, measure distance from front of converter to front mounting surface of transmission housing. See TORQUE CONVERTER DISTANCE SPECIFICATIONS  table to determine if converter is fully installed.
TORQUE CONVERTER DISTANCE SPECIFICATIONS

Application Distance - In. (mm)
GS300 .004 (.10)
GS400, LS400 & SC400 .673 (17.10)
Fig 3: Identifying Thrust Bearing & Race Installation Positions
G99H03691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
THRUST BEARING & RACE SPECIFICATIONS

Application Inner Diameter - In. (mm) Outer Diameter - In. (mm)
"A"
Bearing & Race 1.13 (28.8) 1.98 (50.4)
Race 1.11 (28.1) 1.87 (47.5)
"B"
Race 1.07 (27.2) 1.65 (42.0)
Bearing 1.02 (25.9) 1.85 (47.0)
Race .95 (24.0) 1.89 (48.0)
"C"
Race 1.46 (37.1) 2.32 (59.0)
Bearing & Race 1.32 (33.6) 1.98 (50.3)
"D"
Race 1.46 (37.1) 2.01 (51.0)
Bearing & Race 1.32 (33.5) 1.88 (47.8)
"E"
Race 1.04 (26.3) 1.62 (41.1)
Bearing & Race 1.04 (26.3) 1.73 (44.0)
"F"
Front Race 1.28 (32.5) 2.32 (59.0)
Bearing 1.71 (43.5) 2.35 (59.8)
Rear Race 1.71 (43.5) 2.42 (61.5)
"G"
Front Race 1.54 (39.2) 2.24 (56.8)
Bearing 1.60 (40.7) 2.24 (57.0)
Rear Race 1.62 (41.2) 2.35 (59.8)
"H"
Bearing & Race 2.08 (52.9) 2.78 (70.6)
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