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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, see Fig 5.
  1. Before transmission reassembly, inspect case bushing and extension housing bushing (if equipped). Maximum transmission case bushing inside diameter is 1.504" (38.19 mm). Maximum extension housing bushing inside diameter is 1.578" (40.09 mm). If bushings are not within specifications, manufacturer recommends replacing transmission case and/or extension housing.
  2. Install 1st and reverse brake No. 1 piston to reaction sleeve. Install No. 1 piston with reaction sleeve on No. 2 piston. Align No. 2 piston teeth into proper grooves. Carefully press No. 1 and No. 2 brake pistons into case. Position piston return spring on No. 2 piston. Using Spring Compressor (09350-07050), compress return spring. See Figure.
  3. Install snap ring. Ensure snap ring end-gap is not aligned with spring retainer claw. Ensure 1st and reverse brake pistons move smoothly by applying compressed air to case. See Figure.
  4. Install leaf spring (if equipped). Install rear planetary gear unit with 1st and reverse brake pack and output shaft. Install flange with rounded edge toward planetary ring gear. Install flange. Install plates and discs, starting with disc. Install correct number of plates and discs.
  5. Install 2nd brake drum assembly. Install thrust bearing in case. Align teeth of 2nd brake drum, flange, discs and plates. Align splines of transmission case, assembled rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft into case.
  6. Support output shaft on wooden blocks. Install snap ring in case with chamfered edge toward front of transmission. Ensure ends of snap ring are not aligned with cutout area of case. Measure 1st and reverse brake clearance between 2nd brake drum and plate. See Figure. Clearance should be .028-.048" (.71-1.22 mm).
  7. If clearance is not within specification, select a different thickness flange. Flanges are available in thicknesses of .157-.213" (4.0-5.4 mm) in .008" (.20 mm) increments.
  8. Install 2nd brake piston sleeve. Install NEW brake drum gasket in case. Install No. 1 one-way clutch. Install .071" (1.8 mm) flange plate with rounded edge side of plate facing disc. Install plates and discs starting with disc. Install end flange with rounded edge facing disc. Install snap ring.
  9. Measure 2nd brake clearance between snap ring and flange. See Figure. Clearance should be .024-.078" (.61-1.98 mm). If clearance is not within specifications, check for incorrect assembly.
  10. Install planetary sun gear. Turn planetary sun gear clockwise into No. 1 one-way clutch. Ensure all thrust washers are correctly installed. Install front planetary gear bearing and race. Install front planetary gear into sun gear. Install snap ring. Remove wooden block from under output shaft. Install race on front of planetary gear so race tabs align with planetary gear holes.
  11. Install 2nd coast brake band and pin. Pin must be installed so "E" ring is toward front of transmission. Install "E" ring. Coat thrust bearing and race with petroleum jelly and install on forward clutch. Raised portion of race must be toward front.
  12. Install race on front planetary ring gear. Smooth flat surface must be toward front. Align disc tabs of forward clutch. Install front planetary gear in forward clutch. Ensure gear is aligned with all clutch discs.
  13. Install bearing race and thrust bearing on ring gear. Raised portion of race must be toward rear. Install forward and direct clutch assembly and front planetary ring gear in transmission case. Measure distance between sun gear input drum and direct clutch drum. Clearance should be .209-.287" (5.30-7.30 mm). See Fig 1. If clearance is not within specifications, check for incorrect installation.
  14. Install thrust bearing and race on forward clutch assembly with flat side toward clutch assembly. Install NEW "O" ring on 2nd coast brake cover. Install spring, 2nd coast brake piston assembly and cover to case. Install snap ring.
  15. Place reference mark on 2nd 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 . 2nd coast brake piston stroke should be .059-.118" (1.50-3.00 mm).
  16. If stroke is not within specification, install replacement piston rod. Rods are available in lengths of 2.78" (70.7 mm), 2.81" (71.4 mm), 2.84" (72.2 mm), 2.87" (72.9 mm) and 2.90" (73.1 mm). If stroke is not within specification, install NEW brake band. Install race on overdrive support. Install bolt and oil holes of overdrive support toward valve body side and align with bolt holes of case. Install support.
  17. Ensure support is properly aligned. Install support snap ring with chamfered edge toward front of transmission. End of snap ring must be positioned to valve body side of case within .94" (23.9 mm) from center line of valve body as viewed from front of transmission.
  18. Using dial indicator, check output shaft end play. End play should be .011-.034" (.27-.86 mm). If end play is not within specifications, check for incorrect assembly. Ensure output shaft rotates smoothly.
  19. Install a .157" (4.00 mm) thick flange with rounded edge facing disc. Install correct number of discs and plates, beginning with plate. Install end flange (stepped ring) with flat side toward disc. Install snap ring. Ensure ends of snap ring are not located at cutout areas of case.
  20. Install dial indicator on case and measure piston stroke. Apply 57-114 psi (4-8 kg/cm2 ) at opening of transmission case and note piston stroke. See Figure. See OD BRAKE PISTON STROKE SPECIFICATIONS  table under TRANSMISSION DISASSEMBLY.
  21. If piston stroke is not within specifications, check for incorrect installation. Recheck piston stroke. If piston stroke is not within specifications, install different thickness flange. Flanges are available in thicknesses of .130-.157" (3.3-4.0 mm) in .008" (.20 mm) increments.
  22. Install thrust bearing and races on overdrive support. Ensure race tabs align with hole support. Install overdrive planetary ring gear. Install thrust bearing and race in ring gear. Install race on rear of overdrive planetary gear, aligning race tabs with holes of gear.
  23. Install overdrive planetary gear with overdrive direct clutch and one-way clutch. Install thrust bearing and race onto OD direct clutch with race flat side toward direct clutch.
  24. Install race on rear of oil pump with raised side toward oil pump. Install NEW "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.
    CAUTION: DO NOT apply excessive pressure on oil pump during installation, or oil seal rings will stick to direct clutch drum.
  25. Install oil pump bolts and tighten to specification. See TORQUE SPECIFICATIONS . Ensure input shaft rotates smoothly. Install throttle cable. Apply air pressure to specified oil passage to check operating components. See Fig 2. When air checking OD direct clutch, overdrive accumulator piston hole must be plugged.
    Fig 1: Measuring Input Drum & Direct Clutch Drum Clearance
    G00053970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Air Testing Transmission Components
    G93G25813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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.
  27. 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.
  28. Install accumulator pistons with NEW "O" rings and springs. See Fig 3. 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.
    Fig 3: Identifying Accumulator Piston Assemblies
    G95D20381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    ACCUMULATOR SPRING SPECIFICATIONS (1)

    Spring (Color) Free Length - In. (mm)
    2nd Brake (Light Gray) 2.858 (72.60)
    Direct Clutch
    Inner (Pink) 1.657 (42.10)
    Outer (White/Red) 2.886 (73.30)
    OD Brake (Green) 2.441 (62.00)
    OD Direct Clutch
    Inner (Yellow) 1.811 (46.00)
    Outer (Orange) 2.937 (74.60)
    (1) Spring diameter is not available.
  29. Install check ball body and spring. See Figure. Install throttle cable into transmission case. Install valve body. Align the groove of the manual valve to pin of the lever. Connect the throttle cable to the cam. Confirm the spring into the accumulator pistons are installed correctly.
  30. Install valve body bolts in correct location. See Fig 4. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
    Fig 4: Identifying Valve Body Mounting Bolts
    G95G20368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Install sensor rotor and key on output shaft with snap ring. Install speedometer drive gear and lock ball and snap ring on output shaft. Install extension housing and NEW gasket. Shorter mounting bolts go to bottom of extension housing.
  32. Install transfer case assembly. Install transfer and drive shaft upper dust cover to transmission. Install engine rear mounting. Install dynamic damper. Install breather hose. Hose depth is .51" (13 mm).
  33. Install transmission housing. Install No. 1 and 2 speed sensors (if applicable).
  34. Install speed sensor and fluid temperature sensor (if applicable). 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.
  35. Install control shaft lever. If throttle cable is new, stake stopper on inner cable. Install wire harness and throttle cable clamp. Install torque converter. Using straightedge and depth gauge, measure distance from front of converter to front mounting surface of transmission housing. Distance should be .673" (17.10 mm). Determine if converter is fully installed.
Fig 5: Identifying Thrust Bearing & Race Installation Positions
G95E20382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
THRUST BEARING & RACE SPECIFICATIONS (1)

Application Outer Diameter - In. (mm) Inner Diameter - In. (mm)
"A"
Front Race 1.87 (47.5) 1.11 (28.1)
Bearing 1.98 (50.4) 1.13 (28.8)
"B"
Front Race 1.65 (42.0) 1.07 (27.2)
Rear Race 1.89 (48.0) .94 (24.0)
Bearing 1.85 (47.0) 1.02 (26.0)
"C"
Front Race 2.32 (59.0) 1.46 (37.0)
Bearing 1.98 (50.4) 1.32 (33.5)
"D"
Front Race 2.01 (51.0) 1.46 (37.0)
Bearing 1.88 (47.8) 1.32 (33.5)
"E"
Rear Race 2.11 (53.7) 1.04 (26.5)
Bearing 1.69 (43.0) 1.02 (26.0)
"F"
Rear Race 2.50 (63.6) 2.10 (53.3)
Bearing 2.55 (64.7) 1.96 (49.7)
"G"
Front Race 1.88 (47.8) 1.32 (33.5)
Bearing 1.89 (48.0) 1.39 (35.4)
"H" (2-piece)
Front Race 1.74 (44.2) 1.12 (28.5)
Bearing 1.74 (44.2) 1.08 (27.5)
"I"
Bearing 2.27 (57.7) 1.54 (39.2)
(1) For bearing and race location, refer to illustration. See Fig 5.
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