Automatic Transmission Unit: Reassembly

BEARING POSITION

Check bearing position.

Fig 1: Identifying Bearing Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bearing diameter

BEARING DIAMETER REFERENCE

Mark	Front Race Diameter Inside / Outside	Thrust Bearing Diameter Inside / Outside	Rear Race Diameter Inside / Outside
A	73.6 mm (2.898 in.) /102.0 mm (4.016 in.)	71.9 mm (2.831 in.) / 85.6 mm (3.370 in.)	-
B	38.0 mm (1.496 in.) / 57.0 mm (2.244 in.)	43.4 mm (1.709 in.) / 58.3 mm (2.295 in.)	-
C	-	55.7 mm (2.193 in) / 76.4 mm (3.008 in.)	53.7 mm (2.114 in.)/74 0 mm (2.913 in.)
D	33.4 mm (1.315 in.) / 49.0 mm (1.929 in.)	32.1 mm (1 264 in.) / 49.35 mm (1.943 in.)	32.1 mm (1.264 in.)/ 49.0 mm (1.929 in.)
E	-	21.5 mm (0.847 in.) / 40.8 mm (1.606 in.)	-
F	48.5 mm (1.909 in.) / 62.7 mm (2.469 in)	45.9 mm (1.807 in.) / 64.0 mm (2.520 in.)	-

INSTALL NO. 4 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
2. Coat 2 new O-rings with 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-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE REACTION SLEEVE
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 to the transmission case.
  NOTE: Be careful not to damage the O-rings.
  
  Fig 3: Identifying Brake Reaction Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE PISTON
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.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 4: Identifying O-ring With ATF
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the piston return spring onto the No. 4 brake piston.
  
  Fig 5: Identifying Piston Return Spring Onto No. 4 Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
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: Compressing Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY GEAR ASSEMBLY

Install the thrust needle roller bearing.

Thrust needle roller bearing diameter

ITEM SPECIFICATION

Item	Inside	Outside
Thrust needle roller bearing	45.9 mm (1.807 in.)	64.0 mm (2 520 in.)

Fig 7: Identifying Thrust Needle Roller Bearing Of Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing

Coat the No. 9 thrust bearing race with ATF, and install it onto the rear planetary ring gear.

Bearing and race diameter

ITEM 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.)

Fig 8: Identifying Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the rear planetary gear assembly.

Fig 9: Identifying Rear Planetary Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using vernier caliper, 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 And Reverse Brake Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a vernier caliper, 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 to 1.8 mm (0.010 to 0.071 in.)

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.)

Fig 12: Measuring Thickness Of Brake Flanges
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

H thickness

THICKNESS CHART

No.	Thickness	No.	Thickness
0	0 mm (0 in.)	8	0.8 mm (0.031 in.)
2	0.2 mm (0.008 in.)	10	1.0 mm (0.039 in.)
4	0.4 mm (0.016 in.)	12	1.2 mm (0.047 in.)
6	0.6 mm (0.024 in.)	14	1.4 mm (0.055 in.)

INSTALL NO. 4 BRAKE DISC
1. Install the 7 plates, the 8 discs and the 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 No. 4 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PLATE STOPPER SPRING
1. Install the brake plate stopper spring.
  
  Fig 14: Locating Brake Plate Stopper Spring Of Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft.

Bearing and race diameter

ITEM SPECIFICATION

Item	Inside	Outside
No. 7 thrust bearing race	33.4 mm (1.315 in.)	49 0 mm (1 929 in.)
Thrust needle roller bearing	32.1 mm (1.264 in.)	49.35 mm (1.943 in)
No. 8 thrust bearing race	32.1 mm (1.264 in.)	49.0 mm (1.929 in)

Fig 15: Identifying No. 8 Thrust Bearing Race And Thrust Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 3 ONE-WAY CLUTCH ASSEMBLY
1. Install the No. 3 one-way clutch assembly and one-way clutch inner race to the intermediate shaft.
  
  Fig 16: Identifying No. 3 One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTERMEDIATE SHAFT
1. Install the intermediate shaft with the No. 3 one-way clutch assembly to the case.
  
  Fig 17: Installing Intermediate Shaft With No. 3 One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the snap ring.
  SST 09350-30020 (09350-07050, 09350-07060)
  
  Fig 18: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CENTER PLANETARY GEAR ASSEMBLY

Install the center planetary gear assembly and planetary sun gear to the case.

Coat the thrust bearing race with ATF, and install it onto the center planetary ring gear.

Race diameter

ITEM SPECIFICATION

Item	Inside	Outside
Race	53.7 mm (2.114 in.)	74.0 m (2.913 in.)

Fig 19: Identifying Center Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL NO. 2 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to 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 to the case.
  
  Fig 20: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 BRAKE DISC
1. Install flange, 3 plates, 3 discs and brake piston return spring.
  Install in order: F - P - S - P - D - P - D
  
  HINT:
  
  P = Plate, D = Disc, F = Flange
  
  Fig 21: Identifying No. 2 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and press, install the No. 2 brake spring snap ring.
  SST 09351-40010
  
  Fig 22: Installing No. 2 Brake Spring Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them on 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 O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Install the brake piston return spring and the No. 1 brake piston with No. 1 brake cylinder on the transmission case.
  
  Fig 24: Identifying Brake Piston Return Spring And No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PISTON RETURN SPRING SNAP RING
1. Using SST and a press, install the brake piston return spring snap ring.
  SST 09351-40010
  
  Fig 25: Installing Brake Piston Return Spring Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 BRAKE DISC
1. Install the 3 plates, 3 discs and flange.
  Install in order: F - D - P - D - P - D - P - D - P - D - P - D
  
  HINT:
  
  P = Plate, D = Disc, F = Flange
  
  Fig 26: Identifying No. 1 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CENTER PLANETARY RING GEAR
1. Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear.
  
  Fig 27: Identifying Center Planetary Ring Gear And Front Planetary Ring Gear Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring.
  
  Fig 28: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT PLANETARY RING GEAR

Install the front planetary ring gear and the thrust needle roller bearing on the case.

Thrust needle roller bearing diameter

ITEM SPECIFICATION

Item	Inside	Outside
Thrust needle roller bearing	55.7 mm (2.193 in.)	76.4 mm (3.008 in.)

Fig 29: Identifying Front Planetary Ring Gear

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT PLANETARY GEAR ASSEMBLY

Install the thrust needle roller bearing and the thrust washer.

Coat the thrust race with ATF, and install it onto the front planetary ring gear.

Thrust needle roller bearing and race diameter

ITEM 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.)

Fig 30: Identifying Bearing And Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the front planetary gear assembly and one-way clutch inner race from the case.

Fig 31: Identifying Front Planetary Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON

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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a feeler gauge, measure the B-3 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 B-3 Brake Pack Clearance Between Snap Ring And Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Flange thickness

FLANGE THICKNESS CHART

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

INSTALL 2ND BRAKE PISTON
1. Coat 2 new O-rings with ATF, and install them to 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 O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and press, install the snap ring.
  SST 09351-40010
  
  NOTE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
  
  Fig 35: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE CYLINDER
1. Install the 2nd brake cylinder fro the case.
  
  Fig 36: Installing 2ND Brake Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ONE-WAY CLUTCH ASSEMBLY
1. Install the one-way clutch assembly and thrust washer to the case
  
  Fig 37: Identifying One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2ND BRAKE PISTON HOLE SNAP RING
1. Using SST, install the snap ring.
  SST 09350-30020 (09350-07060)
  
  Fig 38: Installing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 BRAKE DISC
1. Install the 2 flanges, the 4 discs, the 4 plates and cushion plate on 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 Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 BRAKE SNAP RING
1. Using a screwdriver, install the snap ring.
  
  Fig 40: Installing No. 3 Brake Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY
1. Coat the race with ATF, and install it onto the No. 2 clutch drum thrust washer.
2. Install the No. 2 one-way clutch assembly washer.
  
  Fig 41: Identifying No. 2 One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

Install the thrust needle roller bearing.

Coat the race with ATF, and install it onto the clutch drum and input shaft assembly.

Thrust needle roller bearing and diameter

THRUST NEEDLE ROLLER BEARING AND 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.)

Fig 42: Identifying Thrust Needle Roller Bearing And Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.

Fig 43: Installing Input Shaft Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL OIL PUMP ASSEMBLY

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

Thrust bearing race diameter

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 Of Front Oil Pump

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Coat a new O-ring with ATF, and install it around the oil pump assembly.
Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.
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 With ATF
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 10 bolts
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

Fig 46: Installing Oil Pump Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
1. Using SST, drive in 2 new oil seals.
  SST 09350-30020 (09350-07110)
2. Coat the oil seal lips with MP grease.
INSPECT INDIVIDUAL PISTON OPERATION INSPECTION (See INSPECTION )

Fig 47: Installing Manual Valve Lever Shaft Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
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 48: Identifying Manual Valve Lever And Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a hammer, tap in a new spring pin
  
  Fig 49: Tapping Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.
5. Make sure the shaft rotates smoothly.
  
  Fig 50: Aligning Manual Valve Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL SHAFT
1. Install the E-ring to the shaft.
2. Install the parking lock pawl, shaft and spring.
  
  Fig 51: Identifying E-ring To Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK ROD SUB-ASSEMBLY
1. Connect the parking lock rod to the manual valve lever.
  
  Fig 52: Installing Parking Lock Rod Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARKING LOCK PAWL BRACKET
1. Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.
  Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
  
  Fig 53: Installing Parking Lock Pawl Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Manual Valve Lever And Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL C-1 ACCUMULATOR VALVE

Coat a new O-ring with ATF, and install it to the piston.

Fig 55: Identifying C-1 Accumulator Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and accumulator valve to the hole.

Accumulator spring

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 And Accumulator Valve

INSTALL C-3 ACCUMULATOR PISTON

Coat a new O-ring with ATF, and install it to the piston.

Fig 57: Identifying C-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and accumulator piston to the hole.

Accumulator spring

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 And Accumulator Piston

INSTALL B-3 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF, and install them to the piston.

Fig 59: Identifying B-3 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and accumulator piston to the hole.

Accumulator spring

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 And Accumulator Piston

INSTALL C-2 ACCUMULATOR PISTON

Coat 2 new O-rings with ATF, and install them to the piston.

Fig 61: Identifying C-2 Accumulator Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the spring and accumulator piston to the hole.

Accumulator spring

SPRING SPECIFICATION

Spring	Free length Outer diameter	Color
C-2	62.0 mm (2.441 in.) 15.9 mm (03626 in.)	White

Fig 62: Identifying Spring And Accumulator Piston

INSTALL CHECK BALL BODY
1. Install the check ball body and the spring.
  
  Fig 63: Identifying Check Ball Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE DRUM GASKET
1. Install the 3 brake drum gaskets.
  
  Fig 64: Identifying Brake Drum Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSAXLE CASE GASKET
1. Install the 3 transaxle case gaskets.
  
  Fig 65: Identifying Transaxle Case Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION VALVE BODY ASSEMBLY
1. Align the groove of the manual valve with the pin of the lever.
  
  Fig 66: Identifying Manual Valve With Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 19 bolts.
  Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
  
  HINT:
  - Each bolt length is indicated bellow.
  - Bolt length:
    25 mm (0.98 in.) for bolt A
    
    36 mm (1.42 in.) for bolt B
    
    Fig 67: Locating Transmission Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL TRANSMISSION WIRE

Install a new O-ring to the transmission wire.
Install the transmission wire harness.
Install the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
Connect the solenoid connector.

Fig 68: Locating Transmission Wire Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Connect the 7 solenoid connectors.
Install the ATF temperature sensor.

Install the clamp and the 2 bolts.

Torque: Bolt A

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

Bolt B

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

HINT:

Each bolt length is indicated bellow.

Fig 69: Locating Solenoid Valves Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Bolt length:

36 mm (1.42 in.) for bolt A

12 mm (0.47 in.) for bolt B

Sensor wire harness:

WIRE HARNESS SPECIFICATION

Wire harness	Color
for linear control	Orange
for oil temp warning light	Blue

INSTALL VALVE BODY OIL STRAINER ASSEMBLY
1. Coat a new O-ring with ATF, and install them to 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: Locating Transmission Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION OIL CLEANER MAGNET
1. Install the 4 transmission oil cleaner magnets.
INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
1. Install a new gasket on 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: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 71: Identifying Transmission Oil Cleaner Magnets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE ADAPTER OIL SEAL
1. Using SST and a hammer, tap in a new oil seal
  SST 09226-10010
  
  Fig 72: Tapping Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CASE ADAPTER SUB-ASSEMBLY
1. Apply seal packing or equivalent to the 8 bolts
  Seal breadth: 1.0 to 1.5 mm (0.4 to 0.06 in.)
  
  Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
  
  Fig 73: Identifying Transmission Case Seal Packing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Standard bolt length:
  
  50 mm (1.969 in.) for bolt A
  
  45 mm (1.772 In.) for bolt B
  
  Fig 74: Identifying Transmission Case Adapter Sub-Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSMISSION HOUSING
1. Clean the threads of the bolts and the 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
  
  HINT:
  - Each bolt length is indicated bellow.
  - Bolt length:
    Bolt A: 14 mm
    
    Bolt B: 17 mm
    
    Bolt C: 14 mm
    
    Fig 75: Locating Automatic Transmission Housing Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE BREATHER TUBE
1. Install a new O-ring to 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: Locating Automatic Transaxle Breather Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SPEED SENSOR
1. Coat 2 new O-rings with ATF, and install it to the speed sensor.
2. Install the 2 speed sensor.
3. Install the 2 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 77: Locating Speed Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER TUBE UNION
1. Coat a new O-ring with ATF, and install it to oil cooler tube union.
2. Install the oil cooler tube union.
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Fig 78: Identifying Oil Cooler Tube Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
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 the nut.
  Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
  
  Fig 79: Identifying Park/Neutral Position Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.
  Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  
  Fig 81: Aligning Neutral Basic Line
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CONTROL SHAFT LEVER LH
1. Install the washer and the nut to the control shaft lever LH.
  Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
  
  Fig 83: Locating Washer And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002