AC60E AUTOMATIC TRANSMISSION / TRANSAXLE  AUTOMATIC TRANSMISSION UNIT(for 7GR-FKS)  REASSEMBLY  

Install the 2 brake plate stopper springs to the automatic transmission case sub-assembly.

NOTICE:

The shapes of the parts are different. Refer to the illustration when installing the parts.

1.083,0.469 0.917,0.167 0.917,0.167 0.698,0.167 false 2,0.365 1.906,0.188 1.906,0.188 1.688,0.188 false 1.49,0.104 1.802,0.302 0.313,0.198 10 false *1 0.469,0.083 0.781,0.281 0.313,0.198 10 false *2

*1	No. 4 Brake Piston
*2	Brake Reaction Sleeve

Install the No. 4 brake piston to the brake reaction sleeve.

NOTICE:

Be careful not to damage the O-rings.

0.99,1.323 1.188,0.438 1.188,0.438 1.354,0.438 false 1.26,1.542 1.583,0.698 1.583,0.698 1.792,0.698 false 1.406,0.365 1.604,0.604 0.198,0.24 10 false *1 1.854,0.625 2.052,0.865 0.198,0.24 10 false *2

*1	Brake Reaction Sleeve
*2	No. 4 Brake Piston

With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and No. 4 brake piston to the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the O-rings.

Coat a new O-ring with ATF, and install it to the 1st and reverse brake piston.

Install the 1st and reverse brake return spring sub-assembly to the automatic transmission case sub-assembly.

0.781,2.083 0.542,0.531 0.542,0.531 0.344,0.531 false 1.052,2 0.854,0.198 0.854,0.198 0.656,0.198 false 0.146,0.438 0.458,0.635 0.313,0.198 10 false *a 0.323,0.115 0.781,0.313 0.458,0.198 10 false SST

*a	Protective Tape

Place SST on the 1st and reverse brake return spring sub-assembly, and compress the 1st and reverse brake return spring sub-assembly.

SST

09380-60012  (09381-06030, 09381-05040, 09381-06040, 09381-06080, 09381-05050, 09381-06120, 09381-06130, 09381-06140)

0.844,0.5 1.354,0.5 false 0.844,0.781 1.354,0.781 false 0.802,2.125 1.313,2.125 false 0.813,2.438 1.323,2.438 false 0.615,0.427 0.927,0.625 0.313,0.198 10 false *1 0.615,0.719 0.927,0.917 0.313,0.198 10 false *2 0.615,2.052 0.927,2.25 0.313,0.198 10 false *3 0.615,2.354 0.927,2.552 0.313,0.198 10 false *4

*1	Thrust Needle Roller Bearing K
*2	Thrust Bearing Race K
*3	Thrust Needle Roller Bearing L
*4	Thrust Bearing Race L

Coat the thrust bearing race with ATF and install it to the automatic transmission case sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing K	21.0 (0.827)	41.5 (1.634)
Thrust Bearing Race K	23.13 (0.911)	41.5 (1.634)
Thrust Needle Roller Bearing L	43.55 (1.715)	61.0 (2.402)
Thrust Bearing Race L	47.1 (1.854)	67.1 (2.642)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

1.948,2.854 1.948,2.375 false 2.25,2.938 2.25,2.458 false 2.573,3.031 2.573,2.552 false 1.854,2.906 2.167,3.104 0.313,0.198 10 false *1 2.156,3.031 2.469,3.229 0.313,0.198 10 false *2 2.5,3.104 2.813,3.302 0.313,0.198 10 false *3

*1	Thrust Bearing Race M (Front Race)
*2	Needle Roller Bearing M
*3	Thrust Bearing Race M (Rear Race)

Coat the thrust needle roller bearing and 2 thrust bearing races with ATF and install them to the output shaft of the rear planetary gear assembly.

Bearing and Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race M (Front Race)	37.0 (1.457)	51.2 (2.016)
Thrust Needle Roller Bearing M	36.1 (1.421)	52.5 (2.067)
Thrust Bearing Race M (Rear Race)	36.1 (1.421)	51.0 (2.008)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

Using a snap ring expander, install the snap ring.

0.802,2.438 0.729,2.198 0.729,2.198 0.583,2.198 false 0.406,2.115 0.719,2.313 0.313,0.198 10 false *1

*1	Thrust Bearing Race M (Rear Race)
	Mark Area

Using a feeler gauge, measure the clearance between the snap ring and thrust bearing race.

Standard Clearance:

0.02 to 0.12 mm (0.000788 to 0.00472 in.)

If the clearance is outside the standard range, select another thrust bearing race that brings the clearance within the standard range.

HINT:

There are 12 different thicknesses for the thrust bearing race.

Race Thickness

Part No.	Mark	Thickness
35789-35060		3.80 mm (0.150 in.)
35789-50070		3.85 mm (0.152 in.)
35789-35070		3.90 mm (0.154 in.)
35789-50080		3.95 mm (0.156 in.)
35789-35080		4.00 mm (0.157 in.)
35789-50090		4.05 mm (0.159 in.)
35789-35090		4.10 mm (0.161 in.)
35789-50100		4.15 mm (0.163 in.)
35789-35100		4.20 mm (0.165 in.)
35789-50110		4.25 mm (0.167 in.)
35789-50120		4.30 mm (0.169 in.)
35789-50130		4.35 mm (0.171 in.)

1.979,0.219 2.656,0.219 false 1.979,0.406 2.656,0.406 false 1.99,2.51 2.365,2.51 2.365,2.51 2.365,0.406 false 1.979,0.771 2.365,0.771 false 1.979,1.125 2.365,1.125 false 1.979,1.469 2.365,1.469 false 1.979,1.823 2.365,1.823 false 1.979,2.167 2.365,2.167 false 0.51,0.573 1.188,0.573 false 1.188,2.313 0.813,2.313 0.813,2.313 0.813,0.573 false 0.813,0.927 1.198,0.927 false 0.813,1.271 1.198,1.271 false 0.813,1.604 1.198,1.604 false 0.813,1.958 1.198,1.958 false 2,2.708 2.677,2.708 false 2.688,0.104 3,0.26 0.313,0.156 10 false *1 2.688,0.302 3,0.458 0.313,0.156 10 false *2 0.354,0.469 0.667,0.625 0.313,0.156 10 false *3 2.729,2.583 3.042,2.74 0.313,0.156 10 false *1

*1	No. 4 Brake Flange
*2	No. 4 Brake Disc
*3	No. 4 Brake Plate

Install the 2 No. 4 brake flanges, 7 No. 4 brake discs and 6 No. 4 brake plates to the automatic transmission case sub-assembly.

NOTICE:

·

Make sure that the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are installed in the correct order.

·

Install the thicker No. 4 brake flange first, and then install the thinner one.

0.927,0.781 1.49,0.781 false 0.927,1.052 1.49,1.052 false 0.708,0.698 1.021,0.896 0.313,0.198 10 false *1 0.708,0.979 1.021,1.177 0.313,0.198 10 false *2

*1	Thrust Needle Roller Bearing J
*2	Thrust Bearing Race J (Rear Race)

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the intermediate shaft.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing J	32.1 (1.264)	49.35 (1.943)
Thrust Bearing Race J (Rear Race)	32.1 (1.264)	49.0 (1.929)

2.125,0.594 2.615,0.594 false 2.167,1.677 2.656,1.677 false 2.688,0.51 3,0.708 0.313,0.198 10 false *1 2.719,1.594 3.031,1.792 0.313,0.198 10 false *2

*1	Rear Planetary Ring Gear Flange Sub-assembly
*2	Rear Planetary Ring Gear

Install the rear planetary ring gear to the rear planetary ring gear flange sub-assembly.

2.396,0.563 2.708,0.563 false 2.771,0.479 3.083,0.677 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver, install the snap ring to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

NOTICE:

Be careful not to damage the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

HINT:

Tape the screwdriver tip before use.

0.958,0.896 1.479,0.896 false 0.75,0.813 1.063,1.01 0.313,0.198 10 false *1

*1	Thrust Bearing Race J (Front Race)

Coat the thrust bearing race with ATF and install it to the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race J (Front Race)	33.4 (1.315.)	49.0 (1.929)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

2.021,0.552 2.802,0.552 false 2.24,1.323 2.75,1.323 false 2.896,0.469 3.208,0.667 0.313,0.198 10 false *1 2.813,1.26 3.125,1.458 0.313,0.198 10 false *2

*1	One-way Clutch Inner Race
*2	No. 3 One-way Clutch Assembly

Install the one-way clutch inner race to the No. 3 one-way clutch assembly.

HINT:

Rotate the one-way clutch inner race clockwise to install it.

Install the No. 3 one-way clutch assembly with one-way clutch inner race to the automatic transmission case sub-assembly.

1.125,0.792 1.281,1.021 1.281,1.021 1.406,1.021 true 1.448,0.938 1.76,1.094 0.313,0.156 10 false *1 1.927,1.313 2.24,1.469 0.313,0.156 10 false *a 1.188,1.406 1.5,1.563 0.313,0.156 10 false *b

*1	Snap Ring
*a	19°
*b	49°
	Front Side

Using SST, install the snap ring to the automatic transmission case sub-assembly.

SST

09350-30020  (09350-07060)

NOTICE:

·

Install the snap ring so that the tapered side is facing out.

·

Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

With the No. 1 brake piston return spring sub-assembly installed to the No. 1 brake piston, align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston to the No. 1 brake cylinder.

Install the No. 1 brake cylinder with No. 1 brake piston to the automatic transmission case sub-assembly while making sure that the 2 claws of the No. 1 brake cylinder with No. 1 brake piston are positioned as shown in the illustration.

Align the 2 claws of the No. 1 brake piston return spring sub-assembly with the 2 claws of the No. 1 brake cylinder, and then install the No. 1 brake piston return spring sub-assembly to the No. 1 brake piston.

1.021,1.438 0.823,0.865 0.823,0.865 0.552,0.865 true 3.135,0.188 3.344,0.458 0.208,0.271 10 false *a 0.219,0.792 0.677,0.99 0.458,0.198 10 false SST

*a

Turn

Place SST on the No. 1 brake piston return spring sub-assembly, and compress the No. 1 brake piston return spring sub-assembly with a press.

SST

09380-60012  (09381-06010, 09381-06040, 09381-06050, 09381-06070, 09381-06090, 09381-06100, 09381-06110, 09381-06120)

0.333,1.625 0.646,1.781 0.313,0.156 10 false *a 0.427,0.917 0.74,1.073 0.313,0.156 10 false *b

*a	22.5°
*b	37.5°

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

·

Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

·

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

0.469,0.792 1.156,0.792 false 1.948,0.25 2.635,0.25 false 1.958,0.573 2.646,0.573 false 1.938,2.031 2.323,2.031 2.323,2.031 2.323,0.573 false 1.958,1.052 2.323,1.052 false 1.958,1.531 2.323,1.531 false 1.156,2.229 0.813,2.229 0.813,2.229 0.813,0.792 false 0.813,1.271 1.156,1.271 false 0.813,1.76 1.156,1.76 false 2.698,0.479 3.01,0.635 0.313,0.156 10 false *2 0.302,0.698 0.615,0.854 0.313,0.156 10 false *3 2.688,0.146 3,0.302 0.313,0.156 10 false *1

*1	No. 1 Brake Flange
*2	No. 1 Brake Disc
*3	No. 1 Brake Plate

Install the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates to the automatic transmission case sub-assembly.

NOTICE:

Make sure that the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are installed in the correct order.

1.479,0.167 1.792,0.323 0.313,0.156 10 false *a 2.125,0.219 2.438,0.375 0.313,0.156 10 false *b

*a	22.5°
*b	37.5°

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

·

Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

·

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Install the planetary sun gear to the automatic transmission case sub-assembly.

0.927,0.417 1.417,0.417 false 0.708,0.333 1.021,0.531 0.313,0.198 10 false *1

*1	Thrust Bearing Race I

Coat the thrust bearing race with ATF and install it to the center planetary gear assembly.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race I	53.7 (2.114)	74.0 (2.913)

2.25,0.479 2.729,0.479 false 2.323,1.438 2.74,1.438 false 2.823,0.406 3.135,0.604 0.313,0.198 10 false *1 2.813,1.354 3.125,1.552 0.313,0.198 10 false *2

*1	Center Planetary Ring Gear Flange
*2	Center Planetary Ring Gear

Install the center planetary ring gear to the center planetary ring gear flange.

1.417,0.417 1.854,0.417 false 1.927,0.323 2.24,0.521 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver, install the snap ring to the center planetary ring gear flange with center planetary ring gear.

NOTICE:

Be careful not to damage the center planetary ring gear flange with center planetary ring gear.

HINT:

Tape the screwdriver tip before use.

0.813,0.354 1.375,0.354 false 0.823,1.208 1.385,1.208 false 0.625,0.271 0.938,0.469 0.313,0.198 10 false *1 0.615,1.135 0.927,1.333 0.313,0.198 10 false *2

*1	Thrust Needle Roller Bearing H
*2	Thrust Needle Roller Bearing I

Coat the 2 thrust needle roller bearings with ATF and install them to the center planetary ring gear flange with center planetary ring gear.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing H	63.3 (2.492)	78.8 (3.102)
Thrust Needle Roller Bearing I	55.7 (2.193)	76.4 (3.008)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

1.896,0.25 2.542,0.25 false 1.896,0.49 2.542,0.49 false 1.896,2.063 2.25,2.063 2.25,2.063 2.25,0.49 false 0.542,0.698 1.167,0.698 false 1.896,0.896 2.25,0.896 false 1.896,1.281 2.25,1.281 false 1.896,1.667 2.25,1.667 false 1.167,1.885 0.854,1.885 0.854,1.885 0.854,0.698 false 1.896,2.26 2.563,2.26 false 0.854,1.49 1.156,1.49 false 0.854,1.094 1.156,1.094 false 2.594,0.156 2.906,0.313 0.313,0.156 10 false *1 2.594,0.396 2.906,0.552 0.313,0.156 10 false *2 0.375,0.604 0.688,0.76 0.313,0.156 10 false *3 2.615,2.167 2.927,2.323 0.313,0.156 10 false *1

*1	No. 2 Brake Flange
*2	No. 2 Brake Disc
*3	No. 2 Brake Plate

Install the 2 No. 2 brake flanges, 5 No. 2 brake discs and 4 No. 2 brake plates to the automatic transmission case sub-assembly.

NOTICE:

·

Make sure that the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are installed in the correct order.

·

Install the thicker No. 2 brake flange first, and then install the thinner one.

With the No. 2 brake piston return spring sub-assembly installed to the No. 2 brake piston, align the claw of the No. 2 brake piston return spring sub-assembly with the claw of the No. 2 brake cylinder, and then install the No. 2 brake piston to the No. 2 brake cylinder.

NOTICE:

Be careful not to damage the O-rings.

Install the No. 2 brake piston return spring sub-assembly to the automatic transmission case sub-assembly while making sure that the claw of the No. 2 brake piston return spring sub-assembly is positioned as shown in the illustration.

Install the No. 2 brake cylinder with No. 2 brake piston to the automatic transmission case sub-assembly while making sure that the claw of the No. 1 brake cylinder with No. 1 brake piston is positioned as shown in the illustration.

0.479,0.5 0.688,0.5 0.688,0.5 0.844,0.948 true 3.177,0.271 3.406,0.521 0.229,0.25 10 false *a 0.177,0.427 0.51,0.635 0.333,0.208 10 false SST

*a

Turn

Place SST on the No. 2 brake cylinder, and compress the No. 2 brake piston return spring sub-assembly with a press.

SST

09380-60012  (09381-06010, 09381-06020, 09381-06040, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120)

1.385,0.125 1.698,0.281 0.313,0.156 10 false *a 2.063,0.125 2.375,0.281 0.313,0.156 10 false *a

*a

30°

Using a screwdriver, install the snap ring to the automatic transmission case sub-assembly.

NOTICE:

·

Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the illustration.

·

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

2.125,3.396 2.625,3.396 false 2.167,2.552 2.625,2.552 false 2.167,4.052 2.604,4.052 false 2.698,2.469 3.01,2.667 0.313,0.198 10 false *1 2.698,3.313 3.01,3.51 0.313,0.198 10 false *2 2.688,3.979 3,4.177 0.313,0.198 10 false *3

*1	Front Planetary Ring Gear
*2	Snap Ring
*3	Front Planetary Ring Gear Flange Sub-assembly

Set the snap ring onto the front planetary ring gear flange sub-assembly. Using needle-nose pliers, insert the snap ring into the front planetary ring gear while squeezing it, and then expand the snap ring to install it.

NOTICE:

Make sure the snap ring is securely inserted into the groove of the front planetary ring gear.

0.875,0.313 1.406,0.313 false 0.875,1.219 1.406,1.219 false 0.667,0.25 0.979,0.448 0.313,0.198 10 false *1 0.667,1.146 0.906,1.354 0.24,0.208 10 false *2

*1	Thrust Needle Roller Bearing G
*2	Thrust Bearing Race H

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the front planetary ring gear with front planetary ring gear flange sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing G	63.3 (2.492)	78.8 (3.102)
Thrust Bearing Race H	66.3 (2.610)	78.9 (3.106)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

0.833,0.25 1.438,0.25 false 0.885,1.073 1.354,1.073 false 0.635,0.177 0.948,0.375 0.313,0.198 10 false *1 0.656,1.01 0.969,1.208 0.313,0.198 10 false *2

*1	Thrust Bearing Race F
*2	Thrust Bearing Race G

Coat the 2 thrust bearing races with ATF and install them to the front planetary gear assembly.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race F	44.0 (1.732)	62.8 (2.472)
Thrust Bearing Race G	65.8 (2.591)	86.3 (3.398)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

0.865,0.385 1.5,0.385 false 0.823,1.083 1.458,1.083 false 0.656,0.323 0.969,0.521 0.313,0.198 10 false *1 0.646,1.01 0.958,1.208 0.313,0.198 10 false *2

*1	Thrust Bearing Race E
*2	Thrust Needle Roller Bearing F

Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the sun gear input drum sub-assembly.

Thrust Needle Roller Bearing and Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race E	40.83 (1.607)	52.8 (2.079)
Thrust Needle Roller Bearing F	37.1 (1.461)	61.2 (2.409)

NOTICE:

Be sure to install the thrust needle roller bearing and thrust bearing race in the correct direction.

0.802,0.323 1.479,0.323 false 0.792,1.115 1.469,1.115 false 0.604,0.25 0.917,0.448 0.313,0.198 10 false *1 0.604,1.042 0.917,1.24 0.313,0.198 10 false *2

*1	Thrust Needle Roller Bearing D
*2	Thrust Needle Roller Bearing E

Coat the 2 thrust needle roller bearings with ATF and install them to the forward clutch hub sub-assembly.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing D	33.3 (1.311)	56.6 (2.228)
Thrust Needle Roller Bearing E	39.6 (1.559)	52.8 (2.079)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

0.875,0.333 1.438,0.333 false 0.917,1.104 1.375,1.104 false 0.688,0.26 1,0.458 0.313,0.198 10 false *1 0.688,1.031 1,1.229 0.313,0.198 10 false *2

*1	Thrust Bearing Race C
*2	Thrust Bearing Race D

Coat the 2 thrust bearing races with ATF and install them to the multiple disc clutch hub.

Thrust Bearing Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race C	22.6 (0.866)	44.8 (1.764)
Thrust Bearing Race D	38.4 (1.512)	56.5 (2.224)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

Install the direct clutch piston sub-assembly to the direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the O-rings.

2.156,0.344 2.427,0.344 false 2.021,1.021 2.479,1.021 false 2.5,0.281 2.813,0.479 0.313,0.198 10 false *1 2.542,0.948 2.854,1.146 0.313,0.198 10 false *2

*1	No. 2 Clutch Balancer
*2	Direct Clutch Return Spring Sub-assembly

Install the direct clutch return spring sub-assembly to the direct clutch piston sub-assembly.

1.094,0.677 0.781,0.167 0.781,0.167 1.396,0.333 true 0.469,0.094 0.854,0.281 0.385,0.188 10 false SST

Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.

SST

09380-60012  (09381-06030, 09381-06040, 09381-06080, 09381-06100, 09381-06110)

NOTICE:

Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

2.104,0.333 2.656,0.333 false 2.094,0.625 2.646,0.625 false 2.083,2.146 2.396,2.146 2.396,2.146 2.396,0.625 false 2.083,1.021 2.396,1.021 false 2.094,1.406 2.396,1.406 false 2.083,1.781 2.396,1.781 false 0.635,0.802 1.188,0.802 false 1.177,2.323 0.865,2.323 0.865,2.323 0.865,0.802 false 0.865,1.958 1.177,1.958 false 0.865,1.583 1.177,1.583 false 0.865,1.198 1.177,1.198 false 2.708,0.229 3.021,0.385 0.313,0.156 10 false *1 2.698,0.531 3.01,0.688 0.313,0.156 10 false *2 0.469,0.708 0.781,0.865 0.313,0.156 10 false *3

*1	Direct Clutch Flange
*2	No. 2 Clutch Disc
*3	No. 2 Clutch Plate

Install the 5 No. 2 clutch plates, 5 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.

NOTICE:

Make sure that the No. 2 clutch discs, No. 2 clutch plates and direct clutch flange are installed in the correct order.

2.521,0.604 2.74,0.604 false 2.802,0.531 3.115,0.729 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver, install the snap ring to the direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the direct clutch drum sub-assembly.

HINT:

Tape the screwdriver tip before use.

Install the forward clutch piston to the input shaft sub-assembly.

NOTICE:

Be careful not to damage the O-rings.

2.208,0.385 2.604,0.385 false 2.104,0.948 2.635,0.948 false 2.677,0.313 2.99,0.51 0.313,0.198 10 false *1 2.708,0.885 3.021,1.083 0.313,0.198 10 false *2

*1	No. 1 Clutch Balancer
*2	Forward Clutch Return Spring Sub-assembly

Install the forward clutch return spring sub-assembly and No. 1 clutch balancer to the input shaft sub-assembly.

NOTICE:

Be careful not to damage the O-ring.

2.625,1.188 3.031,1.729 3.031,1.729 2.74,0.781 true 2.938,1.771 3.26,1.958 0.323,0.188 10 true SST

Place SST on the No. 1 clutch balancer, and compress the forward clutch return spring sub-assembly with a press.

SST

09387-00110  

NOTICE:

Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

0.635,0.646 1.344,0.646 false 0.813,0.646 0.813,1.896 0.813,1.896 1.385,1.896 false 0.813,1.563 1.354,1.563 false 0.823,1.271 1.365,1.271 false 0.813,0.958 1.354,0.958 false 2.396,0.51 2.396,1.75 2.396,1.75 2.094,1.75 false 2.104,0.844 2.396,0.844 false 2.083,0.51 2.646,0.51 false 2.104,1.146 2.396,1.146 false 2.104,1.458 2.396,1.458 false 2.146,0.281 2.635,0.281 false 0.427,0.563 0.74,0.76 0.313,0.198 10 false *3 2.729,0.438 3.042,0.635 0.313,0.198 10 false *2 2.719,0.177 3.031,0.375 0.313,0.198 10 false *1

*1	Forward Clutch Flange
*2	No. 1 Clutch Disc
*3	No. 1 Clutch Plate

Install the 5 No. 1 clutch plates, 5 No. 1 clutch discs and forward clutch flange to the input shaft sub-assembly.

NOTICE:

Make sure that the No. 1 clutch discs, No. 1 clutch plates and forward clutch flange are installed in the correct order.

2.188,0.458 2.604,0.458 false 2.688,0.385 3,0.583 0.313,0.198 10 false *a

*a	Protective Tape

Using a screwdriver, install the snap ring.

NOTICE:

Be careful not to damage the input shaft sub-assembly.

HINT:

Tape the screwdriver tip before use.

Coat 3 new clutch drum oil seal rings with ATF and install them to the input shaft sub-assembly.

NOTICE:

Do not expand the clutch drum oil seal ring ends excessively.

HINT:

After installing the clutch drum oil seal rings, check that they rotate smoothly.

2.177,0.521 2.625,0.521 false 2.021,1.781 2.635,1.781 false 2.667,0.417 2.979,0.573 0.313,0.156 10 false *1 2.677,1.688 2.99,1.844 0.313,0.156 10 false *2

*1	Direct Clutch Drum Sub-assembly
*2	Input Shaft Sub-assembly

Install the direct clutch drum sub-assembly to the input shaft sub-assembly.

0.938,0.74 1.417,0.74 false 0.938,1.052 1.469,1.052 false 0.969,2.344 1.479,2.344 false 0.76,0.646 1.073,0.802 0.313,0.156 10 false *1 0.76,0.958 1.073,1.115 0.313,0.156 10 false *2 0.792,2.25 1.104,2.406 0.313,0.156 10 false *3

*1	Thrust Needle Roller Bearing A
*2	Thrust Needle Roller Bearing B
*3	Thrust Needle Roller Bearing C

Coat the 3 thrust needle roller bearings with ATF and install them to the clutch drum and input shaft assembly.

Thrust Needle Roller Bearing Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Needle Roller Bearing A	71.9 (2.831)	85.6 (3.370)
Thrust Needle Roller Bearing B	34.6 (1.362)	52.0 (2.047)
Thrust Needle Roller Bearing C	21.3 (0.839)	41.1 (1.618)

NOTICE:

Be sure to install the thrust needle roller bearing in the correct direction.

0.625,0.302 1.49,0.302 false 0.625,0.677 1.438,0.677 false 0.646,1.292 1.052,1.292 false 0.417,0.229 0.729,0.427 0.313,0.198 10 false *1 0.417,0.594 0.729,0.792 0.313,0.198 10 false *2 0.427,1.219 0.74,1.417 0.313,0.198 10 false *3

*1	Thrust Bearing Race B
*2	Thrust Bearing Race A
*3	Oil Pump O-ring

Coat the 2 thrust bearing races with ATF and install them to the oil pump assembly.

Race Diameter:

Item	Inside (mm (in.))	Outside (mm (in.))
Thrust Bearing Race B	40.0 (1.575)	52.8 (2.079)
Thrust Bearing Race A	74.2 (2.921)	87.74 (3.454)

NOTICE:

Be sure to install the thrust bearing race in the correct direction.

Install the oil pump assembly with the 10 bolts.

Torque:

21.1 N*m (215 kgf*cm, 16 ft.*lbf)

1.083,3.635 0.469,2.427 0.469,2.427 1.177,1.021 true 0.115,2.354 0.573,2.552 0.458,0.198 10 false SST

Using SST and a hammer, drive in 2 new manual valve lever shaft oil seals to the automatic transmission case sub-assembly.

SST

09350-30020  (09350-07110)

Standard Depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

0.844,0.646 0.948,0.208 0.948,0.208 1.177,0.208 false 0.656,1.708 0.875,1.708 0.875,1.708 1.115,1.219 false 1.26,0.146 1.573,0.344 0.313,0.198 10 false *1 0.458,1.625 0.771,1.823 0.313,0.198 10 false *2

*1	Manual Valve Lever Sub-assembly
*2	Spacer

Install a new spacer to the manual valve lever sub-assembly.

Using a hammer, drive in a new spring pin.

Using a 3 mm pin punch and a hammer, stake the spacer.

1.354,0.344 1.625,0.344 false 0.802,0.438 0.979,0.438 0.979,0.438 1.75,1.167 true 0.479,0.698 0.667,0.698 0.667,0.698 1.771,1.333 true 0.438,1.021 0.573,1.021 0.573,1.021 1.781,1.854 true 1.115,0.271 1.344,0.448 0.229,0.177 10 true *1 0.594,0.354 0.823,0.531 0.229,0.177 10 true *2 0.292,0.615 0.521,0.792 0.229,0.177 10 true *3 0.26,0.938 0.49,1.115 0.229,0.177 10 true *4

*1	Parking Lock Pawl
*2	E-ring
*3	Parking Lock Pawl Shaft
*4	Spring

Install the parking lock pawl, parking lock pawl shaft and spring to the automatic transmission case sub-assembly.

Install the parking lock rod sub-assembly to the manual valve lever sub-assembly.

Install the parking lock pawl bracket to the automatic transmission case sub-assembly with the 3 bolts.

Torque:

18 N*m (184 kgf*cm, 13 ft.*lbf)

Coat 2 new brake drum gaskets with ATF and install them to the automatic transmission case sub-assembly.

Install the automatic transmission housing to the automatic transmission case sub-assembly with the 8 bolts.

Torque:

33.9 N*m (346 kgf*cm, 25 ft.*lbf)

1.333,1.885 1.49,2.083 0.156,0.198 10 true A 1.885,1.875 2.042,2.073 0.156,0.198 10 true A 0.698,1.5 0.854,1.698 0.156,0.198 10 false B 2.469,1.635 2.625,1.833 0.156,0.198 10 false B

Install 4 bolts to the automatic transmission housing.

Torque:

for bolt A (M10 bolt) : 33.9 N*m (346 kgf*cm, 25 ft.*lbf)

for bolt B (M12 bolt) : 56.8 N*m (579 kgf*cm, 42 ft.*lbf)

0.896,0.313 1.333,0.615 1.333,0.615 1,1.052 true 1,0.74 1.333,0.615 false 1.406,0.531 1.865,0.729 0.458,0.198 10 false SST

Using SST and a press, install a new automatic transmission extension housing oil seal to the extension housing sub-assembly.

Standard Depth:

5.4 to 5.8 mm (0.213 to 0.228 in.)

SST

09950-60011  (09951-00460, 09951-00550, 09952-06010)
09950-70010  (09951-07150)
09710-14013  (09710-00021)

1.042,0.167 1.198,0.167 1.198,0.167 1.375,0.438 true 0.719,0.104 1.177,0.302 0.458,0.198 10 false SST

Using SST and a press, install a new extension housing dust deflector to the extension housing sub-assembly.

SST

09550-55012  (09550-05081)

0.583,0.823 0.948,0.823 true 0.365,0.75 0.677,0.948 0.313,0.198 10 false *a

*a	Seal Packing

Apply seal packing to the extension housing sub-assembly as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:

·

Apply seal packing in a continuous line (width 1.2 mm (0.0472 in.)) along the sealing surface.

·

After applying seal packing, install the extension housing sub-assembly to the automatic transmission case sub-assembly within 3 minutes and tighten the bolts within 10 minutes.

1.083,1.729 1.24,1.927 0.156,0.198 10 true A 1.708,1.823 1.865,2.021 0.156,0.198 10 true A 2.292,1.708 2.448,1.906 0.156,0.198 10 true A 0.896,1.063 1.052,1.26 0.156,0.198 10 true B 1.052,0.323 1.208,0.521 0.156,0.198 10 true B 1.698,0.073 1.854,0.271 0.156,0.198 10 true B 2.344,0.323 2.5,0.521 0.156,0.198 10 true B 2.521,1.063 2.677,1.26 0.156,0.198 10 true B

Install the extension housing sub-assembly to the automatic transmission case sub-assembly with the 8 bolts.

Torque:

33.9 N*m (346 kgf*cm, 25 ft.*lbf)

Bolt Length:

Bolt A	40 mm (1.57 in.)
Bolt B	45 mm (1.77 in.)

1,1.885 0.594,0.719 0.594,0.719 0.438,0.719 true 1.625,0.938 1.781,1.115 0.156,0.177 10 false *a 3.083,2.021 3.292,2.177 0.208,0.156 10 false *b 3.063,2.51 3.271,2.667 0.208,0.156 10 false *c 0.063,0.635 0.354,0.813 0.292,0.177 10 false SST 1.292,0.188 1.5,0.344 0.208,0.156 10 false *d 0.323,2.26 0.531,2.417 0.208,0.156 10 false *e

*a	Torque Wrench Fulcrum Length
*b	18° to 22°
*c	-2° to 2°
*d	Turn
*e	Hold

Using SST, install the 2 oil cooler tube unions to the automatic transmission case sub-assembly.

SST

09268-78010  

Specified tightening torque:

29.4 N*m (300 kgf*cm, 22 ft.*lbf)

HINT:

·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201902,999999,_V1,_078841,_0382392,RM100000001GTX7,

·

When using SST (fulcrum length of 34.5 mm (1.3583 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 24.7 N*m (252 kgf*cm, 18 ft.*lbf)

Coat 6 new O-rings with ATF, and install them to the 6 automatic transmission case plugs.

Using a T55 "TORX" socket wrench, install the automatic transmission case plug to the automatic transmission case sub-assembly.

Torque:

39.2 N*m (400 kgf*cm, 29 ft.*lbf)

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

Install the transmission control shaft lever LH to the manual valve lever shaft with the spring washer and nut.

Torque:

15.7 N*m (160 kgf*cm, 12 ft.*lbf)

0.677,0.406 0.677,0.115 0.677,0.115 0.854,0.115 false 1.833,0.99 1.833,0.667 1.833,0.667 2,0.667 false 2.844,1.385 2.844,1.094 2.844,1.094 3.021,1.094 false 2.427,1.875 2.792,1.875 false 0.896,0.01 1.208,0.167 0.313,0.156 10 false *1 2.063,0.594 2.375,0.75 0.313,0.156 10 false *2 3.063,1.01 3.375,1.167 0.313,0.156 10 false *3 2.229,1.792 2.542,1.948 0.313,0.156 10 false *4

*1	Breather Plug Sub-assembly
*2	Breather Plug Hose
*3	Breather Plug
*4	O-ring

Install the breather plug sub-assembly and breather plug to the breather plug hose.

Install the breather plug hose to the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the O-rings.