Toyota 4Runner manuals

Toyota 4Runner: Reassembly

REASSEMBLY

PROCEDURE

1. BEARING POSITION


Bearing and Race Diameter:

Mark

Front Race Diameter Inside/Outside

Thrust Bearing Diameter Inside/Outside

Rear Race Diameter Inside/Outside

A

74.3 to 74.6 mm (2.93 to 2.94 in.)/87.4 to 87.7 mm (3.44 to 3.45 in.)

72.0 to 72.3 mm (2.83 to 2.85 in.)/85.3 to 85.6 mm (3.36 to 3.37 in.)

-

B

37.0 to 37.3 mm (1.46 to 1.47 in.)/52.1 to 52.3 mm (2.05 to 2.06 in.)

34.7 to 34.9 mm (1.366 to 1.374 in.)/51.6 to 51.9 mm (2.03 to 2.04 in.)

-

C

-

21.4 to 21.6 mm (0.841 to 0.850 in.)/40.8 to 41.0 mm (1.606 to 1.614 in.)

22.7 to 22.9 mm (0.892 to 0.902 in.)/60.0 to 60.4 mm (2.36 to 2.38 in.)

D

33.3 to 33.5 mm (1.31 to 1.32 in.)/56.3 to 56.6 mm (2.22 to 2.23 in.)

38.5 to 38.7 mm (1.515 to 1.524 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.)

-

E

-

42.6 to 42.8 mm (1.68 to 1.69 in.)/60.8 to 61.1 mm (2.39 to 2.41 in.)

-

F

38.0 to 38.2 mm (1.496 to 1.504 in.)/56.5 to 57.0 mm (2.22 to 2.24 in.)

43.4 to 43.6 mm (1.71 to 1.72 in.)/58.0 to 58.4 mm (2.28 to 2.30 in.)

-

G

-

55.8 to 56.0 mm (2.197 to 2.204 in.)/76.1 to 76.4 mm (2.996 to 3.008 in.)

53.8 to 54.0 mm (2.12 to 2.13 in.)/73.7 to 74.0 mm (2.90 to 2.91 in.)

H

33.4 to 33.6 mm (1.31 to 1.32 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)

32.2 to 32.3 mm (1.268 to 1.272 in.)/49.0 to 49.2 mm (1.93 to 1.94 in.)

32.2 to 32.4 mm (1.27 to 1.28 in.)/48.7 to 49.0 mm (1.92 to 1.93 in.)

I

-

21.5 to 21.8 mm (0.846 to 0.858 in.)/40.5 to 40.8 mm (1.59 to 1.61 in.)

-

J

-

43.6 to 43.9 mm (1.72 to 1.73 in.)/60.6 to 60.9 mm (2.39 to 2.40 in.)

47.2 to 47.4 mm (1.86 to 1.87 in.)/66.9 to 67.1 mm (2.63 to 2.64 in.)

K

36.9 to 37.2 mm (1.45 to 1.46 in.)/49.4 to 50.0 mm (1.94 to 1.97 in.)

36.15 to 36.31 mm (1.42 to 1.43 in.)/52.06 to 52.36 mm (2.05 to 2.06 in.)

36.15 to 36.4 mm (1.42 to 1.43 in.)/50.5 to 51.0 mm (1.99 to 2.01 in.)

2. ASSEMBLE NO. 4 BRAKE PISTON AND BRAKE REACTION SLEEVE


(a) Coat 2 new O-rings with ATF and install them to the brake reaction sleeve.

(b) Coat 2 new O-rings with ATF and install them to the No. 4 brake piston.

Text in Illustration

*1

New O-Ring

(c) Install the No. 4 brake piston to the reaction sleeve.

3. INSTALL NO. 4 BRAKE PISTON WITH BRAKE REACTION SLEEVE


(a) Install the No. 4 brake piston with brake reaction sleeve to the transmission case.

NOTICE:

  • Do not damage the O-rings.
  • Make sure the No. 4 brake piston is underneath the brake reaction sleeve.

4. INSTALL 1ST AND REVERSE BRAKE PISTON


(a) Coat a new O-ring with ATF.

(b) Install the O-ring to the 1st and reverse brake piston.

(c) With the spring seat of the piston facing upwards (the front side), install the piston to the transmission case.

NOTICE:

Be careful not to damage the O-ring.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


(a) Install the brake return spring to the 1st and reverse brake piston.

(b) Place SST on the spring retainer and compress the return spring.

SST: 09350-30020

09350-07050


(c) Using SST, install the snap ring.

SST: 09350-30020

09350-07070

Text in Illustration

*1

Snap Ring

6. INSTALL REAR PLANETARY GEAR ASSEMBLY


(a) Install the No. 9 thrust bearing race.

Thrust Bearing Race Diameter:

Item

Inside

Outside

Race J

47.2 to 47.4 mm (1.86 to 1.87 in.)

66.9 to 67.1 mm (2.63 to 2.64 in.)

(b) Coat the 2 thrust needle roller bearings with petroleum jelly and install them to the rear planetary gear.

Thrust Needle Roller Bearing Diameter:

Item

Inside

Outside

Bearing J

43.6 to 43.9 mm (1.72 to 1.73 in.)

60.6 to 60.9 mm (2.39 to 2.40 in.)

Bearing I

21.5 to 21.8 mm (0.846 to 0.858 in.)

40.5 to 40.8 mm (1.59 to 1.61 in.)

Text in Illustration

*1

Bearing I

*2

Bearing J


(c) Install the rear planetary gear assembly.


(d) Install the rear planetary flange thrust bearing race, thrust needle roller bearing and thrust bearing selective race.

Text in Illustration

*1

Race K

*2

Bearing K

*2

Selective Race


(e) Using a snap ring expander, install the snap ring.


(f) Using a dial indicator, measure the rear planetary gear end play.


Standard end play:

0.02 to 0.12 mm (0.000787 to 0.00472 in.)

If the end play is not as specified, replace the thrust bearing race shown in the illustration with one of a different thickness so that the measured value is within the standard range.

HINT:

Use the table below to select a thrust bearing race of an appropriate thickness.

Bearing Race Thickness:













Mark

Thickness

3.775 to 3.825 mm (0.149 to 0.151 in.)

3.825 to 3.875 mm (0.151 to 0.153 in.)

3.875 to 3.925 mm (0.153 to 0.155 in.)

3.925 to 3.975 mm (0.155 to 0.156 in.)

3.975 to 4.025 mm (0.156 to 0.158 in.)

4.025 to 4.075 mm (0.158 to 0.160 in.)

4.075 to 4.125 mm (0.160 to 0.162 in.)

4.125 to 4.175 mm (0.162 to 0.164 in.)

4.175 to 4.225 mm (0.164 to 0.166 in.)

4.225 to 4.275 mm (0.166 to 0.168 in.)

4.275 to 4.325 mm (0.168 to 0.170 in.)

4.325 to 4.375 mm (0.170 to 0.172 in.)

7. SELECT 1ST AND REVERSE BRAKE FLANGE

(a) Using a vernier caliper, measure distance A (from the top surface of the 1st and reverse brake piston to the step in the transmission case) in the illustration.

NOTICE:

Make sure the 1st and reverse brake piston is installed securely to the transmission case.

HINT:

Distance A = 36.35 to 37.09 mm (1.43 to 1.46 in.)


(b) Assemble the 2 flanges, 8 discs and 7 plates, and using a vernier caliper, measure distance B in the illustration at both ends across the diameter, and calculate the average.

HINT:

Distance B = 36.04 to 37.14 mm (1.42 to 1.46 in.)


(c) Select a 1st and reverse brake flange so that the value of measured distance A minus distance B is 2.85 to 3.15 mm (0.112 to 0.124 in.).

Flange H Thickness:

No.

Thickness

0

0 mm (0 in.)

2

0.15 to 0.25 mm (0.00590 to 0.00984 in.)

4

0.35 to 0.45 mm (0.0138 to 0.0177 in.)

6

0.55 to 0.65 mm (0.0217 to 0.0256 in.)

8

0.75 to 0.85 mm (0.0295 to 0.0335 in.)

10

0.95 to 1.05 mm (0.0374 to 0.0413 in.)

12

1.15 to 1.25 mm (0.0453 to 0.0492 in.)

14

1.35 to 1.45 mm (0.0531 to 0.0571 in.)

8. INSTALL NO. 4 BRAKE DISC


(a) Install the 2 flanges, 8 discs and 7 plates.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

Text in Illustration

*1

Flange

*2

Disc

*2

Plate

9. INSTALL BRAKE PLATE STOPPER SPRING


10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


(a) Install the thrust bearing race, thrust needle roller bearing, thrust bearing race and planetary ring gear flange to the intermediate shaft.

Thrust Needle Roller Bearing and Race Diameter:

Item

Inside

Outside

Race H Rear

32.2 to 32.4 mm (1.27 to 1.28 in.)

48.7 to 49.0 mm (1.92 to 1.93 in.)

Bearing H

32.2 to 32.3 mm (1.268 to 1.272 in.)

49.0 to 49.2 mm (1.93 to 1.94 in.)

Race H Front

33.4 to 33.6 mm (1.31 to 1.32 in.)

48.7 to 49.0 mm (1.92 to 1.93 in.)

Text in Illustration

*1

Race H Rear

*2

Race H Front

11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY


(a) Install the 1-way clutch and 1-way clutch inner race to the intermediate shaft.

12. INSTALL INTERMEDIATE SHAFT


(a) Install the intermediate shaft with No. 3 1-way clutch assembly to the case.

(b) Using SST, install the snap ring.

SST: 09350-30020

09350-07060


13. INSTALL CENTER PLANETARY GEAR ASSEMBLY


(a) Install the planetary sun gear and center planetary gear to the case.

(b) Coat the thrust bearing race with petroleum jelly and install it to the center planetary gear.

Thrust Bearing Race Diameter:

Item

Inside

Outside

Race G

53.8 to 54.0 mm (2.12 to 2.13 in.)

73.7 to 74.0 mm (2.90 to 2.91 in.)

14. INSTALL NO. 2 BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them to the brake piston.

Text in Illustration

*1

New O-Ring


(b) Press the brake piston into the brake cylinder with both hands.

NOTICE:

Be careful not to damage the O-rings.

(c) Install the No. 2 brake piston to the case.

15. INSTALL NO. 2 BRAKE DISC


(a) Install the brake piston return spring.

(b) Install the 3 plates, 3 discs and flange.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *3

Text in Illustration

*1

Disc

*2

Plate

*2

Flange

(c) Using SST and a press, compress the return spring and install the No. 2 brake spring snap ring.

SST: 09351-40010


16. INSTALL NO. 1 BRAKE PISTON


(a) Coat 2 new O-rings with ATF and install them to the brake piston.

Text in Illustration

*1

New O-Ring

(b) Press the brake piston into the brake cylinder with both hands.

NOTICE:

Be careful not to damage the O-rings.

17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


(a) Install the No. 1 brake piston with No. 1 brake cylinder and the brake piston return spring to the transmission case.

18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING


(a) Using SST and a press, compress the return spring and install the brake piston return spring snap ring.

SST: 09351-40010

19. SELECT NO. 1 BRAKE FLANGE

(a) Using a feeler gauge, measure the distance between the snap ring and flange.

HINT:

0.42 to 0.72 mm (0.0165 to 0.0283 in.)

If the distance is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the distance is still outside the specification, select No. 1 brake flange so that the value of measured distance is 0.42 to 0.72 mm (0.0165 to 0.0283 in.).

Flange Thickness:

Mark

Thickness

0

1.95 to 2.05 mm (0.0768 to 0.0807 in.)

1

2.15 to 2.25 mm (0.0846 to 0.0886 in.)

2

2.35 to 2.45 mm (0.0925 to 0.0965 in.)

3

2.55 to 2.65 mm (0.100 to 0.104 in.)


20. INSTALL NO. 1 BRAKE DISC


(a) Install the 3 plates, 3 discs and flange.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *3

Text in Illustration

*1

Plate

*2

Disc

*3

Flange

21. INSTALL CENTER PLANETARY RING GEAR

(a) Install the center planetary ring gear and front planetary ring gear flange to the front planetary ring gear.


(b) Using a screwdriver, install the snap ring.


22. INSTALL FRONT PLANETARY RING GEAR


(a) Install the thrust needle roller bearing and front planetary ring gear to the case.

Thrust Needle Roller Bearing Diameter:

Item

Inside

Outside

Bearing G

55.8 to 56.0 mm (2.197 to 2.204 in.)

76.1 to 76.4 mm (2.996 to 3.008 in.)

23. INSTALL FRONT PLANETARY GEAR ASSEMBLY


(a) Install the thrust washer and thrust needle roller bearing.

(b) Coat the No. 5 thrust race with petroleum jelly and install it to the front planetary ring gear.

Thrust Needle Roller Bearing and Race Diameter:

Item

Inside

Outside

Bearing F

43.4 to 43.6 mm (1.71 to 1.72 in.)

58.0 to 58.4 mm (2.28 to 2.30 in.)

Race F

38.0 to 38.2 mm (1.496 to 1.504 in.)

56.5 to 57.0 mm (2.22 to 2.24 in.)

Text in Illustration

*1

Bearing F

*2

Race F

(c) Install the front planetary gear assembly and 1-way clutch inner race to the case.


24. INSTALL 2ND BRAKE PISTON


(a) Coat 2 new O-rings with ATF and install them to the 2nd brake piston.

Text in Illustration

*1

New O-Ring

(b) Press the 2nd brake cylinder into the 2nd brake piston with both hands.

NOTICE:

Be careful not to damage the O-rings.

(c) Install the return spring to the 2nd brake cylinder.

(d) Using SST and a press, compress the return spring and install the snap ring.

SST: 09351-40010

NOTICE:

Make sure the end gap of the snap ring is not aligned with the spring retainer claw.


25. INSTALL 2ND BRAKE CYLINDER


(a) Install the 2nd brake cylinder to the case.

26. INSTALL 1-WAY CLUTCH ASSEMBLY


(a) Install the thrust washer and 1-way clutch to the case.

27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING


(a) Using SST, install the snap ring.

SST: 09350-30020

09350-07060

28. INSTALL NO. 3 BRAKE DISC


(a) Install the cushion plate, 4 plates, 4 discs and flange to the case.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *4

Text in Illustration

*1

Cushion Plate

*2

Plate

*3

Disc

*4

Flange

29. INSTALL NO. 3 BRAKE SNAP RING


(a) Using a screwdriver, install the snap ring.

30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY


(a) Coat 2 new O-rings with ATF and install them to the direct clutch piston.

Text in Illustration

*1

New O-Ring

(b) Install the direct clutch return spring and No. 2 clutch balancer to the direct clutch piston.


(c) Press the direct clutch piston into the clutch drum with both hands.

NOTICE:

Be careful not to damage the O-rings.

(d) Place SST on the direct clutch piston and compress the return spring with a press.

NOTICE:

Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring sheet from being deformed.

SST: 09320-89010

SST: 09350-30020

09350-07070


(e) Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

(f) Position the end gap of the snap ring as shown in the illustration

Text in Illustration

*1

Stopper

NOTICE:

Make sure the end gap of the snap ring is not aligned with the spring retainer claw.


31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the clutch drum.

Text in Illustration

*1

New O-Ring


(b) Coat a new O-ring with ATF and install it to the reverse clutch piston.

Text in Illustration

*1

New O-Ring


(c) Press the clutch drum into the reverse clutch piston with both hands.

NOTICE:

Be careful not to damage the O-ring.


32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the reverse clutch piston.

Text in Illustration

*1

New O-Ring


(b) Install the reverse clutch return spring to the reverse clutch piston.

33. INSTALL NO. 3 CLUTCH BALANCER

(a) Place SST on the No. 3 clutch balancer and compress the clutch balancer with a press.

SST: 09387-00070

SST: 09350-30020

09350-07070

NOTICE:

Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.


(b) Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

(c) Position the end gap of the snap ring as shown in the illustration.

NOTICE:

Make sure the end gap of the snap ring is not aligned with the spring retainer claw.


34. INSTALL DIRECT CLUTCH DISC


(a) Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *3

Text in Illustration

*1

Plate

*2

Disc

*3

Flange

(b) Using a screwdriver, install the snap ring to the clutch drum.


(c) Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air into the oil hole as shown in the illustration.

Standard moving distance (A):

0.55 to 0.85 mm (0.0217 to 0.0335 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.

If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

Flange Thickness:

Mark

Thickness

2

2.95 to 3.05 mm (0.116 to 0.120 in.)

3

3.05 to 3.15 mm (0.120 to 0.124 in.)

4

3.15 to 3.25 mm (0.124 to 0.128 in.)

5

3.25 to 3.35 mm (0.128 to 0.132 in.)

6

3.35 to 3.45 mm (0.132 to 0.136 in.)

7

3.45 to 3.55 mm (0.136 to 0.140 in.)

8

3.55 to 3.65 mm (0.140 to 0.144 in.)

9

3.65 to 3.75 mm (0.144 to 0.148 in.)

A

3.75 to 3.85 mm (0.148 to 0.152 in.)


(d) Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.

35. SELECT REVERSE CLUTCH FLANGE


(a) Using a screwdriver, install the snap ring to the clutch drum.

NOTICE:

Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.

(b) Install the 2 flanges, 5 discs, 4 plates, cushion plate and reverse clutch reaction sleeve to the clutch drum.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1 - *4

Text in Illustration

*1

Flange

*2

Disc

*3

Plate

*4

Cushion Plate


(c) Using a screwdriver, install the hole snap ring.


(d) Using a dial indicator, measure the moving distance (A minus B) of the top surface of the reverse clutch piston (A) and cushion plate at both ends across the diameter (B) while applying compressed air (392 kPa, 4.0 kgf/ cm2, 57 psi) into the oil hole as shown in the illustration. Then choose a flange of an appropriate thickness from the table so that the measured value is within the standard range.


Standard moving distance (A minus B):

0.56 to 0.86 mm (0.0220 to 0.0339 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position indicated by the shaded area in the illustration.

HINT:

Distance (A) = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

Distance (B) = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

Flange Thickness:

Mark

Thickness

0

2.75 to 2.85 mm (0.108 to 0.112 in.)

1

2.85 to 2.95 mm (0.112 to 0.116 in.)

2

2.95 to 3.05 mm (0.116 to 0.120 in.)

3

3.05 to 3.15 mm (0.120 to 0.124 in.)

4

3.15 to 3.25 mm (0.124 to 0.128 in.)

5

3.25 to 3.35 mm (0.128 to 0.132 in.)

6

3.35 to 3.45 mm (0.132 to 0.136 in.)

7

3.45 to 3.55 mm (0.136 to 0.140 in.)

8

3.55 to 3.65 mm (0.140 to 0.144 in.)

9

3.65 to 3.75 mm (0.144 to 0.148 in.)

A

3.75 to 3.85 mm (0.148 to 0.152 in.)

(e) Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.


36. REMOVE REVERSE CLUTCH REACTION SLEEVE


(a) Using a screwdriver, remove the snap ring from the clutch drum.

(b) Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the reverse clutch hub.


37. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat 3 new oil seal rings with ATF.


(b) Squeeze the ends of the 3 oil seal rings together, and then install them to the starter shaft groove.

NOTICE:

Do not excessively widen the rings.

HINT:

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

38. INSTALL FORWARD CLUTCH PISTON


(a) Coat 2 new O-rings with ATF and install them to the forward clutch piston.

Text in Illustration

*1

New O-Ring

(b) Install the forward clutch piston to the input shaft.

39. INSTALL NO. 1 CLUTCH BALANCER


(a) Coat a new O-ring with ATF and install it to the clutch balancer.

Text in Illustration

*1

New O-Ring

(b) Install the forward clutch return spring and clutch balancer.

NOTICE:

Be careful not to damage the O-ring.


(c) Place SST on the No. 1 clutch balancer and compress the return spring with a press.

SST: 09350-30020

09350-07040

09350-07070

NOTICE:

Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.


(d) Install the snap ring with a snap ring expander.

NOTICE:

Do not expand the snap ring excessively.

(e) Position the end gap of the snap ring as shown in the illustration.

NOTICE:

Make sure the end gap of the snap ring is not aligned with the spring retainer claw.


40. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC


(a) Install the 2 flanges, 6 discs and 5 plates to the input shaft assembly.

Install in order:

*1 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *3 - *2 - *1

Text in Illustration

*1

Flange

*2

Disc

*3

Plate

(b) Using a screwdriver, temporarily install the snap ring.


(c) Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while applying compressed air into the oil hole as shown in the illustration.

Standard moving distance (A):

0.61 to 0.91 mm (0.0240 to 0.0358 in.)

NOTICE:

When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position indicated by the shaded area in the illustration.

HINT:

Moving distance (A): 0.26 to 1.36 mm (0.0102 to 0.0535 in.)

If the moving distance (A) is not as specified, select a flange of an appropriate thickness from the table below so that the measured value is within the standard range.

Flange Thickness:

Mark

Thickness

0

2.95 to 3.05 mm (0.116 to 0.120 in.)

1

3.05 to 3.15 mm (0.120 to 0.124 in.)

2

3.15 to 3.25 mm (0.124 to 0.128 in.)

3

3.25 to 3.35 mm (0.128 to 0.132 in.)

4

3.35 to 3.45 mm (0.132 to 0.136 in.)

5

3.45 to 3.55 mm (0.136 to 0.140 in.)

6

3.55 to 3.65 mm (0.140 to 0.144 in.)

7

3.65 to 3.75 mm (0.144 to 0.148 in.)

8

3.75 to 3.85 mm (0.148 to 0.152 in.)

9

3.85 to 3.95 mm (0.148 to 0.152 in.)

A

3.95 to 4.05 mm (0.152 to 0.159 in.)


(d) Temporarily remove the snap ring, replace the flange with the selected flange and reinstall the snap ring.

41. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the input shaft to the clutch drum.


(b) Install the thrust needle roller bearing to the clutch drum.

Thrust Needle Roller Bearing Diameter:

Item

Inside

Outside

Bearing C

21.4 to 21.6 mm (0.841 to 0.850 in.)

40.8 to 41.0 mm (1.606 to 1.614 in.)


42. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Coat the 2 thrust bearing races with petroleum jelly and install them to the multiple disc clutch hub.

Thrust Bearing Race Diameter:

Item

Inside

Outside

Race C

22.7 to 22.9 mm (0.892 to 0.902 in.)

60.0 to 60.4 mm (2.36 to 2.38 in.)

Race D

33.3 to 33.5 mm (1.31 to 1.32 in.)

56.3 to 56.6 mm (2.22 to 2.23 in.)

Text in Illustration

*1

Race C

*2

Race D


(b) Install the multiple disc clutch hub to the clutch drum.


43. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

(a) Coat the 2 thrust needle roller bearings with petroleum jelly and install them to the forward clutch hub.

Thrust Needle Roller Bearing Diameter:

Item

Inside

Outside

Bearing D

38.5 to 38.7 mm (1.515 to 1.524 in.)

56.5 to 57.0 mm (2.22 to 2.24 in.)

Bearing E

42.6 to 42.8 mm (1.68 to 1.69 in.)

60.8 to 61.1 mm (2.39 to 2.41 in.)

Text in Illustration

*1

Bearing D

*2

Bearing E


(b) Install the forward clutch hub to the clutch drum.


44. INSTALL REAR CLUTCH DISC

(a) Install the 5 discs, 4 plates, reverse clutch flange and clutch cushion plate to the reverse clutch hub.

Install in order:

*1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *3 - *4

Text in Illustration

*1

Disc

*2

Plate

*3

Flange

*4

Cushion Plate


45. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve to the reverse clutch hub.


46. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Install the reverse clutch hub to the clutch drum.


(b) Using a screwdriver, install the snap ring to the clutch drum and input shaft.


47. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY

(a) Coat the No. 2 clutch drum thrust washer with petroleum jelly and install it to the clutch drum.


(b) Install the 1-way clutch to the clutch drum.

48. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY


(a) Coat the 2 thrust needle roller bearings and clutch drum thrust washer with petroleum jelly and install them to the clutch drum and input shaft assembly.

Thrust Needle Roller Bearing Diameter:

Item

Inside

Outside

Bearing A

72.0 to 72.3 mm (2.83 to 2.85 in.)

85.3 to 85.6 mm (3.36 to 3.37 in.)

Bearing B

34.7 to 34.9 mm (1366 to 1.374 in.)

51.6 to 51.9 mm (2.03 to 2.04 in.)

Text in Illustration

*1

Bearing A

*2

Bearing B

(b) Install the clutch drum and input shaft assembly to the transmission case.


49. INSTALL OIL PUMP ASSEMBLY


(a) Coat the No. 1 and No. 2 thrust bearing races with petroleum jelly and install them to the front oil pump.

Thrust Bearing Race Diameter:

Item

Inside

Outside

Race A

74.3 to 74.6 mm (2.93 to 2.94 in.)

87.4 to 87.7 mm (3.44 to 3.45 in.)

Race B

37.0 to 37.3 mm (1.46 to 1.47 in.)

52.1 to 52.3 mm (2.05 to 2.06 in.)

Text in Illustration

*1

Race A

*2

Race B

(b) Coat a new O-ring with ATF and install it to the oil pump assembly.

Text in Illustration

*1

New O-Ring


(c) Slide the oil pump onto the input shaft, align the bolt holes of the oil pump assembly with the bolt holes of the transmission case and install the oil pump.

(d) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

NOTICE:

Do not excessively push on the oil pump, as the oil seal rings will stick to the direct clutch drum.

(e) Install the 10 bolts.

Torque:

21 N·m {215 kgf·cm, 16 ft·lbf}


50. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL


(a) Using SST and a hammer, tap in 2 new oil seals.

SST: 09350-30020

09350-07110

(b) Coat the lips of the oil seals with MP grease.

51. INSPECT INDIVIDUAL PISTON OPERATION


52. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY


(a) Install a new spacer to the manual valve lever.

Text in Illustration

*1

Spacer

*2

Manual Valve Lever

(b) Push the manual valve lever shaft through the transmission case, and install the manual valve lever to the manual valve lever shaft.

(c) Using a hammer, tap in a new spring pin.


(d) Align the manual valve lever indentation with the spacer hole, and stake them together with a punch.


(e) Check that the shaft rotates smoothly.

53. INSTALL PARKING LOCK PAWL SHAFT


(a) Install the E-ring to the shaft.

(b) Install the parking lock pawl, shaft and spring.

Text in Illustration

*1

E-Ring

*2

Parking Lock Pawl

*3

Spring

54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


(a) Connect the parking lock rod to the manual valve lever to install it.

55. INSTALL PARKING LOCK PAWL BRACKET


(a) Install the parking lock pawl bracket to the transmission case with the 3 bolts.

Torque:

7.4 N·m {75 kgf·cm, 65 in·lbf}

(b) Move the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked by the lock pawl.

Text in Illustration

*1

Manual Valve Lever

*2

Planetary Ring Gear

*3

Parking Lock Pawl


56. INSTALL C-1 ACCUMULATOR VALVE

(a) Install the 2 springs and accumulator valve to the hole.

Accumulator Spring Diameter:

Spring

Free Length

Outer Diameter

Color

C-1 Inner

30.40 mm (1.20 in.)

11.40 mm (0.449 in.)

Pink

C-1 Outer

48.76 mm (1.92 in.)

16.60 mm (0.654 in.)

Light Green


57. INSTALL C-3 ACCUMULATOR PISTON


(a) Coat 2 new O-rings with ATF and install them to the piston.

Text in Illustration

*1

New O-Ring

(b) Install the 2 springs and accumulator piston to the hole.

Accumulator Spring Diameter:

Spring

Free Length

Outer Diameter

Color

C-3 Inner

44.0 mm (1.73 in.)

14.0 mm (0.551 in.)

Yellow

C-3 Outer

73.35 mm (2.89 in.)

19.90 mm (0.784 in.)

Red

58. INSTALL B-3 ACCUMULATOR PISTON


(a) Coat 2 new O-rings with ATF and install them to the piston.

Text in Illustration

*1

New O-Ring

(b) Install the spring and accumulator piston to the hole.

Accumulator Spring Diameter:

Spring

Free Length

Outer Diameter

Color

B-3

70.5 mm (2.78 in.)

19.7 mm (0.776 in.)

Purple

59. INSTALL C-2 ACCUMULATOR PISTON


(a) Coat 2 new O-rings with ATF and install them to the piston.

Text in Illustration

*1

New O-Ring

(b) Install the spring and accumulator piston to the hole.

Accumulator Spring Diameter:

Spring

Free Length

Outer Diameter

Color

C-2

62.0 mm (2.44 in.)

15.9 mm (0.626 in.)

White

60. INSTALL BRAKE DRUM GASKET


(a) Install the 3 brake drum gaskets.

61. INSTALL TRANSMISSION CASE GASKET


(a) Install the 3 transmission case gaskets.

62. INSTALL CHECK BALL BODY


(a) Install the spring and check ball body.

Text in Illustration

*1

Spring

*2

Check Ball Body

63. INSTALL TRANSMISSION VALVE BODY ASSEMBLY


(a) Insert the pin of the manual valve into the hole of the manual valve lever.

Text in Illustration

*1

Pin

(b) Install the transmission valve body assembly with the 19 bolts.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

HINT:

Each bolt length is indicated below.

36 mm (1.42 in.) for bolt A

25 mm (0.984 in.) for bolt B


(c) Install the detent spring and detent spring cover with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

64. INSTALL TRANSMISSION WIRE


(a) Coat a new O-ring with ATF and install it to the transmission wire connector.

(b) Install the transmission wire harness.

(c) Install the bolt.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

(d) Connect the 7 solenoid connectors.


(e) Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.

Torque:

for bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

for bolt B :

11 N·m {112 kgf·cm, 8 ft·lbf}

Text in Illustration

*1

No. 1 Temperature Sensor

*2

No. 2 Temperature Sensor

HINT:

Each bolt length is indicated below.

12 mm (0.472 in.) for bolt A

36 mm (1.42 in.) for bolt B

Sensor Wire Harness

Wire Harness

Color

No. 1 temperature sensor

Orange

No. 2 temperature sensor

Blue

65. INSTALL VALVE BODY OIL STRAINER ASSEMBLY


(a) Coat a new O-ring with ATF and install it to the valve body oil strainer assembly.

(b) Install the oil strainer with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

66. INSTALL TRANSMISSION OIL CLEANER MAGNET


(a) Install the 4 magnets.

Text in Illustration

*1

Magnet

67. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

(a) Install a new gasket to the oil pan.

(b) Install the oil pan with the 20 bolts.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

(c) Install the drain plug.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

68. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


(a) Coat the lip of a new oil seal with ATF.

(b) Using SST and a hammer, tap in the oil seal.

SST: 09710-30050

SST: 09950-70010

09951-07100

Standard depth:

5.4 to 5.8 mm (0.213 to 0.228 in.)

69. INSTALL EXTENSION HOUSING DUST DEFLECTOR


(a) Using SST and a hammer, tap in a new dust deflector.

SST: 09223-15020

SST: 09950-70010

09951-07100

70. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

(a) Clean the threads of the bolts and case with non residue solvent.

(b) Apply seal packing to the extension housing.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or equivalent

Seal diameter:

1.0 to 1.5 mm (0.0394 to 0.0591 in.)

Text in Illustration

*1

Seal Packing


(c) Apply adhesive to the threads of the 6 bolts.

Adhesive:

Toyota Genuine Adhesive 1324,

Three Bond 1324 or equivalent

(d) Install the extension housing with the 6 bolts.

Torque:

34 N·m {345 kgf·cm, 25 ft·lbf}

HINT:

Each bolt length is indicated below.

45 mm (1.77 in.) for bolt A

35 mm (1.38 in.) for bolt B


71. INSTALL AUTOMATIC TRANSMISSION HOUSING


(a) Clean the threads of the bolts and case with non-residue solvent.

(b) Install the transmission housing with the 10 bolts.

Torque:

for 14 mm head bolt A :

34 N·m {345 kgf·cm, 25 ft·lbf}

for 17 mm head bolt B :

57 N·m {579 kgf·cm, 42 ft·lbf}

for 14 mm head bolt C :

34 N·m {345 kgf·cm, 25 ft·lbf}

72. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE


(a) Coat a new O-ring with ATF and install it to the breather tube.

(b) Install the breather tube with the 2 bolts.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

73. INSTALL SPEED SENSOR

(a) Coat 2 new O-rings with ATF and install one to each speed sensor.


(b) Install the 2 speed sensors.

(c) Install the 2 bolts.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

74. INSTALL OIL COOLER TUBE UNION

(a) Coat a new O-ring with ATF and install one to each oil cooler tube union.


(b) Install the oil cooler tube union.

Torque:

29 N·m {300 kgf·cm, 22 ft·lbf}

75. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY


(a) Install the park/neutral position switch to the manual valve lever shaft, and temporarily install the adjusting bolt.

(b) Install a new lock washer and the nut.

Torque:

6.9 N·m {70 kgf·cm, 61 in·lbf}

(c) Temporarily install the control shaft lever.

(d) Turn the control shaft lever clockwise until it stops, and then turn it counterclockwise 2 notches to set it to the N position.


(e) Remove the control shaft lever.

(f) Align the neutral basic line with the switch groove, and tighten the adjusting bolt.

Text in Illustration

*1

Neutral Basic Line

*2

Groove

Torque:

13 N·m {130 kgf·cm, 9 ft·lbf}


(g) Using a screwdriver, bend the tabs of the lock washer.

HINT:

Bend at least 2 of the lock washer tabs.


76. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH


(a) Install the control shaft lever with the spring washer and nut.

Torque:

16 N·m {160 kgf·cm, 12 ft·lbf}

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