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Transmission Reassembly

NOTE: For bearing race and thrust bearing locations, See Fig 1.
CAUTION: Lubricate all components with ATF. Clutch discs should be soaked in ATF for 15 minutes prior to installation. Coat thrust bearings and races with petroleum jelly. Ensure ends of snap rings are not aligned with cutout area of case.
  1. Position transmission case with front facing upward. Assemblereverse brake inner piston, reaction sleeve and outer piston. Press assembled pistons into case with hand pressure. Using appropriate spring compressor, install piston return spring on outer piston. Install snap ring. Ensure reverse brake piston moves smoothly when compressed air is applied. See Figure.
  2. Install No. 1 bearing race. Install brake apply tube into transmission case, aligning locking tab with cutout in valve body side of transmission case. Ensure lips of tube end are completely inserted onto outer piston. Install output shaft No. 1 thrust bearing into case. Install rear planetary gear and output shaft into case. Install No. 2 thrust bearing. See Figure.
  3. Install pressure plate, with flat surface facing forward. Install 5 discs and 4 plates, starting with a disc and alternating each component. Measure reverse brake clutch pack clearance. See Figure. Clearance should be .029-.098" (.72-2.50 mm).
  4. Remove one-way clutch inner race from planetary gear assembly. Install front planetary gear. Mesh splines of planetary gear with flukes of discs by rotating and pushing planetary gear. Position inner race with notched tooth toward valve body side of case. Push plate into place. Install snap ring. Ensure snap ring is fully seated.
  5. Align oil hole and bolt hole of center support toward valve body side. Align center support bolt holes with case holes and install. Install bolts with wave washers. Tighten bolt on accumulator piston side first to 19 ft. lbs. (25 N.m). Install direct clutch assembly while rotating to align with center support.
  6. If fully installed, splined center of clutch will be even with end of sun gear shaft. Install No. 3 rear bearing race, thrust bearing and front bearing race over splined end of direct clutch. Install No. 4 thrust bearing and bearing race on front clutch. Install front clutch. Rotate and push front clutch to mesh splines of front clutch with flukes of discs.
  7. Using calipers and thrust plate gauge (straightedge), measure distance between top of case and forward clutch drum. See Figure. Distance should be equal to that recorded during disassembly. Install guide rods finger tight in front case bolt holes.
  8. Install OD case over guide pins with cutout area toward valve body side of case. See Fig 2. Install thrust washer on OD case and OD planetary gear. Ensure washer lugs align with holes in OD case and planetary gear assembly. Install No. 5 bearing race on OD planetary gear assembly.
    Fig 1: Identifying Bearing Race & Thrust Bearing Locations
    G95E21257Courtesy of SUZUKI OF AMERICA CORP.
    Fig 2: Aligning OD Case & Transmission Case Oil Holes
    G93I23828Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  9. Install OD planetary gear assembly with OD direct clutch and one-way clutch. Rotate and push OD planetary gear to mesh splines with flukes of discs. Ensure thrust washer does not fall during installation. Using calipers and thrust plate gauge (straightedge), measure distance between top of case and OD clutch drum. See Figure. Distance should be equal to that recorded during disassembly.
  10. Install "O" ring on OD case. Install converter housing to transmission case. Tighten 10-mm bolts to 25 ft. lbs. (34 N.m) and 12 mm bolts to 42 ft. lbs. (57 N.m). Install No. 5 thrust bearing on rear of oil pump. Ensure oil seal rings and "O" ring are installed on oil pump.
  11. Install oil pump over guide studs and into transmission case. Ensure thrust bearing does not fall off oil pump. Coat oil pump retaining bolts below bolt heads with thread sealer. Remove guide studs. Install bolts and tighten to 16 ft. lbs. (21 N.m). Ensure input shaft turns freely. Using a dial indicator, check output shaft end play. Position dial indicator against end of output shaft. End play should be .012-.035" (.30-.90 mm).
  12. Apply air pressure to specific oil passage to check appropriate operating components. See Figure. Component application should be heard while applying air. Install NEW oil seals in transmission case. Lubricate oil seal lips prior to installation. Install NEW spacer on manual valve lever. Install manual valve lever shaft into case and through manual valve lever. Install NEW pin with slot at right angle to shaft.
  13. Align spacer hole to hollow area of lever. Stake spacer to lever. Ensure manual valve lever shaft turns smoothly. Install parking lock pawl, pivot pin and spring in case. Install lock rod on manual valve lever and install parking lock pawl. Install parking pawl bracket on case. Ensure collar on control rod is toward front of transmission. Tighten bracket bolts to 65 INCH lbs. (7.4 N.m).
  14. Check operation of park lock pawl. Ensure output shaft is locked when manual valve lever is in "P" position. Determine proper accumulator piston locations. See Figure. Ensure accumulator piston is proper diameter. See the ACCUMULATOR PISTON DIAMETER  table. Determine proper spring free length and outer diameter for accumulator piston application. See the ACCUMULATOR SPRING SPECIFICATIONS  table.
    ACCUMULATOR PISTON DIAMETER (1)

    Application In. (mm)
    Front & Direct Clutch 1.252 (31.80)
    No. 2 Brake 1.370 (34.80)
    (1) For accumulator piston locations, see Figure.
    ACCUMULATOR SPRING SPECIFICATIONS (1)

    Application Diameter In. (mm) Free Length In. (mm)
    Forward Clutch
    Upper Spring .689 (17.50) 2.251 (57.18)
    Lower Spring .689 (17.50) 1.161 (29.50)
    No. 2 Brake
    Upper Spring .689 (17.50) 2.251 (57.18)
    Lower Spring .689 (17.50) 1.161 (29.50)
    Direct Clutch .646 (15.90) 2.172 (55.18)
    (1) For accumulator spring locations, see Figure.
  15. Install accumulator pistons and springs. Ensure accumulator pistons are pressed fully into bore. Install NEW "O" rings on throttle cable fitting. Install throttle cable. Align manual valve with pin on manual valve lever. Connect throttle cable to cam. Install valve body assembly and tighten bolts to 89 INCH lbs. (10 N.m). See Figure.
  16. Install gasket and oil strainer. Tighten bolts to 48 INCH lbs. (5.4 N.m). Using a plastic hammer, install oil tubes. See Figure. Do not bend or damage oil tubes. Install magnets in oil pan. Ensure magnets do not interfere with oil tubes. Install NEW gasket to transmission case. Align cut part of gasket and transmission case. Install oil pan bolts and tighten to 39 INCH lbs. (4.4 N.m).
  17. Install sensor rotor and snap ring. Install oil supply tube and extension housing with NEW gasket. Clean all bolt threads. Apply thread sealer to top 4 extension housing bolts prior to installation. Install short bolts to bottom of extension housing. Tighten bolts to 25 ft. lbs. (34 N.m).
  18. Lubricate and install new "O" rings on unions. Install unions and tighten to 25 ft. lbs. (34 N.m). Lubricate and install "O" ring to sleeve. Insert speedometer driven gear into sleeve. Install sleeve to extension housing. Install lock plate and bolt. Using control shaft lever, fully turn manual valve lever shaft forward and return 2 notches.
  19. Insert park/neutral position switch on manual valve lever shaft and temporarily tighten adjusting bolt. Install grommet and new lock washer. Install and tighten nut to 35 INCH lbs. (3.9 N.m). Tighten adjusting bolt to 48 INCH lbs. (4.5 N.m). Bend over at least 2 washer tabs.
  20. Install control shaft lever with spring washer and nut. Tighten nut to 61 INCH lbs. (6.9 N.m). Install wire harness and throttle cable clamp. Install torque converter. Ensure torque converter is installed correctly. Using a straightedge and vernier caliper, measure torque converter depth. Distance should be .669" (17.00 mm). See Fig 3.
Fig 3: Measuring Torque Converter Installed Depth
G95F21258Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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