Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Automatic Transmission Unit: Reassembly
- BEARING POSITION
Bearing Position
BEARING POSITION REFERENCEPosition Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Rear Race Diameter Inside/Outside A - 36.2 mm (1.425 in.) / 58.2 mm (2.291 in.) 44.0 mm (1.732 in.) / 62.0 mm (2.441 in.) B - 34.5 mm (1.358 in.) / 49.4 mm (1.945 in.) 36.6 mm (1.441 in.) / 51.9 mm (2.043 in.) C 46.5 mm (1.831 in.) / 60.1 mm (2.366 in.) 47.0 mm (1.850 in.) / 61.9 mm (2.437 in.) - D - 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) 72.7 mm (2.858 in.) / 89.2 mm (3.512 in.) E 30.0 mm (1.181 in.) /49.9 mm (1.965 in.) 31.0 mm (1.221 in.) / 53.1 mm (2.091 in.) - F 31.5 mm (1.240 in.) / 53.0 mm (2.0866 in.) 28.7 mm (1.130 in.) / 52.3 mm (2.059 in.) 28.7 mm (1.130 in.) / 50.4 mm (1.984 in.) G - 30.5 mm (1.201 in.) / 55.7 mm (2.189 in.) 33.5 mm (1.319 in.) / 59.0 mm (2.323 in.) H - 58.9 mm (2.319 in.) / 77.3 mm (3.043 in.) 62.0 mm (2.441 in.) / 82.5 mm (3.248 in.) - INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING
- Using SST, tap in the bearing to the transmission case.
SST 09316-60011 (09316-00011,09316-00021)
- Using needle-nose pliers, install the snap ring.
- Using SST, tap in the bearing to the transmission case.
- INSTALL AUTOMATIC TRANSMISSION REAR OIL SEAL
- Coat the lip of a new oil seal with MP grease.
- Using SST and a hammer, tap in the oil seal until it fits with the transmission case.
SST 09214-76011
Standard oil seal depth:
3.5 +/-0.2 mm (0.138 +/-0.008 in.)
- INSTALL NO. 2 BRAKE PISTON
- Coat 3 new O-rings with ATF, and install them to the brake piston.
- Install the brake piston to the transmission case.
HINT:
Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston's 2 protrusions to the transmission case's spline grooves. (One groove is 3 places clockwise from the top, and the other is 2 places clockwise from the bottom).
- Install the brake return spring to the transmission case.
- Set SST on the brake piston return spring, tighten SST and compress the return spring.
SST 09380-50010
- Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
- SELECT NO. 2 BRAKE FLANGE
- Measure length A (from the tip of the No. 2 brake piston to the step in the transmission case) in the illustration. *1
Standard:
14.77 to 15.37 mm (0.5815 to 0.6051 in.)
- Assemble the 4 No. 2 brakes discs, 3 No. 2 brake plates, and No. 2 brake flange as shown in the illustration. Then with a weight fixture of 500 g (17.64 oz) or less placed on the flange, measure length B. *2
Standard:
14.11 to 14.69 mm (0.5555 to 0.5783 in.)
- Choose a No. 2 brake flange so that the value of measured length A minus length B (from steps *1 and *2) is 0.52 to 0.82 mm (0.0204 to 0.0323 in).
Flange thickness
FLANGE THICKNESS SPECIFICATIONMark Thickness 0 1.95 to 2.05 mm (0.0768 to 0.0807 in.) 1 2.05 to 2.15 mm (0.0807 to 0.0846 in.) 2 2.15 to 2.25 mm (0.0846 to 0.0886 in.) 3 2.25 to 2.35 mm (0.0886 to 0.0925 in.) 4 2.35 to 2.45 mm (0.0925 to 0.0965 in.) 5 2.45 to 2.55 mm (0.0965 to 0.1004 in.) 6 2.55 to 2.65 mm (0.1004 to 0.1043 in.) 7 2.65 to 2.75 mm (0.1043 to 0.1083 in.) 8 2.75 to 2.85 mm (0.1083 to 0.1122 in.)
- Measure length A (from the tip of the No. 2 brake piston to the step in the transmission case) in the illustration. *1
- INSTALL DIRECT CLUTCH PISTON
- Coat a new O-ring with ATF, and install it to the rear clutch drum sub-assembly.
- Coat a new O-ring with ATF, and install it to the clutch piston.
- Install the clutch piston to the rear clutch drum sub-assembly.
- Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.
- Install the direct clutch piston return spring sub-assembly and balancer to the rear clutch drum sub-assembly.
- Place SST on the clutch balancer and compress the return spring with a press.
SST 09387-00020
- Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
- INSTALL NO. 2 CLUTCH DISC SET
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Install the 6 plates, 6 discs and flange to the rear clutch drum.
Install in order:
P - D - P - D - P - D - P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
NOTE: Before assembling new discs, soak them in ATF for at least 2 hours. - Temporarily install the snap ring.
- Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2
cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard value.
Standard:
0.90 to 1.20 mm (0.0354 to 0.0472 in.)
Flange thickness
FLANGE THICKNESS SPECIFICATIONMark Thickness 40 3.95 to 4.05 mm (0.1555 to 0.1594 in.) 41 4.05 to 4.15 mm (0.1594 to 0.1634 in.) 42 4.15 to 4.25 mm (0.1634 to 0.1673 in.) 43 4.25 to 4.35 mm (0.1673 to 0.1713 in.) 44 4.35 to 4.45 mm (0.1713 to 0.1752 in.) 45 4.45 to 4.55 mm (0.1752 to 0.1791 in.) 46 4.55 to 4.65 mm (0.1791 to 0.1831 in.) 47 4.65 to 4.75 mm (0.1831 to 0.1870 in.) 48 4.75 to 4.85 mm (0.1870 to 0.1909 in.) - Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
- Install the 6 plates, 6 discs and flange to the rear clutch drum.
- CONNECT DIRECT CLUTCH ASSEMBLY
- Coat 2 new oil seal rings with ATF, and install them to the direct clutch drum sub-assembly.NOTE: Do not expand the ring ends excessively.
- Coat 3 new oil seal rings with ATF, and install them to the output shaft.
- Coat 2 new oil seal rings with ATF, and install them to the direct clutch drum sub-assembly.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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