A-761E Manual PDF

AKPPHELP.
RU Руководство по ремонту АКПП

01-6 INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

010PZ-01
ABBREVIATIONS USED IN THIS MANUAL

Abbreviations Meaning
ASSY Assembly
AT Automatic Transmission
ATF Automatic Transmission Fluid
B0 Overdrive Brake
B2 3rd Brake
C0 Overdrive Clutch
C2 Direct Clutch
D Disc
F Flange
FIPG Formed in Place Gasket
MP Multipurose
O/D Overdrive
P Plate
SSM Special Service Materials
SST Special Service Tools
w/ With
w/o Without
A761E A/T REPAIR MANUAL (RM1050U)
Author: Date: 6
AKPPHELP.RU Руководство по ремонту АКПП
40-82
AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (A761E)
TRANSMISSION VALVE BODY ASSY (A761E)

4007L-03
COMPONENTS
Shift Solenoid
Valve SL2
Shift Solenoid
6.4 (65, 57 in.⋅lbf)
Valve SLU
6.4 (65, 57 in.⋅lbf)

Lock Plate
Straight Pin
Lock Plate
Straight Pin
Shift Solenoid
Valve S3
10 (102, 7)
10 (102, 7)
Shift Solenoid
Valve S2
Shift Solenoid
Valve S4
10 (102, 7) 10 (102, 7)
Shift Solenoid
Valve S1
Shift Solenoid
Shift Solenoid
Valve SLT
ValveSR
Shift Solenoid
Valve SL1
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

D31387
Author: Date: 102

40-59
AUTOMATIC TRANSMISSION / TRANS - CLUTCH DRUM & INPUT SHAFT ASSY (A761E)
CLUTCH DRUM & INPUT SHAFT ASSY (A761E)

40075-03
COMPONENTS
Shaft Snap Ring
Direct Clutch Return Spring
Direct Clutch Piston
Reverse Clutch Piston O-Ring
Reverse Clutch
Return Spring
Snap Ring Clutch Balance No.2
Forward Clutch Piston

Clutch Drum
O-Ring
O-Ring
Clutch Balancer No.3 Thrust Bearing Race

Hole Snap Ring
Coast Clutch
Clutch Plate Piston
Input Shaft
Input Shaft Oil Seal Ring
Thrust Needle Roller
Bearing
Coast Clutch Hub
Reverse Clutch Flange
Thrust Bearing Race
Hole Snap Ring
Direct Clutch Disc Clutch Disc No.1
Hole Snap Ring
Coast Clutch Disc
Thrust Bearing Race
Clutch Balancer No.1 Thrust Needle Roller Bearing
Flange
Clutch Plate No.1 Snap Ring
Cushion Plate
Coast Clutch Flange Reverse Clutch Flange
Coast Clutch Plate
Shaft Snap Ring Rear Clutch Disc
O-Ring
Forward Clutch Reverse Clutch Hub
Return Spring
Clutch Hub Thrust Washer
Reverse Clutch
Clutch Plate No.3 Reaction Sleeve
Clutch Cushion Plate

Thrust Needle Roller Bearing
Forward Clutch Hub
D31398
Author: Date: 79
40-53
AUTOMATIC TRANSMISSION / TRANS - OIL PUMP ASSY (A761E)
OIL PUMP ASSY (A761E)

40073-03
COMPONENTS
Front Oil
Pump Body Clutch Drum
Stator Shaft Assy O-ring Oil Seal Ring
Front Oil Pump Body
Front Oil Pump

Front Drive Gear
Oil Pump
Oil Seal
× 14
12 (122, 9)
Front Oil Pump
Driven Gear
Front Oil
Pump Body
O-ring

Non-reusable part D27949
Author: Date: 73
40-5
AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSMISSION ASSY (A761E)
AUTOMATIC TRANSMISSION ASSY (A761E)

400XJ-02
COMPONENTS
5.4 (55, 48 in.⋅lbf)

Automatic Transmission Breather Tube
16 (163, 12)
5.4 (55, 48 in.⋅lbf)
6.9 (70, 61 in.⋅lbf)
Park/Neutral Position Switch Assy Transmission Wire
13 (130, 9)
Transmission Revolution
Sensor
5.4 (55, 48 in.⋅lbf)
Lock Washer Oil Cooler O-Ring

Union
Transmission Control 29 (296, 21)
Shaft Lever RH 6.4 (65, 57 in.⋅lbf) O-Ring
O-Ring
34 (345, 25) Transmission Revolution

Sensor
x6
x2 O-Ring
5.4 (55, 48 in.⋅lbf)
x2
34 (345, 25) 5.4 (55, 48 in.⋅lbf)
57 (581, 42)
Automatic Transmission Housing Automatic Transmission

Extension Housing Oil Seal
Oil Seal
34 (345, 25)
Extension Housing Assy
Washer
x4
123 (1,280, 92)
x2 Automatic Transmission
Flange Yoke Assy
34 (345, 25)
Transmission Case Adaptor
RR Cover Sleeve Radial Ball Bearing
Non-reusable part D31343
Author: Date: 25
40-6
Manual Valve Lever

Shaft Oil Seal
Transaxle Case Gasket

Manual Valve
Brake Drum Gasket
Lever Shaft
Spacer
Spring Pin Spring
Manual Valve Spring
C-1
Lever Sub-assy
Accumulator
C-2 Accumulator Piston
Parking Lock Valve
Pawl Bracket B-3 Accumulator Piston
O-Ring
Parking Lock Rod Spring
7.4 (75, 65 in.⋅lbf) O-Ring C-3 Accumulator Piston

Check Ball Body
Parking Lock Pawl
Shaft E-Ring
Parking Lock
Pawl Shaft
Transmission Valve
Parking Lock Pawl Body Assy
Torsion spring x20
Parking Lock Pawl Oil Strainer 11 (110, 8)
O-Ring Valve Body Oil
Strainer Assy
10 (100, 7)
Automatic Transmission
Oil Pan Gasket Transmission Oil
Cleaner Magnet
Automatic Transmission
Oil Pan
Gasket
4.4 (45, 39 in.⋅lbf) Drain Plug
Gasket x20 20 (200, 14)
Over Flow Plug
Non-reusable part 20 (200, 14) D31344
Author: Date: 26
40-7
Front Planetary Ring Brake Disc No.1

Gear Shaft Snap Ring
CTR Planetary
Thrust Needle
Ring Gear
Roller Bearing Front Planetary
Ring Gear
Front Planetary Gear Assy
Brake Plate No.1

Brake Flange No.1
Front Planetary
Ring Gear Flange
Planetary Carrier
2nd Brake
Thrust Washer No.2
Cylinder
Thrust Bearing
Race No.3 2nd Brake Piston
1 Way Clutch
Return Spring
Inner Race 1 Way Clutch Assy 2nd Brake Piston
Planetary Carrier
Cushion Plate
Thrust Washer No.1
Brake Plate No.3
2nd Brake
Piston O-Ring
2nd Brake piston
Snap Ring Brake No.3 Snap Ring
2nd Brake piston
Hole Snap Ring
1 Way Clutch Assy No.2
Brake Disc No.3
Brake Flange No.3
Clutch Drum & Input Shaft Assy
Thrust Bearing
Race No.1
Oil Pump Assy
Clutch Drum
Thrust Washer No.2
Clutch Drum
Thrust Washer No.2
x10
Thrust Needle
O-Ring
Roller Bearing
21 (214, 15)

Non-reusable part
D31345
Author: Date: 27
40-8
Intermediate Shaft
Thrust Bearing
Race No.7
1 Way Clutch
Assy No.3
Thrust Bearing
Race No.8
Thrust Needle
Roller Bearing
Planetary Ring CTR Planetary
Gear Flange Gear Assy
Thrust Needle
1 Way Clutch Roller Bearing
Inner Race
Snap Ring Brake Piston No.2
Brake Piston
Return Spring No.2
Brake Disc No.2 Planetary

Sun Gear
Thrust Bearing
Race No.4
Brake Cylinder No.2

Brake Piston
No.2 O-Ring
Brake No.2 Snap Ring

Brake Plate No.2
Brake Piston No.1
Brake Flange No.2 O-Ring
Brake Cylinder No.1

Brake Piston No.1
Brake Piston
Return Spring Brake Piston
Snap Ring Return Spring
Non-reusable part
D31545
Author: Date: 28
40-9
Snap Ring
Thrust Needle
Roller Bearing
Brake Reaction Sleeve

1st & Reverse Brake Return Inner O-Ring
Spring Shaft Snap Ring
1st & Reverse Brake Piston Brake Piston No.4
Bearing Race
Brake Reaction Brake Piston No.4
Sleeve O-Ring
Brake Apply Tube
Brake Reaction Brake Plate

Sleeve Outer O-Ring Stopper Spring
1st & Reverse Brake

Thrust Needle Piston O-Ring
Roller Bearing
1st & Reverse Brake Thrust Bearing
Return Spring Race No.9
Sub-assy
Thrust Needle
Roller Bearing
Brake Disc No.4
Rear Planetary
Gear Assy
Rear Cover Sleeve

Brake Plate No.4
Brake Flange No.4
Non-reusable part
D31346
Author: Date: 29
INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-7

MANUAL
010Q0-01
GLOSSARY OF SAE AND LEXUS TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their LEXUS equivalents.
SAE LEXUS TERMS
SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (AI)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure -
CAC Charge Air Cooler Inter cooler
CARB Carburetor Carburetor
CFI Continuous Fuel Injection -
CKP Crankshaft Position Crank Angle
CL Closed Loop Closed Loop
CMP Camshaft position Cam Angle
CPP Clutch Pedal Position -
CTOX Continuous Trap Oxidizer -
CTP Closed Throttle Potion -
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition -
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Communication Link (TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode -
ECL Engine Control Level -
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Control Temperature Coolant Temperature, Water Temperature (THW)
Electrically Erasable Programmable Read Only memory
Electrically Erasable Programmable Read Only
EEPROM (EEPROM),
memory
Erasable Programmable Read Only memory (EPROM)
EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV)
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR)
EI Electronic Ignition Distributorless Ignition (DI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)
EVAP Evaporative Emission Evaporative Emission Control (EVAP)
FC Fan Control -
Flash Electrically Erasable Programmable
FEEPROM -
Read Only Memory
FEPROM Flash Erasable Programmable Read Only Memory -
FF Flexible Fuel -
FP Fuel Pump Fuel Pump
GEN Generator Alternator
GND Ground Ground (GND)
HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S)
IAC Idol Air Control Idol Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module -
IFI Indirect Fuel Injection Indirect Injection
IFS Inertia Fuel-Shutoff -
Author: Date: 7
01-8 INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
ISC Idle Speed Control -

KS Knock Sensor Knock Sensor
MAF Mass Air Flow Air Flow Meter
Manifold Pressure
MAP Manifold Absolute Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC Mixture Control Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure -
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
MST Manifold Surface temperature -
MVZ Manifold Vacuum Zone -
NVRAM Non-V olatile Random Access Memory -
O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S)
OBD On-Board Diagnostic On-Board Diagnostic (OBD)
OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CC0
OP Open Loop Open Loop
PAIR Pulsed Secondary Air Injection Air Suction (AS)
PCM Powertrain Control Module -
PNP Park/Neutral Position -
PROM Programmable Read Only Memory -
PSP Power Steering Pressure -
Diesel Particulate Filter (DPF)
PTOX Periodic Trap Oxidizer
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
RM Relay Module -
ROM Read Only Memory Read Only Memory (ROM)
RPM Engine Speed Engine Speed
SC Supercharger Supercharger
SCB Supercharger Bypass -
SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection
SPL Smoke Puff Limiter -
SRI Service Reminder Indicator -
SRT System Readiness Test -
ST Scan Tool -
TB Throttle Body Throttle Body
Single Point Injection
TBI Throttle Body Fuel Injection
Central Fuel Injection (Ci)
TC Turbocharger Turbocharger
TCC Torque Converter Clutch Torque Converter
TCM Transmission Control Module Transmission ECU (Electronic Control Unit)
TP Throttle Position Throttle Position
TR Transmission Range -
Bimetallic Vacuum Switching Valve (BVSV)
TVV Thermal Vacuum Valve
Thermostatic Vacuum Switching Valve (TVSV)
Three-W ay Catalytic (TWC)
TWC Three-W ay Catalytic Converter
CCRO
TWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCO
VAF Volume Air Flow Air Flow Meter
VR Voltage Regulator Voltage Regulator
VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type)
WOT Wide Open Throttle Full Throttle
Author: Date: 8
INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-9

MANUAL
WU-OC Warm Up Oxidation Catalytic Converter -

WU-TWC Warm Up Three-Way Catalytic Converter Manifold Converter
3GR Third Gear -
4GR Fourth Gear -
Author: Date: 9
03-3
SERVICE SPECIFICATIONS - STANDARD BOLT
031QA-01
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard Old Standard Hexagon Nut Class
Hexagon Nut Cold Forging Nut Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer) No Mark (w/ Washer) No Mark
6N
6N
7N (5T)
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
Author: Date: 15
03-1
STANDARD BOLT
031Q8-01
HOW TO DETERMINE BOLT STRENGTH
Bolt Type
Hexagon Head Bolt Class
Stud Bolt Weld Bolt
Normal Recess Bolt Deep Recess Bolt
4 4T
No Mark No Mark No Mark
5 5T
6 6T
w/ Washer w/ Washer
7 7T
8 8T
9 9T
10 10T
11 11T
B06431
Author: Date: 13
INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-1

MANUAL
HOW TO USE THIS AUTOMATIC TRANSMISSION REPAIR

MANUAL
010PY-01
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual was created in accordance with SAE J2008.
(b) Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
(c) This manual explains” Removing and Installing, Replacing, Disassembling, Instaling and Checking,
Adjusting”, but” Final inspection” is omitted.
(d) The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
(1) Operation with a jack or lift
(2) Cleaning of a removed part if necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be
repaired.
3. PREPARATION
(a) Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section in this manual.
Author: Date: 1
01-2 INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
4. REPAIR PROCEDURES
(a) Component drawing is placed as the section or title if necessary.
(b) Illustrations of the parts catalog are placed as the” disassembled parts drawing” so that it enables you
to understand the fitting condition of the components.
(c) Non-reusable parts, grease applied parts, precoated parts and torque are specified in the compo-
nents drawing.
Example:
Stator Shaft Assy Oil Seal Ring
Oil Pump Drive Gear
Oil Seal
x13
10 (100, 7)
Oil Pump Driven Gear
O-Ring
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
D25697
(d) Torque, oil applying position, and non-reusable parts are described as important points in the proce-
dure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In those cases, all
the information such as torque, oil, etc. is described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removal, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be cases where the illustrations of similar models are used. In those cases, the details may
be different from the actual vehicle.
Author: Date: 2
INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-3

MANUAL
(h) Theprocedures are presented in a step-by-step format:

(1) The illustration shows what to do and where to do.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
Illustration: Task heading: what to do

what to do and where
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
SST (a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Detailed text:
how to do task
Set part No. Component part No.

D27528
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being repaired.
HINT Provide additional information to help you perform the repair efficiently.
7. SI UNIT
(a) The UNITS used in this manual are primarily expressed according to the SI UNIT (International System
of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)
Author: Date: 3
40-1
AUTOMATIC TRANSMISSION ASSY (A761E)

4007T-06
PRECAUTION
NOTICE:
The automatic transmission is composed of highly precision-finished parts, necessitating
careful inspection before reassembly because even a small nick could cause fluid leakage or
affect its performance. The instructions here are organized so that you work on only one com-
ponent group at a time. This avoids the possibility of switching similar-looking parts from dif-
ferent sub-assy. The component groups are inspected and repaired from the converter hous-
ing side. As much as possible, complete the inspection, repair and reassembly before
proceeding to the next component group. If a defective part is found in a component group dur-
ing reassembly, inspect and repair the part immediately. If a component group cannot be as-
sembled because parts are being ordered, be sure to keep all parts of the group in a separate
container while proceeding with disassembly, inspection, repair and reassembly of other com-
ponent groups.
Recommended ATF: WS
All disassembled parts should be washed clean, and any fluid passages and holes should be
blown out with compressed air.
Dry all parts with compressed air-never use a shop rag.
When using compressed air, always aim away from yourself to prevent accidentally spraying
ATF or kerosene on your face.
The recommended automatic transmission fluid or kerosene should be used for cleaning.
After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
When disassembling a valve body, be sure to match each valve together with the correspond-
ing spring.
New replacement discs for brakes and clutches replacement must be soaked in ATF for at least
15 minutes before reassembly.
All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
All gaskets and rubber O-rings should be replaced.
Do not apply adhesive cements to gaskets and similar parts.
Make sure that the ends of a snap ring are not aligned with any of the cutouts and are installed
in the groove correctly.
If a worn bushing is replaced, the sub-assembly containing the bushing must also be replaced.
Check thrust bearings and races for wear or damage. Replace if necessary.
Use petroleum jelly to keep parts in place.
When working with FIPG material, you must do the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the
gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.
Author: Date: 21
01-4 INTRODUCTION - REPAIR INSTRUCTION FOR AUTOMATIC
TRANSMISSION REPAIR MANUAL
REPAIR INSTRUCTION FOR AUTOMATIC TRANSMISSION

REPAIR MANUAL
010IC-01
PRECAUTION
1. BASIC REPAIR HINT
(a) PRECOATED PARTS

(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
Seal Lock Adhesive
adhesive and dry with compressed air. Then apply
Z11554 the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
Author: Date: 4
INTRODUCTION - REPAIR INSTRUCTION FOR AUTOMATIC 01-5

TRANSMISSION REPAIR MANUAL
(d) TORQUE WHEN USING EXTENSION TOOL WITH

TORQUE WRENCH
L1 L2
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
D02612 In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T’=T x L2/(L1 + L2)
L1 L2 T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)}
T Torque {N⋅m (kgf⋅cm, ft⋅lbf)}
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
D01201
L1 L2
D01202
Author: Date: 5
03-4
SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE
AUTOMATIC TRANSMISSION / TRANSAXLE

0305K-17
SERVICE DATA
OIL PUMP
Body clearance STD 0.10 to 0.17 mm (0.0039 to 0.0067 in.)
MAX 0.17 mm (0.0067 in.)
Tip clearance STD 0.07 to 0.15 mm (0.0028 to 0.0059 in.)

Max 0.15 mm (0.0059 in.)
Side clearance STD 0.03 to 0.05 mm (0.0012 to 0.0020 in.)

Max 0.05 mm (0.0020 in.)
Drive gear thickness Mark
0 10.736 to 10.742 mm (0.442268 to 0.42291 in.)
1 10.743 to 10.749 mm (0.442296 to 0.42319 in.)
2 10.750 to 10.756 mm (0.442323 to 0.42346 in.)
3 10.757 to 10.763 mm (0.442350 to 0.42374 in.)
4 10.764 to 10.770 mm (0.442378 to 0.42401 in.)
5 10.771 to 10.777 mm (0.442405 to 0.42429 in.)
6 10.778 to 10.784 mm (0.442433 to 0.42457 in.)
Driven gear thickness Mark
0 10.736 to 10.742 mm (0.442268 to 0.42291 in.)
1 10.743 to 10.749 mm (0.442296 to 0.42319 in.)
2 10.750 to 10.756 mm (0.442323 to 0.42346 in.)
3 10.757 to 10.763 mm (0.442350 to 0.42374 in.)
4 10.764 to 10.770 mm (0.442378 to 0.42401 in.)
5 10.771 to 10.777 mm (0.442405 to 0.42429 in.)
6 10.778 to 10.784 mm (0.442433 to 0.42457 in.)
Pump body bushing inside diameter
Max 38.188 mm (1.50349 in.)
Stator shaft bushing inside diameter

Max (Front side) 21.577 mm (0.850 in.)
Max. (Rear side) 32.08 mm (1.263 in.)
FRONT PLANETARY GEAR

Planetary gear bushing inside diameter Maximum 57.48 mm (2.263 in.)
Planetary pinion gear thrust clearance STD 0.20 to 0.60 mm (0.008 to 0.024 in.)
Maximum 0.65 mm (0.026 in.)
CENTER PLANETARY GEAR

Planetary pinion gear thrust clearance STD 0.12 to 0.68 mm (0.005 to 0.027 in.)
Maximum 0.73 mm (0.029 in.)
RR PLANETARY RING GEAR FLANGE

Planetary ring gear flange bushing inside diameter Maximum 32.175 mm (1.267 in.)
COAST AND FORWARD CLUTCH

Forward clutch hub inside diameter STD 26.037 to 26.062 mm (1.0251 to 1.0261 in.)
Max. 26.112 mm (1.028 in.)
Forward clutch return spring free lenght STD 24.64 mm (0.9701 in.)
Min. 13.67 mm (0.538 in.)
Pack clearance Coast clutch 0.3 to 0.6 mm (0.012 to 0.024 in.)

Forward clutct 0.56 to 0.86 mm (0.0220 to 0.339 in.)
Author: Date: 16
03-5
Flange thickness (Coast clutch) Mark

0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
3 3.3 mm (0.130 in.)
4 3.4 mm (0.134 in.)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
9 3.9 mm (0.154 in.)
Flange thickness (Coast clutch) Mark
0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
3 3.3 mm (0.130 in.)
4 3.4 mm (0.134 in.)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
9 3.9 mm (0.154 in.)
A 4.0 mm (0.158 in.)
DIRECT AND REVERSE CLUTCH

Reverse clutch hub inside diameter STD 35.812 to 35.837 mm (1.4099 to 1.4109 in.)
Max. 35.887 mm (1.4129 in.)
Reverse clutch return spring free lenght STD 21.04 mm (0.828 in.)
Min. 11.76 mm (0.423 in.)
Direct clutch return spring free lenght STD 19.51 mm (0.768 in.)
Min. 11.42 mm (0.450 in.)
Pack clearance Direct clutch 0.5 to 0.8 mm (0.020 to 0.031 in.)

Reverse clutch 0.5 to 0.8 mm (0.020 to 0.031 in.)
Piston return spring free length (Direct clutch) 32.9 mm (1.2953 in.)
Flange thickness (Direct clutch) Mark
0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
3 3.3 mm (0.130 in.)
4 3.4 mm (0.134 in.)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
Flange thickness (Reverse clutch) Mark
0 2.8 mm (0.110 in.)
1 2.9 mm (0.114 in.)
2 3.0 mm (0.118 in.)
3 3.1 mm (0.122 in.)
4 3.2 mm (0.126 in.)
5 3.3 mm (0.130 in.)
6 3.4 mm (0.134 in.)
7 3.5 mm (0.138 in.)
8 3.6 mm (0.142 in.)
9 3.7 mm (0.146 in.)
A 3.8 mm (0.150 in.)
NO.4 BRAKE
Pack clearance 0.4 to 0.7 mm (0.016 to 0.028 in.)
Author: Date: 17
03-6
Piston return spring free length STD 23.74 mm (0.935 in.)

Min. 14.42 mm (0.5677 in.)
Flange thickness Mark

0 0 mm (0 in.)
2 0.2 mm (0.00787 in.)
4 0.4 mm (0.01575 in.)
6 0.6 mm (0.02362 in.)
8 0.8 mm (0.03150 in.)
10 0.6 mm (0.03937 in.)
12 0.6 mm (0.04724 in.)
14 0.6 mm (0.05512 in.)
NO.2 BRAKE
Piston stroke 0.6 to 0.9 mm (0.024 to 0.035 in.)
Piston return spring free length STD 22.66 mm (0.8921 in.)
Min. 14.21 mm (0.5594 in.)

0 2.0 mm (0.079 in.)
1 2.1 mm (0.083 in.)
2 2.2 mm (0.087 in.)
3 2.3 mm (0.091 in.)
4 2.4 mm (0.094 in.)
5 2.5 mm (0.098 in.)
6 2.6 mm (0.102 in.)
7 2.7 mm (0.106 in.)
NO.1 BRAKE
Piston stroke 0.42 to 0.72 mm (0.017 to 0.028 in.)
0 2.0 mm (0.079 in.)
1 2.2 mm (0.087 in.)
2 2.4 mm (0.094 in.)
3 2.6 mm (0.102 in.)
INTERMEDIATE SHAFT
Intermediate shaft run out Maximum 0.08 mm (0.003 in.)
Intermediate shaft diameter STD A: 25.962 to 25.975 mm (1.022 to 1.023 in.)
B: 25.962 to 25.975 mm (1.022 to 1.023 in.)
C: 32.062 to 32.075 mm (1.262 to 1.263 in.)
D: 32.062 to 32.075 mm (1.262 to 1.263 in.)
Min A: 25.912 mm (1.020 in.)
B: 25.912 mm (1.020 in.)
C: 32.012 mm (1.260 in.)
D: 32.012 mm (1.260 in.)
ACCUMULATOR
Free length/Outer diameter
Spring Color
mm (in.)
B1 Inner 44.98 (1.7709) / 11.30 (0.445) Natural
Outer 46.36 (1.8252) / 17.10 (0.6732) Natural

C2 63.14 (2.4858) / 16.0 (0.6299) Light Gray
B3 64.5 (2.539) / 19.5 (0.768) Orange
C3 inner 44.0 (1.732) / 14.0 (0.551) Yellow
outer 76.65 (3.0178) / 20.10 (0.7913) Natural
Author: Date: 18
03-7
OUTPUT SHAFT BEARING

Clearance 0.02 to 0.12 mm (0.0008 to 0.0047 in.)
Flange thickness No. 1 3.80 mm (0.1496 in.)
No. 2 3.85 mm (0.1516 in.)
No. 3 3.90 mm (0.1555 in.)
No. 4 3.95 mm (0.1575 in.)
No. 5 4.00 mm (0.1575 in.)
No. 6 4.05 mm (0.1594 in.)
No. 7 4.10 mm (0.1614 in.)
No. 8 4.15 mm (0.1634 in.)
No. 9 4.20 mm (0.1653 in.)
No. 10 4.25 mm (0.1673 in.)
No. 11 4.30 mm (0.1693 in.)
No. 12 4.35 mm (0.1713 in.)
Author: Date: 19
03-2
031Q9-01
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Diameter Pitch
Class Hexagon head bolt Hexagon flange bolt
mm mm
N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf
6 1 5 55 48 in.·lbf 6 60 52 in.·lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
6 1 6.5 65 56 in.·lbf 7.5 75 65 in.·lbf

8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
5T
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 - - -
6 1 8 80 69 in.·lbf 9 90 78 in.·lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 - - -
6 1 10.5 110 8 12 120 9

8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
7T
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 - - -
8 1.25 29 300 22 33 330 24

8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
Author: Date: 14
02-1
PREPARATION - AUTOMATIC TRANSMISSION / TRANS
0237U-01
PREPARATION
SST (Special Service Tools)
09309-37010 Transmission Bearing Replacer AUTOMATIC TRANSMISSION
ASSY(A761E)
09320-89010 Transfer Clutch Spring CLUTCH DRUM & INPUT SHAFT

Compressor ASSY(A761E)
09350-30020 TOYOTA Automatic Transmission AUTOMATIC TRANSMISSION

Tool Set ASSY(A761E)
OIL PUMP ASSY(A761E)
CLUTCH DRUM & INPUT SHAFT
ASSY(A761E)
(09350-06120) No.2 Measure Terminal AUTOMATIC TRANSMISSION
ASSY(A761E)
(09350-07040) No.2 Piston Spring Compressor CLUTCH DRUM & INPUT SHAFT
ASSY(A761E)
(09350-07050) No.3 Piston Spring Compressor AUTOMATIC TRANSMISSION

ASSY(A761E)
(09350-07060) No.1 Snap Ring Expander AUTOMATIC TRANSMISSION

ASSY(A761E)
(09350-07070) No.2 Snap Ring Expander AUTOMATIC TRANSMISSION

ASSY(A761E)
CLUTCH DRUM & INPUT SHAFT
ASSY(A761E)
(09350-07080) Brake Reaction Sleeve Puller AUTOMATIC TRANSMISSION

ASSY(A761E)
(09350-07090) Brake No.1 Piston Puller AUTOMATIC TRANSMISSION

ASSY(A761E)
(09350-071 10) Oil Seal Replacer AUTOMATIC TRANSMISSION

ASSY(A761E)
(09351-32140) Oil Seal Replacer OIL PUMP ASSY(A761E)
09351-40010 Tool Set, TOYOTA Automatic AUTOMATIC TRANSMISSION

Transmission ASSY(A761E)
Author: Date: 10
02-2
(09351-04010) Pipe AUTOMATIC TRANSMISSION

ASSY(A761E)
(09351-04020) Spring Compressor No.1 AUTOMATIC TRANSMISSION

ASSY(A761E)

ASSY(A761E)
(09351-04040) Plate AUTOMATIC TRANSMISSION

ASSY(A761E)
(09351-04050) Bolt AUTOMATIC TRANSMISSION

ASSY(A761E)

ASSY(A761E)
(09351-04070) Bolt Set AUTOMATIC TRANSMISSION

ASSY(A761E)
09387-00070 First & Reverse Brake Wrench CLUTCH DRUM & INPUT SHAFT
ASSY(A761E)
09950-60010 Replacer Set AUTOMATIC TRANSMISSION

ASSY(A761E)
(09951-00350) Replacer 35 AUTOMATIC TRANSMISSION

ASSY(A761E)
09950-70010 Handle Set AUTOMATIC TRANSMISSION

ASSY(A761E)
(09951-07100) Handle 100 AUTOMATIC TRANSMISSION

ASSY(A761E)
Author: Date: 11
02-3
Recomended Tools
09031-00030 Pin Punch AUTOMATIC TRANSMISSION
ASSY(A761E)
SSM
08826-00090 ”Seal Packing 1281,” AUTOMATIC TRANSMISSION
THREE BOND 1281 or equivalent ASSY(A761E)
(FIPG)
Equipment
Feeler gauge
Cylinder Gauge
Vernier calipers
Dial indicator
Micrometer
Feeler gauge
Straight edge
Torque wrench
Angle gauge
V block
Lubricant
Automatic transmission fluid
Dry fill 8.5 liters (9.0 US qts, 7.5 Imp. qts) ATF TYPE WS or equivalent
Drain and refill 2.3 liters (2.4 US qts, 2.0 Imp. qts)
SSM (Special Service Materials)

08826-00090 ”Seal Packing 1281,” AUTOMATIC TRANSMISSION
THREE BOND 1281 or equivalent ASSY(A750E/A750F)
(FIPG)
Author: Date: 12
40-2
40167-01
SYSTEM DESCRIPTION
1. OPERATION
No.2 Clutch (C2)

No.3 Clutch (C3) No.2 Brake (B2)
No.3 Brake (B3) No.4 Brake (B4)
No.1 One-Way Clutch (F1)
No.1 Brake (B1)
No.4 Clutch (C4) No.2 One-Way Clutch (F2)

No.1 Clutch (C1)
D31534
Shift Lever Solenoid Valve Clutch Brake One-way Clutch

Position S1 S2 S3 S4 SR SL1 SL2 SLU C1 C2 C3 C4 B1 B2 B3 B4 F1 F2 F3 F4
P ON ON ON ON
R* ON ON ON ON
N ON ON ON ON
1st ON ON ON ON
2nd ON ON ON ON ON ON
D, 3rd ON ON ON ON ON
S
(6) 4th ON ON ON ON
5th ON ON ON ON
6th ON ON ON ON ON
Author: Date: 22
40-3
Shift Lever Solenoid Valve Clutch Brake One-way Clutch

Position
S1 S2 S3 S4 SR SL1 SL2 SLU C1 C2 C3 C4 B1 B2 B3 B4 F1 F2 F3 F4
1st ON ON ON ON
S
(5) 3rd ON ON ON ON ON
4th ON ON ON ON
5th ON ON ON ON
1st ON ON ON ON
S 2nd ON ON ON ON ON ON
(4)
3rd ON ON ON ON ON
4th* ON ON ON ON
1st ON ON ON ON
S
(3)
3rd* ON ON ON ON
1st ON ON ON ON
S
(2)
2nd* ON ON ON ON ON ON
S
(1) 1st* ON ON ON
: Operation
: Operate but is not related to power transmission
*: with Engine Brake
Author: Date: 23
40-4
2. FUNCTION OF COMPONENTS
B3
F2 F 1 B1 B2 F3 B4
C3
C2
C1 F4
IN C4 OUT
D31535
Component Function
C1 No.1 Clutch Connects input shaft and intermediate shaft.
C2 No.2 Clutch Connects input shaft and center planetary carrier.
C3 No.3 Clutch Connects input shaft and front sun gear.
C4 No.4 Clutch Connects input shaft and intermediate shaft.
Prevents front planetary carrier from turning both clockwise
B1 No.1 Brake
and counterclockwise.
Prevents front and center ring gear from turning both clock-
B2 No.2 Brake
wise and counterclockwise.
Prevents outer race of F2 from turning both clockwise and
B3 No.3 Brake
counterclockwise.
Prevents rear ring gear from turning both clockwise and coun-
B4 No.4 Brake
terclockwise.
F1 No.1 One-Way Clutch Prevents front planetary carrier from turning counterclockwise.
When B3 is operating, prevents planetary sun gear from turn-
F2 No.2 One-Way Clutch
ing counterclockwise.
Prevents center planetary carrier and rear ring gear from turn-
F3 No.3 One-Way Clutch
ing counterclockwise.
F4 No.4 One-Way Clutch Prevents intermediate shaft from turning counterclockwise.
Author: Date: 24
03-8
0305L-17
TORQUE SPECIFICATION
Part tightened N·m kgf·cm ft·lbf
Transmission housing x Transmission case 14 mm 34 345 25

17 mm 57 581 42
Automatic transaxle breather tube x Transmission case 5.4 55 48 in.·lbf
Park/Neutral position
osition switch assy Bolt 13 130 9
Nut 6.9 70 61 in.·lbf
Transmission wire x Transmission case 5.4 55 48 in.·lbf
Oil cooler tube union x Transmission case 29 296 21
Transmission control shaft lever RH 16 163 12
Transmission revolution sensor x Transmission case 5.4 55 48 in.·lbf
Extension housing assy x Transmission case 34 345 25
Oil pan x Transmission case 4.4 45 39 in.·lbf
Valve body oil strainer assy x Transmission valve body assy 10 100 7
Transmission valve body assy x Transmission case 11 110 8
Parking lock pawl bracket x Transmission case 7.4 75 65 in.·lbf
Drain plug 20 204 15
Over flow plug 20 204 15
Flange yoke x Output shaft 126 1,280 92
Oil pump x Transmission case 21 214 15
Oil pump body x Stator shaft assy 12 122 9
Detent spring x Transmission valve body assy 11 110 8
Lock plate x Transmission valve body assy 6.4 65 57 in.·lbf
Shift solenoid valve SR x Transmission valve body assy 10 100 7
Shift solenoid valve S1 x Transmission valve body assy 10 100 7
Shift solenoid valve S2 x Transmission valve body assy 10 100 7
ATF Temperature sensor x Transmission valve body assy 10 100 7
Transmission wire x Transmission valve body assy 10 100 7
Author: Date: 20
40-83
40169-01
OVERHAUL
1. REMOVE TRANSMISSION VALVE BODY ASSY

(a) Remove the 20 bolts.
(b) Remove the valve body assy.
D31360
2. REMOVE SHIFT SOLENOID VALVE SL2

(a) Remove the bolt, the 2 straight pins and the lock plate.
(b) Remove the the shift solenoid valve SL2.
D31388
3. REMOVE SHIFT SOLENOID VALVE SLU

(a) Remove the shift solenoid valve SLU.
D31389
4. REMOVE SHIFT SOLENOID VALVE SLT

(a) Remove the bolt, the 2 straight pins and the lock plate.
(b) Remove the shift solenoid valve SLT.
D31396
Author: Date: 103

40-84

(a) Remove shift solenoid valve SL1.
D31395
6. REMOVE SHIFT SOLENOID VALVE SR

(a) Remove the shift solenoid valve SR.
D31394
7. REMOVE SHIFT SOLENOID VALVE S1

(a) Remove the bolt and the shift solenoid valve S1.
D31393

D31392

(a) Remove the shift solenoid valve S2.
D31391
Author: Date: 104

40-85

D31390
11. INSTALL SHIFT SOLENOID VALVE S3

(a) Instal the bolt and the shift solenoid valve S3.
Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)
D31390

(a) Install the shift solenoid valve S2.
D31391

(a) Install the shift solenoid valve S4 with the bolt.
D31392

(a) Install the shift solenoid valve S1 with the bolt.
D31393
Author: Date: 105

40-86
15. INSTALL SHIFT SOLENOID VALVE SR

(a) Install the shift solenoid valve SR.
D31394
16. INSTALL SHIFT SOLENOID VALVE SL1

(a) Install the shift solenoid valve SL1.
D31395
17. INSTALL SHIFT SOLENOID VALVE SLT

(a) Install the shift solenoid valve SLT.
(b) Install the bolt, the 2 straight pins and the lock plate.
Torque: 6.4 N·m (65 kgf·cm, 57 in.⋅lbf)
D31396
18. REMOVE SHIFT SOLENOID VALVE SLU

(a) Install the shift solenoid valve SLU.
D31389

(a) Install the shift solenoid valve SL2.
(b) Install the bolt, the 2 straight pins and the lock plate.
Torque: 6.4 N·m (65 kgf·cm, 57 in.⋅lbf)
D31388
Author: Date: 106

40-87
20. INSTALL TRANSMISSION VALVE BODY ASSY

Pin
(a) Align the groove of the manual valve with the pin of the
lever.
D31555
A (b) Install the 20 bolts.

C HINT:
B Each bolt length is indicated below.
D
Blot length:
A Bolt A: 25 mm (0.98 in.)
A Bolt B: 36 mm (1.42 in.)
Bolt C: 45 mm (1.77 in.)
A B C A D A D31360 Bolt D: 50 mm (1.97 in.)
Author: Date: 107

40-60
40168-01
OVERHAUL
1. FIX CLUTCH DRUM & INPUT SHAFT ASSY

(a) Place the oil pump onto the torque converter clutch, and
then place the clutch drum & input shaft assy onto the oil
Oil Pump Torque pump.
Converter
Clutch
D31375
2. REMOVE REVERSE CLUTCH HUB SUB-ASSY

(a) Using a screwdriver, remove the snap ring from the clutch
drum and the input shaft assy.
D27996
(b) Remove the reverse clutch hub sub assy with the reverse
clutch reaction sleeve, the clutch cushion plate, the re-
verse clutch flange, the 5 reverse clutch discs, and the 4
clutch plates from the clutch drum assy.
D27997
3. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Remove the reverse clutch reaction sleeve from the re-
verse clutch hub sub assy.
D27998
Author: Date: 80
40-61
Cushion Plate 4. REMOVE REAR CLUTCH DISC

(a) Remove the clutch cushion plate, the reverse clutch
F flange, the 4 plates and the 5 discs from the reverse clutch
D P hub.
D
P
D P
D P
D
D27999
5. INSPECT REAR CLUTCH DISC

(a) Check whether the sliding surface of the disc, the plate
and the flange are worn or burnt. If necessary, replace
them.
NOTICE:
If the lining of the disc is peeled off or discolored, or
even if only a part of the printed numbers is damaged,
replace all discs.
D01216 Before assembling new discs, soak them in ATF for
at least 15 minutes.
6. INSPECT REVERSE CLUTCH HUB SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
reverse clutch hub bushing.
Standard inside diameter:
35.812 to 35.837 mm (1.4099 to 1.4109 in.)
Maximum inside diameter: 35.887 mm (1.4129 in.)
If the inside diameter is greater than the maximum inside diam-
eter, replace the reverse clutch hub.
D28000
7. REMOVE FORWARD CLUTCH HUB SUB-ASSY

(a) Remove the forward clutch hub sub assy and thrust wash-
er from the clutch drum assy.
D31376
(b) Remove the 2 thrust needle roller bearings from the for-
ward clutch hub sub assy.
D28500
Author: Date: 81
40-62
8. INSPECT FORWARD CLUTCH HUB SUB-ASSY

forward clutch hub bushing.
Standard inside diameter:
26.037 to 26.062 mm (1.0251 to 1.0261 in.)
eter, replace the forward clutch hub.
D28501
9. REMOVE COAST CLUTCH HUB SUB-ASSY

(a) Remove the coast clutch hub sub-assy from the clutch
drum sub-assy.
D31377
10. INSPECT CLUTCH ASSY, 1 WAY NO.4

(a) Hold the coast clutch hub and turn the 1 way clutch assy.
(b) Check that the 1 way clutch assy turns freely counter-
clockwise and locks clockwise.
If there is a problem with the 1 way clutch, replace the 1 way
clutch.
D31382
11. REMOVE CLUTCH ASSY, 1 WAY NO.4

(a) Remove the 1 way clutch No.4 and the 2 shaft thrust bear-
ing races from the coast clutch hub.
D31381
12. REMOVE FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
(a) Using a screwdriver, remove the hole snap ring.
D31378
Author: Date: 82
40-63
(b) Remove the flange, cushion plate, 4 discs and 4 plates

from the input shaft assy.
D31379
13. INSPECT FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
them.
NOTICE:
D01216 replace all discs.
Before assembling new discs, soak them in ATF for
14. REMOVE COAST CLUTCH DISC

(a) Using a screwdriver, remove the hole snap ring.
D31380
Author: Date: 83
40-64
(b) Remove the flange, the 3 discs and the 3 plates from the
input shaft assy.
D31384
15. INSPECT COAST CLUTCH DISC

them.
NOTICE:
replace all discs.
16. REMOVE INPUT SHAFT ASSY

(a) Remove the thrust needle roller bearing from the input
shaft assy.
D31521
(b) Remove the input shaft assy from the clutch drum assy.
D31522
Author: Date: 84
40-65
(c) Remove the thrust needle roller bearing and thrust bear-
ing race from the clutch drum assy.
D31523
17. REMOVE INPUT SHAFT OIL SEAL RING

(a) Remove the 4 oil seal rings from the input shaft assy.
D31399
18. REMOVE CLUTCH BALANCER NO.1

(a) Place SST on the clutch balancer No.1, and compress the
return spring with a press.
SST 09350-30020 (09350-07040)
(b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)
D31412
(c) Remove the clutch balancer No.1 and the forward clutch
return spring from the input shaft assy.
D31520
(d) Remove the O-ring from the clutch balancer No.1.
D28523
Author: Date: 85
40-66
19. INSPECT FORWARD CLUTCH RETURN SPRING

SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 24.64 mm (0.9701 in.)
Minimum free length: 13.67 mm (0.538 in.)
If the inside diameter is shorter than the minimum free length,
replace the clutch return spring sub-assy.
C59838
20. REMOVE FORWARD CLUTCH PISTON SUB-ASSY

(a) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the input
shaft to remove the forward clutch piston.
D31400
(b) Remove the coast clutch piston from the forward clutch
piston.
D31383
21. REMOVE REVERSE CLUTCH FLANGE

(a) Remove the reverse clutch flange from the clutch drum
assy.
D28506
22. REMOVE DIRECT CLUTCH DISK

(a) Using a screwdriver, remove the 2 hole snap rings from
the clutch drum assy.
D28507
Author: Date: 86
40-67
(b) Remove the reverse clutch flange, the 6 plates and the 5
discs from the clutch drum assy.
D28508
23. INSPECT DIRECT CLUTCH DISK

them.
NOTICE:
replace all discs.
24. REMOVE CLUTCH BALANCER NO.3
(a) Place SST on the clutch balancer No.3, and compress the
SST
SST 09387-00070
(b) Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)
D28509
25. REMOVE REVERSE CLUTCH RETURN SPRING

SUB-ASSY
(a) Remove the reverse clutch return spring and the O-ring
from the reverse clutch piston.
D28510
Author: Date: 87
40-68
26. INSPECT REVERSE CLUTCH RETURN SPRING

SUB-ASSY
C59838
27. REMOVE REVERSE CLUTCH PISTON SUB-ASSY

(a) Remove the reverse clutch piston sub-assy from the
clutch drum sub assy.
D28511
(b) Remove the O-ring from the reverse clutch piston sub
assy.
D28512
(c) Remove the O-ring from the clutch drum sub assy.
D28513
28. REMOVE DIRECT CLUTCH PISTON SUB-ASSY

(a) Place SST on the direct clutch piston, and compress the
SST 09320-89010, 09350-30020 (09350-07070)
SST
D28514
Author: Date: 88
40-69
(b) Using 2 screw drivers, remove the direct clutch piston sub
assy from the clutch drum.
D28515
(c) Remove the clutch balancer No.2 and the direct clutch re-
turn spring sub assy from the direct clutch piston sub
assy.
D28517
(d) Remove the 2 O-rings from the direct clutch piston sub-
assy.
D28816
29. INSPECT DIRECT CLUTCH RETURN SPRING

SUB-ASSY
C59838
30. INSTALL DIRECT CLUTCH PISTON SUB-ASSY

(a) Coat 2 new O-rings with ATF, and install them in the direct
clutch piston.
D28816
Author: Date: 89
40-70
(b) Install the clutch balancer No.2 and the direct clutch re-
turn spring to the direct clutch piston sub assy.
(c) Be careful not to damage the O-rings. Press in the direct
clutch piston into the clutch drum by hands.
D28517
(d) Place SST on the direct clutch piston, and compress the
SST 09320-89010, 09350-30020 (09350-07070)
(e) Install the snap ring with a snap ring expander.
NOTICE:
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
Stop pressing when the spring sheet is lowered to the
place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevent the spring sheet from being de-
formed.
Do not expand the snap ring excessively.
D31401
(f) Set the end gap of the snap ring in the piston as shown
in the illustration.
Stopper
D28536
31. INSTALL REVERSE CLUTCH PISTON SUB-ASSY

(a) Coat a new O-ring with ATF, and install it on the clutch
drum sub assy.
D28513
Author: Date: 90
40-71
(b) Coat a new O-ring with ATF, and install it on the reverse
clutch piston sub assy.
D28512
(c) Be careful not to damage the O-ring. Press in the clutch

drum sub assy into the reverse clutch piston with both
hands.
D28511
32. INSTALL REVERSE CLUTCH RETURN SPRING

SUB-ASSY
(a) Coat a new O-ring with ATF, and install it on the reverse
(b) Install the reverse clutch return spring onto the reverse
D28510
33. INSTALL CLUTCH BALANCER NO.3

SST (a) Place SST on the clutch balancer No.3, and compress the
clutch balancer with a press.
SST 09387-00070
(b) Install the snap ring with a snap ring expander.
SST 09350-30020 (09350-07070)
NOTICE:
Be sure the end gap of the snap ring is not aligned
D28514 with the spring retainer claw.
place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevent the spring sheet from being de-
formed.
Author: Date: 91
40-72
(c) Set the end gap of the snap ring in the piston as shown
Snap Ring
OK:
Snap Ring
NG:
D31539
34. INSTALL DIRECT CLUTCH DISK

(a) Install the reverse clutch flange, the 6 plates and the 5
F
discs on the clutch drum sub assy.
D Install in order: P = Plate, D = Disc, F = Flange,
P
D F - D - P - D - P - D - P - D - P - D - P - P
P
D
P
D
P
D
P
P
D28508
(b) Using a screwdriver, install the 2 hole snap rings on the

clutch drum sub assy.
D28507
Author: Date: 92
40-73
35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

(a) Using a dial gauge, measure the moving distance (dis-
tance A) of the clutch flange at the both ends across a di-
A
ameter while blowing air from the oil hole as shown in the
illustration, and calculate the average.
HINT:
Flange moving distance A = 0.26 to 1.14 mm
Pack Clearance = Flange moving distance A - 0.05 mm
Pack Clearance: 0.5 to 0.8 mm (0.020 to 0.031 in.)
NOTICE:
Install a selective flange (t = 3.4 mm) when measuring the
moving distance. (shaded area in the illustration.)
(b) If the pack clearance is outside the standard, select and
install a clutch flange that brings the pack clearance with-
in the standard.
HINT:
There is 9 type of flanges that can be used to adjust the pack
clearance. Select the one with the most appropriate thickness.
D29841 Flange thickness:
No. Thickness No. Thickness
0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
4 3.4 mm (0.134 in.) - -
36. INSTALL REVERSE CLUTCH FLANGE

(a) Install the reverse clutch flange to the clutch drum sub
assy.
D28506
Author: Date: 93
40-74
37. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve, the clutch cush-
S ion plate, the reverse clutch flange, the 5 reverse clutch
discs, and the 4 clutch plates to the reverse clutch hub.
C Install in order: P = Plate, D = Disc, F = Flange,
S = Sleeve, C = Cushion Plate
F S - C - F - D - P - D - P - D - P - D - P - D
D (b) Using a screwdriver, install the hole snap ring.
P
D
P 38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
D (a) Using a dial gauge, measure the reverse clutch piston
P stroke (distance A) and the moving distance (distance B)
D of the reverse clutch flange at the both ends across a di-
P
ameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) from
the oil hole as shown in the illustration, and calculate the
D average.
HINT:
D31540 Piston stroke A = 1.05 to 2.15 mm
Flange moving distance B = 0.72 to 1.08 mm
Pack Clearance = Piston stroke A - Flange moving distance B
- 0.06
NOTICE:
A
B
D28538
Author: Date: 94
40-75

in the standard.
HINT:
There are 11 types of flanges that can be used to adjust the
pack clearance. Select the one with the most appropriate thick-
ness.
Flange Thickness:
0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.)
1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.)
2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.)
3 3.1 mm (0.122in.) 9 3.7 mm (0.146 in.)
4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.)
5 3.3 mm (0.130 in.) -
39. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Using a screwdriver, remove the snap ring from the clutch
drum assy.
D29844
(b) Remove the reverse clutch reaction sleeve, the clutch

cushion plate, the reverse clutch flange, the 5 reverse
clutch discs, and the 4 clutch plates from the reverse
clutch hub sub assy.
D29843
40. INSTALL FORWARD CLUTCH PISTON SUB-ASSY

(a) Install the coast clutch piston to the forward clutch piston.
(b) Install the forward clutch piston sub-assy to the input
shaft.
D31383
Author: Date: 95
40-76
41. INSTALL CLUTCH BALANCER NO.1

(a) Coat a new O-ring with ATF and install it on the clutch ba-
lancer No.1.
D28523
(b) Install the clutch balancer No.1 and the forward clutch re-
turn spring sub assy.
NOTICE:
Be careful not to damage the O-ring.
D31520
(c) Place SST on the clutch balancer No.1, and compress the
SST 09350-30020 (09350-07040, 09350-07070)
(d) Install the snap ring with a snap ring expander.
NOTICE:
Be sure that the end gap of the snap ring is not aligned
with the spring retainer claw.
D31412 place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevents the spring sheet from being de-
formed.
(e) Set the end gap of the snap ring in the piston as shown
Snap Ring
OK:
Snap Ring
NG:
D31536
Author: Date: 96
40-77
42. INSTALL COAST CLUTCH DISC

D (a) Install the flange, the 3 discs and the 3 plates to the for-
F ward clutch piston.
P (b) Using a screwdriver, install the hole snap ring.
P
P
D31384
43. INSPECT PACK CLEARANCE OF COAST CLUTCH

HINT:
Flange moving distance A =
0.38 to 1.48 mm (0.01496 to 0.0583 in.)
Pack Clearance =
Flange moving distance A - 0.02 mm (0.0008 in.)
NOTICE:
in the standard.
HINT:
D31403 There are 11 types of flanges that can be used to adjust the
ness.
Flange thickness
0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
4 3.4 mm (0.134 in.) 9 3.9 mm (0.154 in.)
Author: Date: 97
40-78
44. INSTALL FORWARD MULTIPLE DISC CLUTCH

CLUTCH DISC
(a) Install the flange, the 4 discs and the 5 plates to the input
F shaft assy.
D Install in order: P = Plate, D = Disc, F = Flange,
P F - D - P - D - P - D - P - D - P - P
D
P
D
P
D
P
P
D31379
(b) Using a screwdriver, install the hole snap ring.
D28519
(c) Install the thrust needle roller bearing and thrust bearing
race.
Inside Outside
Thrust needle roller bear-
21.3 mm (0.839 in.) 41.1 mm (1.618 in.)
ing
Thrust bearing race No.2 22.6 mm (0.890 in.) 44.8 mm (1.764 in.)
D31523
45. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat the 4 oil seal rings with ATF.
(b) Squeeze the ends of the 4 oil seal rings together, and then
install them to the starter shaft groove.
NOTICE:
Do not expand the ring ends excessively.
HINT:
After installing the oil seal rings, check that they rotate smooth-
D31399 ly.
Author: Date: 98
40-79
46. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

HINT:
Flange moving distance A = 0.36 to 1.50 mm
Pack Clearance = Flange moving distance A - 0.11 mm
Pack Clearance: 0.56 - 0.86 mm (0.0220 to .0339 in.)
NOTICE:
A Install a selective flange (t = 3.4 mm) when measuring the
in the standard.
HINT:
There are 11 types of flanges that can be used to adjust the
D28537 ness.
Flange thickness
0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.)
1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.)
2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.)
3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.)
4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.)
5 3.5 mm (0.138 in.) -
47. INSTALL INPUT SHAFT ASSY

(a) Install the input shaft assy to the clutch drum.
D31522
(b) Install the thrust needle roller bearing to the clutch drum
assy.
Thrust needle roller bearing diameter:
Inside Outside
21.3 (0.839) 41.1 (1.618)
ing
D31521
Author: Date: 99
40-80
48. INSTALL COAST CLUTCH HUB SUB-ASSY

(a) Install the thrust bearing race No.2 and the input shaft
thrust bearing race RR to the multiple disc clutch clutch
hub.
Bearing and race diameter:
Inside Outside
Input shaft bearing race
22.6 mm (0.890 in.) 44.8 mm (1.764 in.)
RR
D31381
(b) Install the multiple disc clutch clutch hub to the clutch
drum assy.
D31377
49. INSTALL FORWARD CLUTCH HUB SUB-ASSY

(a) Install the 2 thrust needle roller bearings to the forward
Bearing A
clutch hub sub assy.
Inside Outside
Bearing A 42.5 (1.673) 61.2 (2.409)
Bearing B 35.6 mm (1.402 in.) 56.6 mm (2.228 in.)
Bearing B
D28500
(b) Install the forward clutch hub sub assy to the clutch drum
assy.
D31376
Cushion Plate 50. INSTALL REAR CLUTCH DISC

(a) Install the clutch cushion plate, the reverse clutch flange,
F the 4 plates and the 5 discs to the reverse clutch hub.
D P
D
P
D P
D P
D
D27999
Author: Date: 100

40-81
51. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve to the reverse
clutch hub.
D27998
52. INSTALL REVERSE CLUTCH HUB SUB-ASSY

(a) Install the reverse clutch hub sub assy, the reverse clutch
reaction sleeve, the clutch cushion plate, the reverse
clutch flange, the 5 reverse clutch discs, and the 4 clutch
plates to the clutch drum assy.
D27997
(b) Using a screwdriver, install the snap ring on the clutch

drum and the input shaft assy.
D27996
Author: Date: 101

40-54
400XH-02
OVERHAUL
1. REMOVE FRONT OIL PUMP BODY O-RING

(a) Remove the O-ring from the oil pump assy.
D27950
Torque Converter 2. FIX OIL PUMP ASSY

Clutch (a) Place the oil pump body on the torque converter clutch.
D27951
3. REMOVE CLUTCH DRUM OIL SEAL RING

(a) Remove the 3 oil seal rings.
D27952
4. REMOVE STATOR SHAFT ASSY

(a) Remove the 14 bolts, and then remove the stator shaft
from the oil pump body.
D27953
Author: Date: 74
40-55
5. REMOVE FRONT OIL PUMP BODY O-RING

(a) Remove the O-ring from the oil pump body.
(b) Remove the oil pump body from the torque converter
clutch.
D27963
6. INSPECT FRONT OIL PUMP BODY SUB-ASSY

oil pump body bushing.
eter, replace the oil pump body.
D27954
7. INSPECT STATOR SHAFT ASSY

stator shaft bushing.
Maximum inside diameter:
Front side: 21.577 mm (0.850 in.)
Rear side: 32.08 mm (1.263 in.)
If the inside diameter is grater than the maximum inside diame-
ter, replace the stator shaft.
D27955
8. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY

(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 to 0.17 mm (0.0039 to 0.0067 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum clearance,
check the drive gear, the driven gear and the pump body.
D27956
(c) Using a feeler gauge, measure the clearance between

the driven gear teeth and the drive gear teeth.
Standard tip clearance:
0.070 to 0.150 mm (0.0028 to 0.0059 in.)
Maximum tip clearance: 0.150 mm (0.0059 in.)
If the tip clearance is greater than the maximum clearance,
D27957
Author: Date: 75
40-56
(d) Using a steel straight edge and a feeler gauge, measure

the side clearance of both gears.
Standard side clearance:
0.03 to 0.05 mm (0.0012 to 0.002 in.)
Maximum side clearance: 0.05 mm (0.002 in.)
(e) There are 7 different thicknesses for the drive and driven
gears.
Drive and driven gears thickness:
D01286 Mark Thickness
0 10.736 to 10.742 mm (0.42268 to 0.42291 in.)
1 10.743 to 10.749 mm (0.42296 to 0.42319 in.)
2 10.750 to 10.756 mm (0.42323 to 0.42346 in.)
3 10.757 to 10.763 mm (0.42350 to 0.42374 in.)
4 10.764 to 10.770 mm (0.42378 to 0.42401 in.)
5 10.771 to 10.777 mm (0.42405 to 0.42429 in.)
6 10.778 to 10.784 mm (0.42433 to 0.42457 in.)
If the side clearance is greater than the maximum thickness,

9. REMOVE FRONT OIL PUMP DRIVE GEAR
D27958
10. REMOVE FRONT OIL PUMP DRIVEN GEAR
D27959
11. REMOVE FRONT OIL PUMP OIL SEAL

(a) Using a screwdriver, remove the oil seal.
NOTICE:
Be careful not to damage the bushing and the oil pump
body.
D27960
Author: Date: 76
40-57
12. INSTALL FRONT OIL PUMP OIL SEAL

(a) Using SST and a hammer, install a new oil seal.
HINT:
The oil seal end should be flush with the outer edge of the pump
body.
SST SST 09350-30020 (09351-32140)
(b) Coat the oil seal lip with MP grease.
D27961
13. FIX FRONT OIL PUMP BODY SUB-ASSY

(a) Place the oil pump body on the torque converter clutch.
14. INSTALL FRONT OIL PUMP DRIVEN GEAR

(a) Coat the driven gear with ATF.
(b) Install the driven gear to the oil pump body.
D27959
15. INSTALL FRONT OIL PUMP DRIVE GEAR

(a) Coat the drive gear with ATF.
(b) Install the drive gear to the oil pump body.
D27958
16. INSTALL FRONT OIL PUMP BODY O-RING

(a) Install the O-ring to the oil pump body.
D27963
Author: Date: 77
40-58
17. INSTALL STATOR SHAFT ASSY

(a) Align the stator shaft with each bolt hole.
(b) Install the 14 bolts.
Torque: 12 N·m (122 kgf·cm,9 ft·lbf)
D27953
18. INSTALL CLUTCH DRUM OIL SEAL RING

(a) Coat the 3 oil seal rings with ATF.
(b) Squeeze the ends of the 3 oil seal rings together with the
wrap distance 8 mm or less, and then install them to the
starter shaft groove.
NOTICE:
Do not expand the ring ends excessively.
HINT:
D27952 After installing the oil seal rings, check that they rotate smooth-
ly.
19. INSPECT OIL PUMP DRIVE GEAR ROTATION
(a) Make sure that the drive gear rotates smoothly.
(b) Remove the oil pump assy from the torque converter.
D27962
20. INSTALL FRONT OIL PUMP BODY O-RING

(a) Install the O-ring to the oil pump assy.
D27950
Author: Date: 78
40-10
400XK-02
OVERHAUL
1. REMOVE TRANSMISSION CONTROL SHAFT LEVER

RH
(a) Remove the nut and the transmission control shaft lever
RH.
D31347
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY

(a) Using a screwdriver, unstake the lock washer.
(b) Remove the lock washer, the nut and the bolt.
(c) Remove the park/neutral position switch.
D31348
3. REMOVE OIL COOLER TUBE UNION

(a) Remove the 2 oil cooler tube unions.
(b) Remove the O-rings from the oil cooler tube unions.
D31349
Author: Date: 30
40-1 1
4. REMOVE TRANSMISSION REVOLUTION SENSOR

(a) Remove the 2 bolts and the 2 transmission revolution
sensors.
(b) Remove the O-ring from each sensor.
D31350
5. REMOVE AUTOMATIC TRANSMISSION BREATHE

TUBE
(b) Remove the breather tube.
D31351
6. REMOVE AUTOMATIC TRANSMISSION FLANGE

YOKE ASSY
(b) Remove the transmission housing.
D31352
7. REMOVE AUTOMATIC TRANSMISSION FLANGE

YOKE ASSY
(a) Using a hammer and chisel, loosen the staked part of the
nut.
(b) Remove the nut and flange yoke assy.
D31353
Author: Date: 31
40-12
(c) Remove the oil seal from the flange yoke assy.
D01118
8. REMOVE EXTENSION (ATM) HOUSING SUB-ASSY

D31354
(b) Using a snap ring expander, remove the snap ring.

(c) Remove the thrust needle roller bearing and the 2 bearing
race.
D29874
(d) Use a screwdriver to remove the extension housing sub-

assy.
D31355
9. REMOVE RR COVER SLEEVE

(a) Remove the 2 washers and RR cover sleeve.
10. REMOVE TRANSMISSION CASE ADAPTOR RADIAL
BALL BEARING
(a) Remove the transmission case adaptor radial ball bearing
from the extension housing sub-assy.
D31410
Author: Date: 32
40-13
11. REMOVE AUTOMATIC TRANSMISSION EXTENSION

HOUSING OIL SEAL
(a) Using a screwdriver, remove the oil seal.
D01409
12. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSY

(a) Install the transmission case on the overhaul attachment.
13. REMOVE AUTOMATIC TRANSMISSION OIL PAN
SUB-ASSY
NOTICE:
Do not turn the transmission over as this will contaminate
the valve body with foreign matter located at the bottom of
the pan.
D31356 (a) Remove the drain plug and the gasket.
(b) Remove the 20 bolts, oil pan and gasket.
14. INSPECT AUTOMATIC TRANSMISSION OIL PAN
SUB-ASSY
(a) Remove the magnets, and use them to collect steel par-
ticles.
(b) Carefully look at the foreign matter and particles in the
pan and on the magnets to anticipate the type of wear you
will find in the transmission.
Steel (magnetic): bearing, gear and clutch plate
D01124 wear
Brass (non-magnetic): bushing wear
15. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Turn over the transmission.
(b) Remove the 4 bolts holding the valve body oil strainer
assy to the valve body.
(c) Remove the O-ring from the valve body oil strainer assy.
D31357
Clamp 16. REMOVE TRANSMISSION WIRE

(a) Remove the ATF temperature sensor.
(b) Remove the 2 bolts and disconnect the 2 clamps.
(c) Disconnect the 9 connectors from the shift solenoid
valves.
D31358
Author: Date: 33
40-14
(d) Remove the bolt from the case.

(e) Pull the transmission wire out of the transmission case.
(f) Remove the O-ring from the transmission wire.
D31359
17. REMOVE TRANSMISSION VALVE BODY ASSY

(a) Remove the bolt and detente spring.
D31546
(b) Remove the 20 bolts.

(c) Remove the valve body assy.
D31360
18. REMOVE TRANSAXLE CASE GASKET

(a) Remove the 3 transaxle case gaskets.
D27968
19. REMOVE BRAKE DRUM GASKET

(a) Remove the 3 brake drum gaskets.
D27969
Author: Date: 34
40-15
20. REMOVE CHECK BALL BODY

(a) Remove the check ball body and the spring.
Check Ball
Body
Spring
D27914
21. REMOVE C-2 ACCUMULATOR PISTON

(a) While bowing compressed air into the oil hole, remove the
C-2 accumulator piston and the spring.
(b) Remove the 2 O-rings from the piston.
NOTICE:
Take care as the C-3 and B-3 accumulator piston may
eject.
22. REMOVE B-3 ACCUMULATOR PISTON
D27915 (a) Applying compressed air to the oil hole, remove the B-3
accumulator piston and the spring.
NOTICE:
Take care as the C-3 accumulator piston may jump out.
23. REMOVE C-3 ACCUMULATOR PISTON

(a) While blowing compressed air into the oil hole, remove
the C-3 accumulator piston and the 2 springs.
D27916
24. REMOVE B-1 ACCUMULATOR VALVE

(a) Remove the B-1 accumulator valve and the 2 springs.
D27917
Author: Date: 35
40-16
25. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 3 bolts and the parking lock pawl bracket.
D31361
26. REMOVE PARKING LOCK ROD SUB-ASSY

(a) Disconnect the parking lock rod from the manual valve le-
ver.
D31551
27. REMOVE PARKING LOCK PAWL SHAFT

(a) Pull out the parking lock pawl shaft from the front side,
then remove the lock pawl and the spring.
(b) Remove the E-ring from the shaft.
D31552
28. REMOVE MANUAL VALVE LEVER SUB-ASSY

(a) Using a hammer and a screwdriver, cut off the spacer and
remove it from the shaft.
D31553
(b) Using a pin punch and a hammer, drive out the spring pin.
HINT:
Slowly drive out the spring pin so that it does not fall into the
transmission case.
(c) Pull the manual valve lever shaft out through the case,
and remove the manual valve lever.
D31554
Author: Date: 36
40-17
29. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using a screwdriver, remove the 2 oil seals.
D31362
30. REMOVE OIL PUMP ASSY

(a) Remove the 10 bolts from the transmission case.
D31363
Pull (b) Using screwdriver, pull out the oil pump.
D31364
(c) Remove the thrust bearing race No.1 from the oil pump.
D28809
31. REMOVE CLUTCH DRUM & INPUT SHAFT ASSY

(a) Remove the clutch drum & input shaft assy from the trans-
mission case.
D27923
Author: Date: 37
40-18
(b) Remove the clutch drum thrust washer, 2 thrust needle

Thrust Needle roller bearings and bearing race.
Roller Bearing
Clutch drum
thrust washer
Bearing Race
D31541
32. INSPECT 1 WAY N0.2 CLUTCH ASSY

(a) Hold the reverse clutch hub and turn the 1 way clutch assy
No.2.
(b) The 1 way clutch assy No.2 turns freely clockwise and
locks counterclockwise.
clutch.
D27993
33. REMOVE 1 WAY N0.2 CLUTCH ASSY

(a) Remove the 1 way clutch assy No.2 and clutch drum
thrust washer from the clutch drum and input shaft assy.
D27994
34. REMOVE BRAKE NO.3 SNAP RING

(a) Using a screwdriver, remove the brake No.3 snap ring
from the case.
D27925
35. REMOVE 2ND BRAKE DISC SET

(a) Remove the flange, cushion plate, 4 discs and the 4
plates from the case.
D27926
Author: Date: 38
40-19
36. INSPECT 2ND BRAKE DISC SET

(a) Check whether the sliding surface of the disc, the plate or
the flange are worn or burnt.
If necessary, replace them.
NOTICE:
if any part of the printed numbers is damaged, replace
all discs.
37. REMOVE 2ND BRAKE PISTON HOLE SNAP RING
(a) Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)
D27927
38. REMOVE 1 WAY CLUTCH ASSY

(a) Remove the 1 way clutch assy and the planetary carrier
thrust washer No.1 from the case.
D27928
39. REMOVE 2ND BRAKE CYLINDER

(a) Remove the 2nd brake cylinder from the case.
D27929
40. REMOVE 2ND BRAKE PISTON

SST
(a) Using SST and a press, remove the snap ring.
SST 09351-40010 (09351-04060, 09351-04070)
(b) Remove the 2nd brake piston return spring.
D28817
Author: Date: 39
40-20
(c) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.
D28545
(d) Remove the 2 O-rings from the 2nd brake piston.
D28546
41. INSPECT BRAKE PISTON RETURN SPRING

SUB-ASSYNO.3
replace the brake piston return spring sub-assy No.3.
D29828
42. REMOVE FRONT PLANETARY GEAR ASSY

(a) Remove the front planetary gear assy and the 1 way
clutch inner race from the case.
D27930
(b) Remove the thrust needle roller bearing, the thrust bear-
ing race No.3 and the planetary carrier thrust washer No.2
from the front planetary gear assy.
D27931
Author: Date: 40
40-21
43. INSPECT FRONT PLANETARY GEAR ASSY

(a) Using a feeler gauge, measure the front planetary pinion
gear thrust clearance.
Standard clearance:
0.20 to 0.60 mm (0.008 to 0.024 in.)
Maximum clearance: 0.65 mm (0.026 in.)
If the clearance is greater than the maximum clearance, replace
the front planetary gear assembly.
D28544
(b) Using a dial indicator, measure the inside diameter of the

front planetary gear bushing.
eter, replace the front planetary gear assy.
D28543
44. INSPECT 1 WAY CLUTCH ASSY

(a) Install the 1 way clutch assy to 1 way clutch inner race.
(b) Hold the 1 way clutch inner race and turn the 1 way clutch
assy.
(c) Check that the 1 way clutch assy turns freely counter-
clutch.
D28542 (d) Remove the 1 way clutch assy from the 1 way clutch inner
race.
45. REMOVE FRONT PLANETARY RING GEAR
(a) Remove the front planetary ring gear from the transmis-
sion case.
D31542
46. REMOVE CTR PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring.
D31543
Author: Date: 41
40-22
(b) Remove the CTR planetary ring gear and the front plane-
tary ring gear flange from the front planetary ring gear.
D31544
47. REMOVE BRAKE DISC NO.1

(a) Remove the flange, the 3 discs and the 3 plates from the
case.
D27933
48. INSPECT BRAKE DISC NO.1

(a) Check whether the sliding surface of the disc, the plate or
the flange are worn or burnt.
NOTICE:
if any part of the groove is damaged, replace all discs.
Before assembling new discs, soak them in ATF for
D01216 at least 15 minutes.
49. REMOVE BRAKE PISTON RETURN SPRING SNAP

RING
(a) Using a screwdriver, remove the brake piston return
spring snap ring from the case.
D27934
50. REMOVE BRAKE PISTON RETURN SPRING

SUB-ASSY
(a) Remove the brake piston return spring and the brake pis-
ton No.1 with the brake cylinder No.1 from the transmis-
sion case.
D27935
Author: Date: 42
40-23

SUB-ASSY
replace the brake piston return spring sub-assy.
D03830
52. REMOVE BRAKE PISTON NO.1

(a) Hold the brake piston No.1 and apply compressed air
(392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to
remove the brake piston No.1.
HINT:
If the piston does not pop out with compressed air, lift the piston
out with needle-nose pliers.
(b) Remove the 2 O-rings from the brake piston No.1.
D27936

(a) Using a screwdriver, remove the snap ring from the case.
D27937
(b) Remove the 2 flanges, the brake piston return spring, the
4 discs and the 3 plates from the case.
D31547

and the flange are worn or burnt.
NOTICE:
If the lining of the disc is peeled off or discolor, or if
any part of the printed numbers is damaged, replace
all discs.
Author: Date: 43
40-24

SUB-ASSYNO.2
replace the brake piston return spring sub-assy No.2.
D29829

(a) Hold the brake piston No.2 and apply compressed air
(392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to
remove the brake piston No.2 with the cylinder.
HINT:
(b) Remove the piston from the cylinder.
D27939 (c) Remove the 2 O-rings from the brake piston No. 2.
57. REMOVE CTR PLANETARY GEAR ASSY

(a) Remove the CTR planetary gear assy, the planetary sun
gear, thrust needle roller bearing and the thrust bearing
race No.4 from the case.
D31532
58. INSPECT CTR PLANETARY GEAR ASSY

(a) Using a feeler gauge, measure the CTR planetary gear
pinion thrust clearance.
Standard clearance:
0.12 to 0.68 mm (0.005 to 0.027 in.)
the CTR planetary gear assy.
D28533
59. REMOVE INTERMEDIATE SHAFT

(a) Using SST, remove the snap ring from the case.
SST 09350-30020 (09350-07060)
D31365
Author: Date: 44
40-25
(b) Remove the intermediate shaft with the 1 way clutch assy
No.3 from the case.
D27942
60. INSPECT 1WAY NO.3 CLUTCH ASSY

(a) Hold the RR planetary ring gear flange sub assy and turn
the 1 way clutch assy.
(b) Check that the 1 way clutch assy turns freely counter-
clutch.
D28532
61. REMOVE 1WAY NO.3 CLUTCH ASSY

(a) Remove the 1 way clutch assy No.3 and the 1 way clutch
inner race from the intermediate shaft.
D27964
62. REMOVE RR PLANETARY RING GEAR FLANGE

Trust Bearing Thrust Bearing
SUB-ASSY
Race No.7 Race No.8
(a) Remove the thrust bearing race No.8, the thrust needle
roller bearing, the thrust bearing race No.7 and the plane-
tary ring gear flange from the intermediate shaft.

D27965
63. INSPECT RR PLANETARY RING GEAR FLANGE

SUB-ASSY
RR planetary ring gear bushing.
eter, replace the RR planetary ring gear.
D28531
Author: Date: 45
40-26
64. INSPECT INTERMEDIATE SHAFT

(a) Using a dial indicator, check the intermediate shaft run
out.
Maximum run out: 0.08 mm (0.003 in.)
If the bend exceeds the specification, replace the intermediate
shaft with a new one.
D28529
(b) Using a micrometer, check the outer diameter of the inter-

mediate shaft positions shown in the diagram.
Standard diameter:
A: 25.962 to 25.975 mm (1.022 to 1.023 in.)
B: 25.962 to 25.975 mm (1.022 to 1.023 in.)
C: 32.062 to 32.075 mm(1.262 to 1.263 in.)
D: 32.062 to 32.075 mm (1.262 to 1.263 in.)
Minimum diameter:
A: 25.912 mm (1.020 in.)
B: 25.912 mm (1.020 in.)
C: 32.012 mm (1.260 in.)
D: 32.012 mm (1.260 in.)
A B C D If the outer diameter is outside the standard, replace the inter-
mediate shaft with the new one.
D28530
65. REMOVE BRAKE PLATE STOPPER SPRING

(a) Remove the brake plate stopper spring from the case.
D27943
Author: Date: 46
40-27

(a) Remove the sleeve, 4 plates, 4 discs and flange from the
case.
D31366

and the flange are worn or burnt.
NOTICE:
If the lining of the disc is peeled off or discolor, or if
any part of the printed numbers is damaged, replace
all discs.
68. REMOVE REAR PLANETARY GEAR ASSY
(a) Remove the rear planetary gear assy from the case.
D31368
(b) Remove the thrust bearing race No.9 and the thrust
Thrust Needle needle roller bearing from the rear planetary gear assy.
Roller Bearing
Race
D31369
Author: Date: 47
40-28
(c) Remove the thrust needle roller bearing from the case.
D27947
69. INSPECT REAR PLANETARY GEAR ASSY

(a) Using a feeler gauge, measure the rear planetary gear
pinion thrust clearance.
Standard clearance: 0.2 to 0.6 mm (0.008 to 0.024 in.)
the planetary gear assy.
D31370
(b) Using a dial indicator, measure the inside diameter of the

rear planetary gear bushing.
eter, replace the rear planetary gear assy.
D31371
70. REMOVE 1ST & REVERSE BRAKE RETURN SPRING

SST Snap Ring SUB-ASSY
(a) Place SST on the 1st & reverse brake return spring sub-
assy and compress the brake return spring.
SST 09350-30020 (09350-07050)
(b) Using SST, remove the snap ring and the brake return
spring.
SST 09350-30020 (09350-07070)
D31372
71. INSPECT 1ST & REVERSE BRAKE RETURN SPRING

SUB-ASSY
replace the brake piston return spring sub-assy.
D29830
Author: Date: 48
40-29
72. REMOVE 1ST & REVERSE BRAKE PISTON

(a) Hold the 1st & reverse brake piston and blow compressed
air (392 kPa, 4 kgf/cm2, 57 psi) into the transmission case
to remove the brake piston.
HINT:
(b) Remove the brake apply tube from the piston.
D31373 (c) Remove the O-ring from brake piston.
73. REMOVE BRAKE REACTION SLEEVE

SST (a) Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
(b) Remove the 2 O-rings from the reaction sleeve.
D28079

SST (a) Using SST, remove the brake piston No.4.
SST 09350-30020 (09350-07090)
(b) Remove the 2 O-rings from the piston No.4.
D01240
Author: Date: 49
40-30
75. BEARING POSITION
D31374
Front Race Diameter Thrust Bearing Diameter Rear Race Diameter

Mark
Inside / Outside Inside / Outside 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) / 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) / 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) / 62.7 mm (2.469 in.) 45.9 mm (1.807 in.) / 64.0 mm (2.520 in.) -
G 37 mm (1.45 in.) / 52.3 mm (2.059 in.) 34.6 mm (1.362 in.) / 52.0 mm (2.047 in.) -
H 36.9 mm (1.453 in.) / 49.7 mm (1.957 in.) 36.1 mm (1.421 in.) / 52.5 mm (2.067 in.) 36.1 mm (1.421 in.) / 51.0 mm (2.007 in.)
Author: Date: 50
40-31
O-Ring 76. INSTALL BRAKE PISTON NO.4

(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
brake piston No.4.
(c) Install the brake piston No.4 to the reaction sleeve.
O-Ring
D28795
77. INSTALL BRAKE REACTION SLEEVE

Brake Reaction (a) Coat a new O-ring with ATF, and install it to the reaction
Sleeve sleeve.
Brake Piston No.4 (b) With the brake piston No.4 underneath (the rear side),
install the brake reaction sleeve and the brake piston
No.4 to the transmission case.
NOTICE:
Be careful not to damage the O-rings.
D28080
78. INSTALL 1ST & REVERSE BRAKE PISTON

(a) Coat a new O-ring with ATF.
1st & Reverse Brake Piston (b) Install the O-ring on the 1st & reverse brake piston .
(c) With the spring seat of the piston facing upwards (the
front side), place the piston in the transmission case.
NOTICE:
Be careful not to damage the O-ring.
D28081
(d) Place the piston return spring onto the brake piston No.4.
D28549
SST 79. INSTALL 1ST & REVERSE BRAKE RETURN SPRING

Snap Ring SUB-ASSY
(a) Place SST on the brake return spring, and compress the
return spring.
SST 09350-30020 (09350-07050)
(b) Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
D31538
Author: Date: 51
40-32
80. INSTALL REAR PLANETARY GEAR ASSY

(a) Install the thrust needle roller bearing.
Inside Outside
45.9 mm (1.807 in.) 64.0 mm (2.520 in.)
ing
D27947
Thrust Needle (b) Install the thrust needle roller bearing.

Roller Bearing (c) Coat the thrust bearing race No.9 with petroleum jelly, and
install it onto the rear planetary ring gear.
Bearing & race diameter:
Inside Outside
race 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.)
D31369
(d) Install the rear planetary gear assy.
D31368
81. INSPECT PACK CLEARANCE OF FIRST & REVERSE

BRAKE
(a) Make sure that the 1st & reverse brake piston move
smoothly when pulling and releasing the compressed air
gun lever while applying compressed air into the trans-
mission case.
D27966
Author: Date: 52
40-33
(b) Using vernier calipers, measure the level difference

(length A) between the upper surface of the brake apply
tube and the hitting surface of the brake flange No.4 at
both ends across the 1st & reverse brake piston diameter,
A and calculate the average.
NOTICE:
The 1st & reverse brake piston must be securely installed
to the end face of the transmission case.
HINT:
Length A = 22.05 to 22.91 mm (0.8681 to 0.9020 in.)
D31404
(c) Using vernier calipers, measure the thickness (length B)

of the brake flanges the 4 brake plates No.4 and the 4
H brake discs No.4 altogether at the both ends across a di-
ameter, and calculate the average.
B HINT:
Length B = 23.11 to 23.89 mm (0.9098 to 0.9405 in.)
Pack Clearance =
Length A - Length B - 0.22 mm (0.0087 in.) + 1.8 mm (0.071
D31405 in.)

(d) If the pack clearance is outside the standard, select and
install a brake flange that brings the pack clearance to be
within the standard.
HINT:
There are 8 types of flanges that can be used to adjust the pack
clearance. Select the one with the most appropriate thickness.
Thickness H:
No. Thickness H No. Thickness H
0 0 mm (0 in.) 8 0.8 mm (0.03150 in.)
2 0.2 mm (0.00787 in.) 10 1.0 mm (0.03937 in.)
4 0.4 mm (0.01575 in.) 12 1.2 mm (0.04724 in.)
6 0.6 mm (0.02362 in.) 14 1.4 mm (0.05512 in.)
Author: Date: 53
40-34
82. INSTALL BRAKE DISC NO.4

(a) Install the sleeve, 4 plates, the 4 discs and the flange.
F
Install in order: P = Plate, D = Disc, F = Flange,
D S = Sleeve
P F - D - P - D - P - D - P - D - P - S
D
P
D
P
D
P
D31366
83. INSTALL BRAKE PLATE STOPPER SPRING

(a) Install the brake plate stopper spring.
D27943
Thrust Bearing 84. INSTALL RR PLANETARY RING GEAR FLANGE

Thrust Bearing
Race No.7 SUB-ASSY
Race No.8
(a) Install the thrust bearing race No.8, the thrust needle roll-
er bearing, the thrust bearing race No.7 and the planetary
ring gear flange to the intermediate shaft.
Inside Outside
D27965 Thrust needle roller bear-
32.1 mm (1.264 in.) 49.35 mm (1.943 in.)
ing
Author: Date: 54
40-35
85. INSTALL 1WAY NO.3 CLUTCH ASSY

(a) Install the 1 way clutch assy No.3 and the 1 way clutch in-
ner race to the intermediate shaft.
D27964
86. INSTALL INTERMEDIATE SHAFT

(a) Install the intermediate shaft with the 1 way clutch assy
No.3 to the case.
D31411
(b) Using SST, install the snap ring.

SST 09350-30020 (09350-07050, 09350-07060)
D31365
87. INSTALL CTR PLANETARY GEAR ASSY

(a) Install the center planetary gear assy and the planetary
sun gear to the case.
(b) Coat the thrust bearing race with petroleum jelly, and
install it onto the CTR planetary ring gear.
Race diameter:
Inside Outside
Race 53.7 mm (2.114 in.) 74.0 mm (2.913 in.)
D31532 Bearing 55.7 mm (2.192 in.) 76.4 mm (3.008 in.)
88. INSTALL BRAKE PISTON NO.2

O-Ring
(a) Coat 2 new O-rings with ATF, and install them to the
brake piston No.2.
(b) Being careful not to damage the O-rings, press the brake
piston No.2 into the brake cylinder No.2.
(c) Install the brake piston No.2 to the case.
HINT:
Install the brake cylinder No.2 so that the projection protrudes
D28797 from the upside of the transmission case.
Author: Date: 55
40-36
(d) Check that the oil pressure apply hole of the brake cylin-
der No.2 aligns with the oil pressure apply hole of the
transmission case.
D31529
89. INSTALL BRAKE DISC NO.2

F (a) Install the flange, the 3 plates, 3 discs and brake piston
P return spring.
D Install in order: P = Plate, D = Disc, F = Flange
P F - P - D - P - D - P - D
D
P
D
D27938
(b) Using SST and a press, install the brake No.2 spring snap
SST ring.
SST 09351- 40010 (09351- 04010, 09351- 04020,
09351-04040, 09351-04050)
D28818
90. INSPECT PISTON STROKE OF BRAKE PISTON NO.2

(a) Make sure that the brake piston No.2 moves smoothly
when pulling and releasing the compressed air gun lever
while applying compressed air into the transmission case.
D31408
Author: Date: 56
40-37
(b) Using a SST and a dial gauge, measure the moving dis-
tance (distance A) of the clutch disc at the both ends
across a diameter while blowing air from the oil hole as
shown in the illustration, and calculate the average.
SST 09350-30020 (09350-06120)
Pack clearance: 0.6 to 0.9 mm (0.024 to 0.035 in.)
(c) If the piston stroke is outside the standard, select & install
a brake flange that brings the piston stroke within the
standard.
HINT:
There are 7 types of flanges that can be used to adjust the pack
clearance. Select one with the most appropriate thickness.
A
Flange thickness:
0 2.0 mm (0.079 in.) 4 2.4 mm (0.094 in.)
1 2.1 mm (0.083 in.) 5 2.5 mm (0.098 in.)
2 2.2 mm (0.087 in.) 6 2.6 mm (0.102 in.)
3 2.3 mm (0.091 in.) 7 2.7 mm (0.106 in.)
D31406
O-Ring
91. INSTALL BRAKE PISTON NO.1
(a) Coat 2 new O-rings with ATF, and install them on the
brake piston No.1.
(b) Be careful not to damage the O-rings. Press the brake
piston No.1 into the brake cylinder No.1 by hands.
D28539
92. INSTALL BRAKE PISTON RETURN SPRING

SUB-ASSY
(a) Install the brake piston return spring and the brake piston
No.1 with the brake cylinder No.1 to the transmission
case.
HINT:
Install the brake cylinder No.1 so that the projection protrudes
from the upside of the transmission case.
D27935
Author: Date: 57
40-38
(b) Check that the oil pressure apply hole of the brake cylin-
der NO.2 aligns with the oil pressure apply hole of the
transmission case.
D31528
93. INSTALL BRAKE PISTON RETURN SPRING SNAP

RING
(a) Using SST and press, install the brake piston return
spring snap ring.
SST 09351- 40010 (09351- 04010, 09351- 04030,
09351-04040, 09351-04050)
SST
D28819
94. INSTALL CTR PLANETARY RING GEAR

(a) Install the CTR planetary ring gear and the front planetary
ring gear flange on the front planetary ring gear.
D31544
(b) Using a screwdriver, install the snap ring.

NOTICE:
Install the snap ring to the ring gear so that the both ends
of the snap ring come to the center of a protrusion on the
ring gear.
D31548
95. INSTALL FRONT PLANETARY RING GEAR

(a) Install the front planetary ring gear and the thrust needle
roller bearing to the case.
Inside Outside
55.7 mm (2.193 in.) 76.4 mm (3.008 in.)
ing
D31542
Author: Date: 58
40-39
Race 96. INSTALL FRONT PLANETARY GEAR ASSY

(a) Install the thrust needle roller bearing and the thrust
washer.
Bearing
(b) Coat the thrust race with petroleum jelly, and install it onto
the front planetary ring gear.
Thrust needle roller bearing and race diameter:
Inside Outside
Bearing 43.4 mm (1.709 in.) 58.3 mm (2.295 in.)
D27931 Race 38.0 mm (1.496 in.) 57.0 mm (2.244 in.)
(c) Install the front planetary gear assy and the 1 way clutch
inner race to the case.
D27930
97. INSPECT PISTON STROKE OF BRAKE PISTON NO.1

(a) Make sure the brake piston No.1 moves smoothly when
pulling and releasing the compressed air gun lever while
applying compressed air into the transmission case.
D28814
Author: Date: 59
40-40
(b) Using vernier calipers, measure the level difference

(length A) between the upper surface of the brake piston
No.1 and the hitting surface of the brake flange No.1 at
A both ends across the brake piston No.1 diameter.
(c) Using vernier calipers, measure the thickness (length B)
of the brake flange, the 3 brake plates No.1 and the 3
brake discs No.1 altogether at the both ends across a di-
ameter, and calculate the average.
HINT:
Length A = 15.29 to 15.77 mm (0.6020 to 0.6209 in.)
Length B = 14.72 to 15.12 mm (0.5795 to 0.5953 in.)
Piston stroke = Length A - Length B
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
B been assembled incorrectly, so check and reassemble again.
If the piston stroke is not still outside the specification range, se-
lect another flange.
D31407 HINT:
There are 4 different thickness for the flange.
Flange 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.)
Flange 98. INSTALL BRAKE DISC NO.1

(a) Install the the 3 plates, the 3 discs and the flange.
D Install in order: P = Plate, D = Disc, F = Flange
P F - D - P - D - P - D - P
D
P
D
P
D27933
99. INSTALL 2ND BRAKE PISTON

O-Ring
(a) Coat 2 new O-rings with ATF, and install them to the 2nd
brake piston.
(b) Be careful not to damage the O-rings. Press the 2nd
brake cylinder into the 2nd brake piston by hands.
D28546
Author: Date: 60
40-41
(c) Using SST and press, install the snap ring.

SST
NOTICE:
Be sure that the end gap of the snap ring is not aligned with
the spring retainer claw.
SST 09351-40010 (09351-04060, 09351-04070)
D28817
100. INSTALL 2ND BRAKE CYLINDER

(a) Install the 2nd brake cylinder to the case.
D27929
(b) Check that the oil pressure apply hole of the brake cylin-
der No.2 aligns with the oil pressure apply hole of the
transmission case.
D31530
101. INSTALL 1 WAY CLUTCH ASSY

(a) Install the 1 way clutch assy and the thrust washer to the
case.
D27928
102. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

(a) Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
D27927
Author: Date: 61
40-42
103. INSTALL 2ND BRAKE DISC SET

F (a) Install the flange, the 4 discs and the 4 plates to the case.
D
Install in order: P = Plate, D = Disc, F = Flange
P
D C = Cushion
P
D F - D - P - D - P - D - P - D - P - C
P
D
P
C
D27926
104. INSTALL BRAKE NO.3 SNAP RING

(a) Using a screwdriver, install the snap ring.
SST 09350-30020 (09350-07060)
D27925
105. INSTALL 1 WAY N0.2 CLUTCH ASSY

(a) Coat the race with petroleum jelly and install it onto the
clutch drum thrust washer No.2.
(b) Install the 1 Way clutch assy No.2 and washer No.2.
D27994
Thrust Needle 106. INSTALL CLUTCH DRUM & INPUT SHAFT ASSY
Roller Bearing B (a) Install the thrust needle roller bearing.
(b) Coat the race with petroleum jelly and install it onto the
Race B
clutch drum & input shaft assy.
Thrust needle roller bearing and diameter:
Race A
Inside Outside
71.9 mm (2.831 in.) 85.6 mm (3.370 in.)
Thrust Needle ing A
Roller Bearing A D31541
Race A 73.6 mm (2.898 in.) 102.0 mm (4.016 in.)
34.6 mm (1.362 in.) 52.0 mm (2.047 in.)
ing B
Race B 37.0 mm (1.457 in.) 52.3 mm (2.059 in.)
Author: Date: 62
40-43
(c) Install the input shaft sub assy with the clutch drum &input
shaft assy onto the transmission case.
D29833
107. INSTALL OIL PUMP ASSY

(a) Install the thrust bearing race No.1 to the front oil pump
Inside Outside
Race 74.2 mm (2.921 in.) 87.74 mm (3.454 in.)
D28809
(b) Coat a new O-ring with ATF, and install it around the oil
pump assy.
(c) Place the oil pump through the input shaft, and align the
bolt holes of the oil pump assy with the transmission case.
(d) Hold the input shaft, and lightly press the oil pump body
to slide the oil seal rings into the overdrive direct clutch
drum.
D28796
(e) Install the 10 bolts.

D27921
108. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST, drive in 2 new oil seals.
SST 09350-30020 (09350-07110)
(b) Coat the oil seal lips with MP grease.
D28548
Author: Date: 63
40-44
109. INSPECT INDIVIDUAL PISTON OPERATION

C2 C4 C1
INSPECTION
(a) Check the operating sound while applying compressed
air into the oil holes indicated in the illustration.
C3 HINT:
When inspecting the O/D direct clutch, check with the C3 accu-
mulator piston hole closed.
If there is no sound, disassemble and check the parts installa-
tion condition.
B3 (1) Clutch No.2 (C2)
(2) Clutch No.4 (C4)
B1
(3) Clutch No.3 (C3)
B2 (4) Clutch No.1 (C1)
(5) Brake No.3 (B3)
(6) Brake No.1 (B1)
(7) Brake No.2 (B2)
(8) Brake No.4 (B4)
B4(IN) B4(OUT)
D31549
110. INSTALL MANUAL VALVE LEVER SUB-ASSY

Spacer (a) Install a new spacer to the manual valve lever.
(b) Install the manual valve lever shaft to the transmission
case through the manual valve lever.
Manual
Valve Lever
D31556
(c) Using a hammer, drive in a new spring pin.
D28799
(d) Align the manual valve lever indentation with the spacer
hole, and stake them together with the punch.
(e) Make sure that the shaft rotates smoothly.
D31557
Author: Date: 64
40-45
Parking 111. INSTALL PARKING LOCK PAWL SHAFT

Lock Pawl (a) Install the E-ring to the shaft.
(b) Install the parking lock pawl, the shaft and the spring.
E-ring
Spring
D31552
112. INSTALL PARKING LOCK ROD SUB-ASSY

(a) Connect the parking lock rod to the manual valve lever.
D31551
113. INSTALL PARKING LOCK PAWL BRACKET

(a) 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)
D31361
Planetary Ring Gear (b) Shift the manual valve lever to the P position, and confirm
Manual the planetary ring gear is correctly locked up by the lock
Valve pawl.
Lever
Lock
Pawl
D28801
114. INSTALL B-1 ACCUMULATOR VALVE

(a) Install the spring and the accumulator valve to the hole.
D31524
Author: Date: 65
40-46
B-1 Accumulator spring:

Inner spring:
Free length Outer diameter Color
44.98 mm (1.7709 in.) 11.30 mm (0.445 in.) Natural
Outer spring:
Free length Outer diameter) Color
D28803
115. INSTALL C-3 ACCUMULATOR PISTON

(a) Coat a new O-ring with ATF, and install it to the piston.
(b) Install the spring and the accumulator piston to the hole.
D31525
C-3 Accumulator spring:

Inner spring:
44.0 mm (1.732 in.) 14.0 mm (0.551 in.) Yellow
Outer spring:
D28804
116. INSTALL B-3 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the pis-
ton.
D31526
Accumulator spring:
64.5 mm (2.539 in.) 19.5 mm (0.768 in.) Orange
D28805
Author: Date: 66
40-47
117. INSTALL C-2 ACCUMULATOR PISTON

(a) Coat 2 new O-rings with ATF, and install them to the pis-
ton.
D31527
Accumulator spring:
63.14 mm (2.4858 in.) 16.0 mm (0.6299 in.) Light Gray
D28806
118. INSTALL CHECK BALL BODY

(a) Install the check ball body and the spring.
Check Ball
Body
Spring
D27914
119. INSTALL BRAKE DRUM GASKET

(a) Install the 3 brake drum gaskets.
D27969
120. INSTALL TRANSAXLE CASE GASKET

(a) Install the 3 transaxle case gaskets.
Gasket
D27968
Author: Date: 67
40-48
121. INSTALL TRANSMISSION VALVE BODY ASSY

Pin
(a) Align the groove of the manual valve with the pin of the
lever.
D31555
A (b) Install the 20 bolts.

C HINT:
B Each bolt length is indicated below.
D
Blot length:
A Bolt A: 25 mm (0.98 in.)
A Bolt B: 36 mm (1.42 in.)
Bolt C: 45 mm (1.77 in.)
A B C A D A D31360 Bolt D: 50 mm (1.97 in.)
(c) Install the detente spring with the bolt.

D31546
122. INSTALL TRANSMISSION WIRE

(a) Install a new O-ring to the transmission wire.
(b) Install the transmission wire harness.
(c) Install the bolt.
Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf)
D27912
Clamp (d) Connect the 9 solenoid connectors.

(e) Install the ATF temperature sensor.
(f) Install the clamp and the 2 bolts.
D31358
Author: Date: 68
40-49
123. INSTALL VALVE BODY OIL STRAINER ASSY

(a) Coat new O-ring with ATF, and install them to the valve
body oil strainer assy.
(b) Install the oil strainer with the 4 bolts.
D31357
124. INSTALL TRANSMISSION OIL CLEANER MAGNET

(a) Install the 3 transmission oil cleaner magnets.
Magnet D31533
125. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSY

(a) Install a new gasket on the oil pan.
(b) Install and torque the 20 bolts.
Torque 4.4 N·m (45 kgf·cm, 39 in.·lbf)
(c) Install a new gasket and the drain plug.
Torque 20 N·m (204 kgf·cm, 15 ft⋅lbf)
(d) Install a new gasket and the over flow plug.
Torque 20 N·m (204 kgf·cm, 15 ft⋅lbf)
126. INSTALL AUTOMATIC TRANSMISSION EXTENSION

HOUSING OIL SEAL
SST (a) Using SST and a hammer, install a new oil seal.
SST 09309-37010
127. INSTALL TRANSMISSION CASE ADAPTOR RADIAL
BALL BEARING
D27978
128. INSTALL RR COVER SLEEVE

(a) Install the 2 washers and RR cover sleeve to the output
shaft.
D31410
Author: Date: 69
40-50
129. INSTALL EXTENSION (ATM) HOUSING SUB-ASSY

(a) Install the thrust needle roller bearing and the 2 bearing
races.
(b) Using a snap ring expander, install the snap ring.
D29874
(c) Using feeler gauge, measure the clearance between the

snap ring and the race.
Clearance: 0.02 to 0.12 mm (0.0008 to 0.0047 in.)
If the clearance is still standard, select another race.
HINT:
There are 12 different thickness for the race.
Flange thickness:
D29875
1 3.80 mm (0.1496 in.) 7 4.10 mm (0.1614 in.)
2 3.85 mm (0.1516 in.) 8 4.15 mm (0.1634 in.)
3 3.90 mm (0.1535 in.) 9 4.20 mm (0.1653 in.)
4 3.95 mm (0.1555 in.) 10 4.25 mm (0.1673 in.)
5 4.00 mm (0.1575 in.) 11 4.30 mm (0.1693 in.)
6 4.05 mm (0.1594 in.) 12 4.35 mm (0.1713 in.)
(d) Clean the threads of the bolts and the case with white
gasoline.
(e) Apply FIPG to the extension housing as shown in the il-

lustration.
FIPG:
FIPG Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
D31409
(f) Install the extension housing with new 6 bolts.

A A HINT:
Each blot length is indicated below.
Bolt length:
Bolt A: 45 mm (1.772 in.)
Bolt B: 35 mm (1.378 in.)
B D31354
Author: Date: 70
40-51
130. INSTALL AUTOMATIC TRANSMISSION FLANGE

YOKE ASSY
(a) Using SST, install a new oil seal to the automatic transmis-
sion flange yoke.
SST 09950- 60010 (09951- 00350), 09950- 70010
(09951-07100)
(b) Install the automatic transmission flange yoke assy to the
output shaft with a new nut.
D01118 Torque: 126 N·m (1,280 kgf·cm, 92 ft·lbf)
(c) Using a hammer and chisel, stake the nut.
131. INSTALL AUTOMATIC TRANSMISSION HOUSING
A A (a) Clean the threads of the bolts and the case with white
gasoline.
(b) Install the transmission housing with the 10 bolts.
Torque:
B B A (14 mm bolt): 34 N·m (347 kgf·cm, 25 ft·lbf)
B (17 mm bolt): 57 N·m (581 kgf·cm, 42 ft·lbf)
A A
D31352
132. INSTALL TRANSMISSION REVOLUTION SENSOR

(a) Coat 2 new O-rings with ATF, and install it to the transmis-
sion revolution sensor.
(b) Install the 2 transmission revolution sensors.
(c) Install the 2 bolts.
D31350
133. INSTALL OIL COOLER TUBE UNION

(a) Coat new O-ring with ATF, and install it to oil cooler tube
union.
(b) Install the oil cooler tube union as shown in the illustration.
20 2 Torque: 29 N·m (296 kgf·cm, 21 ft·lbf)
20 2
D31550
Author: Date: 71
40-52
134. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY

(a) Install the park/neutral position switch onto the manual
valve lever shaft, and temporarily install the adjusting bolt.
(b) Install the new lock washer. Install and torque the nut.
D27903
Neutral Position (c) Using the control shaft lever, turn the manual lever shaft
back all the way and then forward 2 notches. It is now in
neutral.
D31531
(d) Align the neutral basic line with the switch groove as
shown in the illustration, and tighten the adjusting bolt.
Bolt
Neutral
Basic Line
Groove
D27980
(e) Using a screwdriver, bend the tabs of the lock washer.

HINT:
Bend at least 2 of the lock washer tabs.
D27990
135. INSTALL TRANSMISSION CONTROL SHAFT LEVER

RH
(a) Install the washer and the nut to the control shaft lever
RH.
D31347
Author: Date: 72

A-761E Manual PDF

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

A-761E Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

A-761E Manual PDF

Uploaded by

Copyright:

Available Formats

AKPPHELP.

RU Руководство по ремонту АКПП

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

ABBREVIATIONS USED IN THIS MANUAL

A761E A/T REPAIR MANUAL (RM1050U)

TRANSMISSION VALVE BODY ASSY (A761E)

6.4 (65, 57 in.⋅lbf)

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

A761E A/T REPAIR MANUAL (RM1050U)

Author: Date: 102

CLUTCH DRUM & INPUT SHAFT ASSY (A761E)

Snap Ring Clutch Balance No.2

Forward Clutch Piston

Clutch Balancer No.3 Thrust Bearing Race

Clutch Cushion Plate

A761E A/T REPAIR MANUAL (RM1050U)

OIL PUMP ASSY (A761E)

Front Oil Pump Body

Front Oil Pump

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

A761E A/T REPAIR MANUAL (RM1050U)

AUTOMATIC TRANSMISSION ASSY (A761E)

5.4 (55, 48 in.⋅lbf)

Lock Washer Oil Cooler O-Ring

34 (345, 25) Transmission Revolution

34 (345, 25) 5.4 (55, 48 in.⋅lbf)

Automatic Transmission Housing Automatic Transmission

A761E A/T REPAIR MANUAL (RM1050U)

Manual Valve Lever

Transaxle Case Gasket

7.4 (75, 65 in.⋅lbf) O-Ring C-3 Accumulator Piston

Front Planetary Ring Brake Disc No.1

Brake Plate No.1

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

Brake Disc No.2 Planetary

Brake Cylinder No.2

Brake No.2 Snap Ring

Brake Cylinder No.1

Brake Reaction Sleeve

Brake Apply Tube

Brake Reaction Brake Plate

1st & Reverse Brake

Rear Cover Sleeve

Brake Flange No.4

INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-7

GLOSSARY OF SAE AND LEXUS TERMS

ISC Idle Speed Control -

A761E A/T REPAIR MANUAL (RM1050U)

INTRODUCTION - TERMS FOR AUTOMATIC TRANSAXLE REPAIR 01-9

WU-OC Warm Up Oxidation Catalytic Converter -

A761E A/T REPAIR MANUAL (RM1050U)

HOW TO DETERMINE NUT STRENGTH

No Mark (w/ Washer) No Mark (w/ Washer) No Mark

*: Nut with 1 or more marks on one side surface of the nut.

HOW TO DETERMINE BOLT STRENGTH

No Mark No Mark No Mark

A761E A/T REPAIR MANUAL (RM1050U)

INTRODUCTION - HOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR 01-1