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Home >> Lexus >> 2009 >> IS 250 RWD V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Transmission Unit >> Reassembly >> Part 1

Part 1








A960E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

REASSEMBLY

Part 1 of 2

1. BEARING POSITION









2. INSTALL NO. 4 BRAKE PISTON





(a) Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
(b) Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
(c) Install the No. 4 brake piston to the reaction sleeve.
NOTE:
Be careful not to damage the 4 O-rings.

3. INSTALL BRAKE REACTION SLEEVE





(a) With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and the No. 4 brake piston to the transmission case.
NOTE:
Be careful not to damage the O-rings.

4. INSTALL 1ST AND REVERSE BRAKE PISTON





(a) Coat a new O-ring with ATF.
(b) Install the O-ring on the 1st and reverse brake piston.
(c) With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.
NOTE:
Be careful not to damage the O-ring.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Place the brake return spring onto the brake piston.





(b) Place SST on the brake return spring, and compress the return spring.
SST: 09350-30020
09350-07050
(c) Using the SST, install the snap ring.
SST: 09350-30020
09350-07070
6. INSTALL BRAKE APPLY TUBE





(a) Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.
7. INSTALL REAR PLANETARY GEAR ASSEMBLY





(a) Install the thrust needle roller bearing.
Thrust needle roller bearing diameter:










(b) Install the thrust needle roller bearing.
(c) Coat the No. 9 thrust bearing race and thrust bearing race with petroleum jelly, and install them onto the rear planetary gear.
Bearing and race diameter:










(d) Install the rear planetary gear assembly.
8. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE Transmission Unit
9. INSTALL NO. 4 BRAKE DISC





(a) Install the 4 plates, the 5 discs and the 2 flanges.
Install in order:
P = Plate, D = Disc, F = Flange
F - D - P - D - P - D - P - D - P - D - F
10. INSTALL BRAKE PLATE STOPPER SPRING





(a) Install the brake plate stopper spring.
11. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY





(a) Install the No. 8 thrust bearing race, the thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange to the intermediate shaft.
Bearing and race diameter:






12. INSTALL NO. 3 ONE WAY CLUTCH ASSEMBLY





(a) Install the No. 3 one way clutch assembly and the one way clutch inner race to the intermediate shaft.
13. INSTALL INTERMEDIATE SHAFT





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





(b) Using SST, install the snap ring.
SST: 09350-30020
09350-07050
09350-07060
14. INSTALL CENTER PLANETARY GEAR ASSEMBLY





(a) Install the center planetary gear assembly and the planetary sun gear to the case.
(b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.
Race diameter:






15. INSTALL NO. 2 BRAKE PISTON





(a) Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.
(b) Press the No. 2 brake piston into the No. 2 brake cylinder.
NOTE:
Be careful not to damage the 2 O-rings.

(c) Install the No. 2 brake piston to the case.
HINT:
Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.





(d) Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.
16. INSTALL NO. 2 BRAKE DISC





(a) Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.
Install in order:
P = Plate, D = Disc, F = Flange
F -D - P - D - P - D - P - D - F





(b) Using SST, a screwdriver and a press, install the No. 2 brake spring snap ring.
SST: 09351-40010
09351-04010
09351-04020
09351-04040
09351-04050
17. INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON Transmission Unit
18. INSTALL NO. 1 BRAKE PISTON





(a) Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.
(b) Press the No. 1 brake piston into the No. 1 brake cylinder.
NOTE:
Be careful not to damage the 2 O-rings.

19. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





(a) Install the brake piston return spring and the No. 1 brake piston with the No. 1 brake cylinder to the transmission case.
HINT:
Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.





(b) Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.
20. INSTALL BRAKE PISTON RETURN SPRING SNAP RING





(a) Using SST, a screwdriver and a press, install the brake piston return spring snap ring.
SST: 09351-40010
09351-04010
09351-04030
09351-04040
09351-04050
21. INSTALL CENTER PLANETARY RING GEAR
(a) Install the thrust needle roller bearing to the front planetary ring gear flange.
Thrust needle roller bearing diameter:










(b) Install the center planetary ring gear flange to the center planetary ring gear.
(c) Using a screwdriver, install the snap ring.





(d) Install the center planetary ring gear to the front planetary ring gear.
(e) Using a screwdriver, install the snap ring.
NOTE:
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.

22. INSTALL FRONT PLANETARY RING GEAR





(a) Install the front planetary ring gear to the case.
23. INSTALL FRONT PLANETARY GEAR ASSEMBLY





(a) Install the thrust needle roller bearing and the thrust washer.
(b) Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.
Thrust needle roller bearing and race diameter:










(c) Install the front planetary gear assembly and the one way clutch inner race to the case.
24. INSPECT PISTON STROKE OF BRAKE PISTON Transmission Unit
25. INSTALL NO. 1 BRAKE DISC





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





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





(b) Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.
27. INSTALL ONE WAY CLUTCH ASSEMBLY





(a) Install the one way clutch assembly and the thrust washer to the case.
28. INSTALL 2ND BRAKE PISTON HOLE SNAP RING





(a) Using SST, install the snap ring.
SST: 09350-30020
09350-07060
29. INSTALL 2ND BRAKE DISC SET





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





(a) Using a screwdriver, install the snap ring.
SST: 09350-30020
09350-07060

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