Part 2
30. INSTALL OVERDRIVE CLUTCH DISC SET(a) Install the 4 plates, 4 discs and flange to the overdrive direct clutch drum.
Install in order:
P - D - P - D - P - D - P - D - F
HINT
P = Plate
D = Disc
F = Flange
NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.
(c) Using a dial indicator, measure the distance (distance A) the clutch flange moves at both ends while blowing compressed air (196 kPa, 2.0 kgf*cm2, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value will be within the standard value.
Standard:
0.6 to 0.9 mm (0.0236 to 0.0354 in.)
Flange thickness:
(d) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.
31. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary sun gear to the front planetary gear.
(b) Coat 2 new oil seal rings with ATF, and install them to the planetary gear.
NOTICE:
Do not expand the ring ends excessively.
(c) Coat 3 new oil seal rings with ATF, and install them to the planetary gear.
NOTICE:
Do not expand the ring ends excessively.
(d) Install the clutch drum thrust washer to the planetary gear.
NOTICE:
Use a small amount of MP grease to secure the thrust washer in place.
(e) Assemble the front planetary gear assembly with the front planetary sun gear to the overdrive and reverse clutch disc assembly.
32. SELECT NO. 1 BRAKE FLANGE
(a) Measure length A (from the step of the oil pump installation surface of the transmission case to the step of the No. 1 brake flange installation surface) in the illustration.*1
Standard:
59.77 to 60.03 mm (2.3531 to 2.3634 in.)
(b) Measure length B (from the flange face of the oil pump assembly to the tip of the stator shaft piston) in the illustration.*2
Standard:
34.636 to 34.964 mm (1.3636 to 1.3765 in.)
(c) Assemble the 5 brake plates, 5 brake discs, and brake flange, and measure length C in the illustration.*3
Standard:
23.84 to 24.36 mm (0.9386 to 0.9591 in.)
(d) Choose a No. 1 brake flange from the table so that the value of measured length A minus lengths B and C (from steps *1, *2, *3) will be 0.75 to 1.05 mm (0.0295 to 0.0413 in.).
Flange thickness:
33. INSTALL OVERDRIVE AND REVERSE CLUTCH DISC WITH FRONT PLANETARY GEAR ASSEMBLY
(a) Install the thrust bearing race, thrust needle roller bearing, overdrive and reverse multiple disc clutch assembly with front planetary gear assembly to the transmission case.
Standard bearing and race diameter:
NOTICE:
* Before installing the sun gear input drum, apply ATF to the contact surfaces inside the sun gear input drum. After the installation, check that the sun gear input drum rotates smoothly.
* Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
34. INSTALL NO. 1 BRAKE DISC SET
(a) Install the selected flange, 5 discs and 5 plates to the transmission case.
Install in order:
F - D - P - D - P - D - P - D - P - D - P
HINT
F = Flange
D = Disc
P = Plate
NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.
35. INSTALL OIL PUMP ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil pump.
(b) Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transmission case.
(c) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the No. 3 clutch drum.
(d) Install the 11 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
* Make sure to apply seal packing to the flanges of the bolts.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent
* Do not allow seal packing to contact the bolts' threads.
* During installation, do not allow oil to contact the bolts or the surface of the oil pump body.
36. INSPECT INDIVIDUAL PISTON OPERATION
(a) Check for operating sounds while applying compressed air into the oil holes indicated in the illustration.
HINT
C1 = Forward multiple clutch
C2 = No. 2 clutch
C3 = No. 3 clutch
C4 = Reverse clutch
B1 = No. 1 brake
B2 = No. 2 brake
37. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal.
SST : 09350-30020
09350-07110
Standard depth:
-0.3 to 0.3 mm (-0.012 to 0.012 in.)
(b) Coat the lip of the oil seal with MP grease.
38. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(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.
(c) Using a hammer, tap in a new spring pin.
(d) Align the manual valve lever indentation with the spacer hole, and stake them together with a punch.
(e) Make sure that the shaft rotates smoothly.
39. INSTALL PARKING LOCK PAWL SHAFT
(a) Install the E-ring to the shaft.
(b) Install the parking lock pawl, shaft and spring.