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Toyota A442F, Repair Manual

The Toyota A442F Repair Manual is a comprehensive guide to maintaining and servicing your vehicle. With detailed instructions and diagrams, this manual is essential for DIY mechanics and professionals alike. Download it for free from manualshive.com to keep your Toyota running smoothly for years to come.

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AT-119

AUTOMATIC TRANSMISSION - COMPONENT PARTS INSTALLATION

27. INSTALL OIL PUMP
(a) Place a new gasket on the transmission case.

(b) Align the bolt holes of the pump body and transmis-

sion case.

(c) Apply sealant to the threads of the oil pump set bolts.

Sealant: Part No. 08833-00080, THREE BOND 1344,

LOCTITE 242 or equivalent.

(d) Install and tighten the eleven bolts.

Torque: 21 N-m (210 kgfcm. 16 ftlbf)

Summary of Contents for A442F

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Page 4: ...IN 1 INTRODUCTION HOW TO USE THIS MANUAL I N 2 GENERAL REPAIR INSTRUCTIONS I N 5 ABBREVIATIONS USED IN THIS MANUAL I N 7 STANDARD BOLT TORQUE SPECIFICATIONS I N 8...

Page 5: ...ded tools equipment lubricant and SSM Special Service Materials which should be prepared before beginning the operation and explains the purpose of each one REPAIR PROCEDURES Most repair operations be...

Page 6: ...TRACK to the information needed The upper case task heading can be read at a glance when necessary and the text below it provides detailed information Important specifications and warnings always sta...

Page 7: ...ssibility of damage to the components being repaired HINTS are separated from the text but do not appear in bold They provide additional information to help you perform the repair efficiently SI UNIT...

Page 8: ...ean the battery terminal posts and cable ter minals with a clean shop rag Do not scrape them with a file or other abrasive objects e Install the cable terminal to the battery post with the nut loose a...

Page 9: ...air Be sure to use SST and SSM where specified and follow the proper work proce dure A list of SST and SSM can be found at the preparation of AT section 10 When replacing fuses be sure the new fuse ha...

Page 10: ...MANUAL Automatic Transaxle Fluid Overdrive Brake 2nd Brake 1 st and Reverse Brake Overdrive Direct Clutch Front Clutch Rear Clutch Disc Except Flange Overdrive One way Clutch No 2 One way Clutch Mult...

Page 11: ...LT STRENGTH Hexagon head bolt Hexagon flange bolt w washer hexagon bolt No mark Hexagon head bolt Two protruding lines No mark Hexagon flange bolt w washer hexagon bolt Two protruding lines Hexagon he...

Page 12: ...INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS IN 9 SPECIFIED TORQUE FOR STANDARD BOLTS...

Page 13: ...MEMO...

Page 14: ...IVE UNIT A T 38 FRONT CLUTCH A T 5 2 REAR CLUTCH A T 5 9 SECOND BRAKE A T 64 FRONT AND REAR PLANETARY GEAR UNIT A T 7 0 FIRST AND REVERSE BRAKE A T 7 9 VALVE BODY A T 80 UPPER VALVE BODY A T 8 7 LOWER...

Page 15: ...s shift response A high performance super flow torque converter is used to improve starting off acceleration and fuel economy For easier operation the shift lever positions have been reduced from 7 P...

Page 16: ...chanism Gear Ratio 1st Gear 2nd Gear 3rd Gear O D Gear Reverse Gear Number of Discs and Plates Disc and Plate Front Clutch C Rear Clutch C2 O D Direct Clutch Co 2nd Brake B2 st and Reverse Brake B3 O...

Page 17: ...AT 4 AUTOMATIC TRANSMISSION OPERATION OPERATION OPERATING CONDITIONS...

Page 18: ...AT 5 AUTOMATIC TRANSMISSION OPERATION FUNCTION OF COMPONENTS...

Page 19: ...AT 6 AUTOMATIC TRANSMISSION OPERATION The condition of operation for each gear position are shown on the following illustration...

Page 20: ...AT 7 AUTOMATIC TRANSMISSION OPERATION...

Page 21: ...mulators the clutches and brakes as well as the fluid passages which connect all of these components Based on the hydraulic pressure crated by the oil pump the hydraulic control system governed the hy...

Page 22: ...rature increases above 150 C 302 F the ECT ECU lights the warning light located the combination meter The light goes off when the temperature falls below 120 C 248 F A T P Automatic Transmission Parki...

Page 23: ...AT 10 AUTOMATIC TRANSMISSION PREPARATION PREPARATION SST SPECIAL SERVICE TOOLS...

Page 24: ...AUTOMATIC TRANSMISSION PREPARATION AT 11 RECOMMENDED TOOL EQUIPMENT...

Page 25: ...AT 12 AUTOMATIC TRANSMISSION PREPARATION LUBRICANT SSM SPECIAL SERVICE MATERIALS...

Page 26: ...AT 13 AUTOMATIC TRANSMISSION COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL COMPONENTS...

Page 27: ...AT 14 AUTOMATIC TRANSMISSION COMPONENT PARTS REMOVAL...

Page 28: ...AT 15 AUTOMATIC TRANSMISSION COMPONENT PARTS REMOVAL...

Page 29: ...o screwdrivers pry out the breather plug b Remove the 0 ring from the breather plug 3 REMOVE CONTROL SHAFT LEVER Remove the two nuts and the lever 4 REMOVE OIL COOLER PIPES a Remove the mount stay bol...

Page 30: ...m the sensor 7 REMOVE OIL COOLER UNIONS a Remove the two unions b Remove the 0 rings from the both unions 8 REMOVE TRANSMISSION HOUSING a Remove the throttle cable clamp bolt b Remove the eight bolts...

Page 31: ...ealer SST 09302 00100 NOTICE Be careful not to damage the oil pan flange 12 EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel particles Carefully look at the foreign matter...

Page 32: ...onnect the throttle cable from the cam and remove the valve body 15 REMOVE O D CASE AND CENTER SUPPORT APPLY GASKETS Remove the four apply gaskets 16 REMOVE THROTTLE CABLE Using 10 mm socket driver re...

Page 33: ...B2 accumulator pistons d Remove the 0 ring from the accumulator pistons 19 REMOVE SOLENOID WIRING a Remove the bolt and the solenoid wiring b Remove the 0 ring from it 20 CHECK THRUST CLEARANCE OF OV...

Page 34: ...pump gasket d Remove the race and thrust bearing from the 0 D direct clutch drum or oil pump 22 REMOVE OVERDRIVE PLANETARY GEAR OVER DRIVE DIRECT CLUTCH AND ONE WAY CLUTCH ASSEMBLY a Place SST on the...

Page 35: ...ASSEMBLY a Remove the ring gear assembly from the O D case b Remove the thrust bearing and race from the O D case or ring gear flange 24 CHECK THRUST CLEARANCE OF INPUT SHAFT FRONT CLUTCH DRUM a Temp...

Page 36: ...Standard thrust clearance 0 30 0 70 mm 0 0118 0 0276 in Maximum thrust clearance 0 70 mm 0 0276 in 25 REMOVE OVERDRIVE CASE ASSEMBLY a Remove three bolts b Using SST remove the O D case assembly SST...

Page 37: ...assembly c Remove the front clutch assembly d Remove the race and thrust bearing from the rear clutch drum or front clutch hub 27 REMOVE REAR CLUTCH ASSEMBLY Install two wires into flukes of the clut...

Page 38: ...tops of SST and the thrust washer on the front planetary gear e Using calipers measure the thickness B of SST f Remove the three center support set bolts g Using SST remove the center support assembl...

Page 39: ...m 0 0354 in j Remove the thrust washer from the center support 29 REMOVE SPEEDSENSOR 30 REMOVE TRANSFER ADAPTOR AND OUTPUT SHAFT REAR BEARING a Remove the five bolts and the tear bearing retainer b Us...

Page 40: ...adaptor e Remove the gasket 31 REMOVE OUTPUT SHAFT SPACER a Using snap ring pliers remove the snap ring b Remove the output shaft spacer 32 REMOVE SPEED SENSOR ROTOR 33 REMOVE PLANETARY GEARS ONE WAY...

Page 41: ...IRST AND REVERSE BRAKE PISTON Using SST and a dial indicator measure the piston stroke by applying and releasing the compressed air 392 785 kPa 4 8 kgf cm2 5 7 1 1 4 psi sa shown SST 09350 36010 09350...

Page 42: ...nd compress the return spring SST 09350 36010 09350 06030 d Using snap ring pliers remove the snap ring e Remove the piston return spring f Hold first and reverse brake piston with hand remove first a...

Page 43: ...b Remove the accumulator piston and spring by apply ing compressed air to the oil hole c Remove the 0 rings from accumulator piston 37 REMOVE TRANSMISSION REAR COVER Remove the three bolts six screws...

Page 44: ...ll the manual valve lever shaft out through the case remove the manual valve lever parking lock rod as sembly the two plate washers and wave washer d Disconnect the parking lock rod from the manual va...

Page 45: ...ed air to dry parts always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene on your face 3 The recommended automatic transmission fluid or kerosene shou...

Page 46: ...AT 33 AUTOMATIC TRANSMISSION OIL PUMP OIL PUMP COMPONENTS COMPONENTS DISASSEMBLY 1 USE TORQUE CONVERTER AS WORK STAND 2 REMOVE OIL SEAL RINGS remove the two oil seal rings...

Page 47: ...Using a dial indicator measure the inside diameter Standard inside diameter 42 050 42 075 mm 1 6555 106565 in Maximum inside diameter 42 13 mm 1 6587 in If the inside diameter is greater than maximum...

Page 48: ...learance between the gear teeth and the crescent shaped part of the pump body Standard tip clearance 0 14 0 24 mm 0 0055 0 0094 in Maximum tip clearance 0 3 mm 0 012 in If the tip clearance is greater...

Page 49: ...to the oil seal lip OIL PUMP ASSEMBLY 1 PLACE OIL PUMP BODY ONTO TORQUE CON VERTER 2 INSTALL DRIVEN AND DRIVE GEARS TO OIL PUMP BODY a Coat the driven and drive gears with ATF b Install the driven an...

Page 50: ...50 06110 5 INSTALL OIL SEAL RINGS a Coat the two oil seal rings with ATF b Contract the oil seal rings and install them onto the stator shaft NOTICE Do not spread the ring ends too match HINT After in...

Page 51: ...AT 38 AUTOMATIC TRANSMISSION OVERDRIVE UNIT OVERDRIVE UNIT COMPONENTS...

Page 52: ...CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH a Place the oil pump onto the torque converter and then place the O D direct clutch assembly onto the oil pump b Using SST and a dial indicator measure...

Page 53: ...Remove the spring seat and twenty four return springs 6 REMOVE OVERDRIVE DIRECT CLUTCH PISTON a Place the oil pump onto the torque converter and then place the O D direct clutch onto the oil pump b Ho...

Page 54: ...move the ring gear flange 9 REMOVE ONE WAY CLUTCH FROM OVERDRIVE PLANETARY GEAR a Using small screwdriver remove the snap ring b Remove the No 4 thrust washer c Remove the one way clutch together with...

Page 55: ...E OF OVERDRIVE BRAKE a Place the O D case assembly onto the rear clutch assembly b Using SST and a dial indicator measure the piston stroke by applying and releasing the compressed air 392 785 kPa 4 8...

Page 56: ...ve the snap ring c Remove the return spring 14 REMOVE OVERDRIVE BRAKE PISTON a Place the return spring on the brake piston and then place SST on the return spring SST 09350 36010 09350 06020 b Hold SS...

Page 57: ...check ball is free by shaking the piston b Check that the valve does not leak by applying low pressure compressed air 3 INSPECT BUSHINGS OF OVERDRIVE DIRECT CLUTCH DRUM Using a dial indicator measure...

Page 58: ...DRIVE CASE Using a dial indicator measure the inside diameter Standard inside diameter 33 10 33 50 mm 1 3031 1 3189 in Maximum inside diameter 33 20 mm 1 3071 in If the inside diameter is greater than...

Page 59: ...FLANGE TO OVERDRIVE PLANETARY RING GEAR a Install the gear flange as shown b Using a screwdriver install the snap ring 3 INSTALL OIL SEAL RING Coat the oil seal ring with ATF and install it to the ri...

Page 60: ...RETURN SPRING a Place the piston return spring on the clutch piston b Place SST on the spring seat and compress the return spring with a shop press SST 09350 3601 0 09350 0601 0 c Using snap ring plie...

Page 61: ...392 785 kPa 4 8kgf cm2 5 7 1 1 4 psi as shown SST 09350 3601 0 09350 06110 Piston stroke 1 80 2 00 mm 0 0709 0 0787 in If the piston stroke is less than specified parts may have been assembled incorr...

Page 62: ...F and install them on the brake piston b Align the protrusions of the brake piston with the grooves of the O D case c Push in the brake piston into the O D case with both hands NOTICE Be careful not t...

Page 63: ...is not aligned with the cutout portion of the O D case 14 CHECK PISTON STROKE OF OVERDRIVE BRAKE a Place the O D case assembly onto the rear clutch assembly b Using SST and a dial indicator measure t...

Page 64: ...AT 51 AUTOMATIC TRANSMISSION OVERDRIVE UNIT 15 INSTALL RING RETAINERS Using needle nose pliers install the three ring retain ers into the oil holes of the O D case...

Page 65: ...TRANSMISSION FRONT CLUTCH FRONT CLUTCH COMPONENTS 1 PLACE FRONT CLUTCH ASSEMBLY ONTO OVER DRIVE CASE ASSEMBLY 2 REMOVE REAR AND FRONT CLUTCH HUBS a Using a screwdriver remove the snap ring FRONT CLUT...

Page 66: ...ace the assembled SST and a dial indicator on the clutch piston c Install the rear clutch hub with the snap ring d Using SST and a dial indicator measure the piston stroke by applying and releasing th...

Page 67: ...e spring seat and compress the return springs with a shop press SST 09350 3601 0 09350 0601 0 b Using snap ring pliers remove the snap ring c Remove the piston return spring 6 REMOVE FRONT CLUTCH PIST...

Page 68: ...ssembling new discs soak them in ATF for at least fifteen minutes 2 INSPECT FRONT CLUTCH PISTON a Check that check ball is free by shaking the piston b Check that the valve does not leak by applying l...

Page 69: ...INGS a Install the piston return spring b Place SST on the spring seat and compress the return springs with a shop press SST 09350 36010 09350 06010 c Using snap ring pliers install the snap ring HINT...

Page 70: ...piston stroke by applying and releasing the compressed air 392 785 kPa 4 8 kgf cm2 57 114 psi as shown SST 09350 36010 09350 06110 Piston stroke 3 93 4 23 mm 0 1547 0 1665 in If the piston stroke is...

Page 71: ...f the front clutch hub with the flukes of the discs by rotating the front clutch hub clockwise or counterclockwise c Install the rear clutch hub onto the clutch drum d Using a screwdriver install the...

Page 72: ...ce so that the sun gear does not touch the rear clutch drum b Place the rear clutch assembly into the center support assembly c Using SST and a dial indicator measure the piston stroke by applying the...

Page 73: ...eturn spring with a shop press SST 09350 3601 0 09350 0601 0 b Using snap ring pliers remove the snap ring c Remove the piston return spring 4 REMOVE REAR CLUTCH PISTON a Place the center support asse...

Page 74: ...discs Before assembling new discs soak them in ATF for at least fifteen minutes 2 INSPECT REAR CLUTCH PISTON a Check that check ball is free by shaking the piston b Check that the valve does not leak...

Page 75: ...der P Plate D Disc P D P D P D P D P D b Install the flange facing the rounded edge upward HINT If the flange is step edged install the flange with the step edge facing downward c Using a screwdriver...

Page 76: ...392 785 kPa 4 8 kgf cm2 57 114 psi as shown SST 09350 36010 09350 06110 Piston stroke 2 00 2 20 mm 0 0790 0 0866 in If the piston stroke is less than specified parts may have been assembled incorrectl...

Page 77: ...D BRAKE COMPONENTS SECOND BRAKE DISASSEMBLY 1 REMOVE RING RETAINERS Using needle nose pliers remove the three ring re tainers from the oil holes of the center support 2 REMOVE FRONT PLANETARY SUN GEAR...

Page 78: ...wn SST 09350 36010 09350 06120 Piston stroke 1 86 2 06 mm 0 0732 0 0811 in If the piston stroke is greater than the specified in spect the discs 4 REMOVE FLANGE DISCS AND PLATES a Using a screwdriver...

Page 79: ...ston SST 09350 36010 09350 06020 c Remove the two oil seal rings from the center support 7 REMOVE OIL SEAL RINGS Remove the two oil seal rings from the center support SECOND BRAKE INSPECTION 1 INSPECT...

Page 80: ...er 25 070 mm 0 9870 in If the inside diameter is greater than the maximum replace the front planetary sun gear SECOND BRAKE ASSEMBLY 1 INSTALL OIL SEAL RINGS a Coat the two oil seal rings with ATF b C...

Page 81: ...e end gap of the snap ring is not aligned with the cutout portion of the center support 4 INSTALL PLATES DISCS AND FLANGE a Install the five plates and five discs in order P Plate D Disc P D P D P D P...

Page 82: ...0732 0 0811 in If the piston stroke is less than specified parts may have been assembled incorrectly check and reas semble again If the piston stroke is not as specified select another flange HINT Th...

Page 83: ...PONENTS FRONT AND REAR PLANETARY GEAR UNIT DISASSEMBLY 1 REMOVE REAR PLANETARY GEAR AND OUTPUT SHAFT ASSEMBLY Remove the rear planetary gear and output shaft as sembly from the front planetary gear 2...

Page 84: ...ld turn freely counterclockwise and should lock clock wise If operation is not as specified replace the one way clutch 4 REMOVE ONE WAY CLUTCH Remove the one way clutch from the front planetary gear 5...

Page 85: ...rear planetary gear b Remove the thrust bearing from the front side of the ring gear flange 7 REMOVE REAR PLANETARY SUN GEAR Remove the sun gear from the rear planetary gear 8 REMOVE OIL SEAL RING Us...

Page 86: ...ring pliers remove the snap ring from the front side of the intermediate shaft 10 REMOVE REAR PLANETARY RING GEAR FLANGE a Using a small screwdriver remove the snap ring d Remove the ring gear flange...

Page 87: ...ARY GEAR UNIT INSPECTION 1 INSPECT BUSHING OF OUTPUT SHAFT Using a dial indicator measure the inside diameter Standard inside diameter 17 000 17 018 mm 0 6693 0 6700 in Maximum inside diameter 17 07 m...

Page 88: ...NO 2 THRUST WASHER Coat the thrust washer with petroleum jelly and in stall it onto the rear planetary gear HINT Securely fit the lips of the thrust washer into the holes of the rear planetary gear 3...

Page 89: ...planetary ring gear b Using a small screwdriver install the snap ring 5 INSTALL REAR PLANETARY RING GEAR AND FLANGE ASSEMBLY a Using snap ring pliers install the snap ring on the front side of the int...

Page 90: ...EDIATE SHAFT ASSEMBLY a Coat the thrust bearing with petroleum jelly b Install the thrust bearing onto the front side of the ring gear flange HINT Race and bearing diameter c Install the ring gear and...

Page 91: ...e front planetary gear should turn freely counterclockwise and should lock clock wise If operation of not as specified replace the one way clutch 11 CHECK OPERATION OF ONE WAY CLUTCH Hold the one way...

Page 92: ...PLATES AND CUSHION PLATE Check to see of the sliding surface of the disc plate and flange are worn or burnt If necessary replace them HINT If the lining of the disc is peeling off or discolored or eve...

Page 93: ...AT 80 AUTOMATIC TRANSMISSION VALVE BODY VALVE BODY COMPONENTS...

Page 94: ...OVE DRAIN TUBE 2 REMOVE OIL TUBES a Remove the two tube clamps b Using a large screwdriver pry out the three oil tubes 3 REMOVE MANUAL VALVE 4 REMOVE MANUAL DETENT SPRING a Turn over the valve body as...

Page 95: ...en bolts wave washers body cover two gaskets and body plate 7 REMOVE TWO PLATS 8 SEPARATE UPPER AND LOWER VALVE BODYS a Remove the thirteen bolts from the upper valve body b Remove the five bolts from...

Page 96: ...look similar use the illustrations below to differentiate them Place a new No 1 gasket the body plate and a new No 2 gasket on the lower valve body 2 INSTALL LOWER VALVE BODY a Turn over the valve bod...

Page 97: ...dicated in the figure Bolt length 25 mm 0 98 in 28 mm 1 10 in 32 mm 1 26 in 36 mm 1 42 in 42 mm 1 65 in 4 INSTALL TWO PLATES HINT Each bolt length mm in is indicated in the figure Bolt length 10 5 mm...

Page 98: ...ghten the seven bolts Torque 5 4 N m 55 kgfcm 48 in lbf b Lower Side Tighten the nine bolts Torque 5 4 N m 55 kgfcm 48 in lbf 7 INSTALL FOUR SOLENOID VALVES Torque 5 4 Nm 55 kgfcm 48 in lbf 8 INSTALL...

Page 99: ...ic faced hammer tap in the oil tubes NOTICE Be careful not to bend or damage the tubes b Install the tube clamps with the two wave washers and bolts HINT Use the bolt which is 10 5 mm 0 41 in in lengt...

Page 100: ...AT 87 AUTOMATIC TRANSMISSION UPPER VALVE BODY UPPER VALVE BODY CONPONENTS...

Page 101: ...AT 88 AUTOMATIC TRANSMISSION UPPER VALVE BODY VALVE BODY SPRINGS SPECIFICATIONS...

Page 102: ...AT 89 AUTOMATIC TRANSMISSION UPPER VALVE BODY RETAINER PINS AND CHECK BALLS LOCATION 1 RETAINERS AND PINS...

Page 103: ...AT 90 AUTOMATIC TRANSMISSION UPPER VALVE BODY 2 CHECK BALLS...

Page 104: ...AT 91 AUTOMATIC TRANSMISSION LOWER VALVE BODY LOWER VALVE BODY COMPONENTS...

Page 105: ...AT 92 AUTOMATIC TRANSMISSION LOWER VALVE BODY VALVE BODY SPRINGS SPECIFICATIONS...

Page 106: ...AT 93 AUTOMATIC TRANSMISSION LOWER VALVE BODY PARTS LOCATIONS 1 RETAINERS AND PINS LOWER SIDE...

Page 107: ...AT 94 AUTOMATIC TRANSMISSION LOWER VALVE BODY UPPER SIDE...

Page 108: ...AT 95 AUTOMATIC TRANSMISSION LOWER VALVE BODY 2 CHECK VALVE BALL AND SPRINGS...

Page 109: ...AT 96 AUTOMATIC TRANSMISSION LOWER VALVE BODY 3 STRAINERS...

Page 110: ...andard inside diameter 64 000 64 050 mm 2 5197 2 5216 in Maximum inside diameter 64 10 mm 2 5236 in If the inside diameter is greater than the maximum replace the transmission case 2 IF NECESSARY REPL...

Page 111: ...T 98 AUTOMATIC TRANSMISSION PARKING LOCK PAWL PARKING LOCK PAWL COMPONENTS PARKING LOCK PAWL DISASSEMBLY 1 REMOVE PARKING LOCK PAWL SHAFT Remove the pawl shaft and snap ring 2 REMOVE PARKING LOCK PAWL...

Page 112: ...all the pawl bracket with the two bolts b Using SST and calipers set the pawl bracket so that so the distance between the transfer adaptor surface and the top of the bracket tab is specified distance...

Page 113: ...STALL PARKING LOCK PAWL SHAFT a Install the spring b Install the spring end to the hole of the transfer ada ptor and install the pawl shaft c Hold the pawl shaft hook another spring end to the pawl wi...

Page 114: ...e automatic transmission is composed of highly precision finished parts necessitating careful inspection before assembly because even a small nick could cause fluid leakage of affect performance 2 Bef...

Page 115: ...AT 102 AUTOMATIC TRANSMISSION COMPONENT PARTS INSTALLATION BEARINGS AND RACES LOCATION...

Page 116: ...0 09350 06150 b Apply MP grease to the oil seal lip b Assemble a new spacer to the manual valve lever d Connect the parking lock rod to the manual valve lever e Install the manual valve lever shaft to...

Page 117: ...ar cover with the three bolts and six screws Torque 7 8 N m 80 kgf cm 69 in lbf 3 INSTALL CACCUMULATOR PISTON AND SPRING a coat new two 0 rings with ATF and install them to the piston b Install the sp...

Page 118: ...ansmission case on a cylinder NOTICE Be careful not to damage the transmission case Tape the top of the cylinder b Coat new two 0 rings with ATF and install them to the brake piston c Using SST pushin...

Page 119: ...inward h Install the six plates and six discs in order P Plate D Disc P D P D P D P D P D P D i Install the flange facing the rounded edge outward HINT If the flange is step edged install the flange...

Page 120: ...ansmission case on a cylinder b Install the rear planetary carrier and output shaft as sembly to the transmission case c Temporarily install two bolts to the front planetary carrier HINT Use two 6 mm...

Page 121: ...ion case h Coat the thrust washer with petroleum jelly and in stall it onto the front planetary carrier HINT Securely fit the claws of the thrust washer into the grooves of the front planetary gear 7...

Page 122: ...ween the parking lock pawl and bracket and attach the transfer adaptor on the transmission case c Install the transfer adaptor with ten bolts Torque 37 Nm 380 kgf cm 27 ftlbf 10 INSTALL OUTPUT SHAFT S...

Page 123: ...pport b Install SST two bolts to the center support SST 09350 36010 09350 06140 c Align the oil holes and bolt holes of the center support and transmission case d Install the center support assembly i...

Page 124: ...ST and the thrust washer on the front planetary gear e Using calipers measure thickness B of SST f Remove the three center support set bolts g Using SST remove the center support assembly from the tra...

Page 125: ...09350 36010 09350 06140 c Align the oil holes and bolt hole of the center support and transmission case d Install the center support assembly into the trans mission case e Apply sealant to the thread...

Page 126: ...s by rotating and pushing the front clutch drum clockwise or counterclockwise 18 CHECK CORRECT INSTALLATION OF FRONT CLUTCH ASSEMBLY a Place SST on the installation surface of the oil pump SST 09350 3...

Page 127: ...RUM a Push the transmission output shaft toward the front of the transmission by applying a force of 49 98 N 5 1 0 kgf 11 0 22 0 Ibf b Push the O D case toward the rear of the transmis sion by applyin...

Page 128: ...ct a spacer HINT There are five different thicknesses for spacer h Install the spacer two races and bearing onto the front clutch drum i Reinstall the oil seal ring to the input shaft 21 INSTALL OVERD...

Page 129: ...the ring gear assembly into the O D case 23 INSTALL OVERDRIVE PLANETARY GEAR OVER DRIVE DIRECT CLUTCH AND ONE WAY CLUTCH ASSEMBLY a Coat the bearing with petroleum jelly and install them onto the pla...

Page 130: ...and the clutch drum If the distance corresponds to that during disasse mbly the O D planetary gear O D direct clutch and one way clutch assembly is installed correctly 25 TEMPORARILY INSTALL OIL PUMP...

Page 131: ...measure the thrust clearance of the input shaft Standard thrust clearance 0 40 0 90 mm 0 0157 0 0354 in Maximum thrust clearance 0 90 mm 0 0354 in If the thrust clearance is greater than the maximum...

Page 132: ...gasket on the transmission case b Align the bolt holes of the pump body and transmis sion case c Apply sealant to the threads of the oil pump set bolts Sealant Part No 08833 00080 THREE BOND 1344 LOCT...

Page 133: ...oat new 0 rings with ATF and install them to the pistons b Install the three springs and accumulator pistons into the bore of the transmission case as shown HINT Piston diameter HINT Spring diameter a...

Page 134: ...solenoid wiring to the transmission case 32 INSTALL CENTER SUPPORT APPLY GASKET Install new four gaskets facing the pitted side toward the transmission case 33 INSTALL VALVE BODY a Align the groove of...

Page 135: ...acts the center of the roller at the tip of the detent spring e Tighten the bolts Torque 10 N m 100 kgf cm 7 in lbf 34 CONNECT FOUR SOLENOID CONNECTORS 35 INSTALL OIL STRAINER Install a new gasket and...

Page 136: ...PROTECTOR Install the protector with the four bolts 39 INSTALL TRANSFER ASSEMBLY Install the transfer assembly with six bolts 40 INSTALL TRANSMISSION HOUSING a Install the transmission housing with t...

Page 137: ...front union Torque 34 Nm 350 kgf cm 25 ftlbf 43 INSTALL CONTROL SHAFT LEVER Torque 13 Nm 130 kgf cm 9 ftlbf 44 INSTALL NEUTRAL START SWITCH a Temporarily install the neutral start switch with the two...

Page 138: ...AT 125 AUTOMATIC TRANSMISSION COMPONENT PARTS INSTALLATION 45 INSTALL BREATHER PLUG AND HOSE a Coat a new 0 ring with ATF and install it to the breather plug b Install the breather plug and hose...

Page 139: ...AT 126 AUTOMATIC TRANSMISSION SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA...

Page 140: ...AT 127 AUTOMATIC TRANSMISSION SERVICE SPECIFICATIONS...

Page 141: ...AT 128 AUTOMATIC TRANSMISSION SERVICE SPECIFICATIONS UPPER VALVE BODY Spring Specifications Retainers and Pins Specifications Check Balls Specifications LOWER VALVE BODY Springs Specifications...

Page 142: ...AT 129 AUTOMATIC TRANSMISSION SERVICE SPECIFICATIONS Retainers and Pins Specifications Check Valve Ball and Springs Specifications ACCUMULATOR...

Page 143: ...AT 130 AUTOMATIC TRANSMISSION SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS...

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