A43

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IN-9
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS

MANUAL
IN01H-0M
ATF
Automatic Transmission Fluid
B0
Overdrive Brake
B1
No.1 Brake
B2
No.2 Brake
B3
No.3 Brake
C0
Overdrive Direct Clutch
C1
Front Clutch
C2
Rear Clutch
Disc
Flange
F0
O/D One-way Clutch
F1
No.1 One-way Clutch
F2
No.2 One-way Clutch
MP
Multipurpose
O/D
Overdirve
Plate
SSM
Special Service Materials
SST
Special Service Tools
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IN-6
INTRODUCTION
GLOSSARY OF SAE AND TOYOTA TERMS

IN016-02
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE
recommendations, as well as their Toyota equivalents.
SAE
TOYOTA 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
BARO
Barometric Pressure
CAC
Charge Air Cooler
Intercooler
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 Position
DFI
Direct Fuel Injection (Diesel)
DI
Distributor Ignition
DLC1
Data Link Connector 1
1: Check Connector
DLC2
2: Toyota Diagnosis Communication Link (TDCL)
DLC3
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 Coolant Temperature
Coolant Temperature, Water Temperature (THW)
EEPROM
Electrically Erasable Programmable Read Only

Memory
+B, Battery Voltage

-
Direct Injection (DI)

-
Electrically Erasable Programmable Read Only Memory

(EEPROM),
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
Toyota Distributorless Ignition (TDI)
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
FEEPROM
Flash Electrically Erasable Programmable
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)
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INTRODUCTION
IAC
Idle Air Control
Idle Speed Control (ISC)
IAT
Intake Air Temperature
Intake or Inlet Air Temperature
ICM
Ignition Control Module
IFI
Indirect Fuel Injection
IFS
Inertia Fuel-Shutoff
ISC
Idle Speed Control
KS
Knock Sensor
Knock Sensor
MAF
Mass Air Flow
Air Flow Meter
MAP
Manifold Absolute Pressure
Indirect Injection
Manifold Pressure
Intake Vacuum
Electric Bleed Air Control Valve (EBCV)
MC
Mixture Control
Mixture Control Valve (MCV)
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), CCo
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
PTOX
Periodic Trap Oxidizer
RAM
Random Access Memory
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
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SRT
System Readiness Test
ST
Scan Tool
TB
Throttle Body
TBI
Throttle Body Fuel Injection
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
Electric Air Control Valve (EACV)

-
Diesel Particulate Filter (DPF)

Diesel Particulate Trap (DPT)
Random Access Memory (RAM)
-
Electronic Fuel Injection (EFI), Sequential Injection
Throttle Body
Single Point Injection
Central Fuel Injection (Ci)
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IN-8
INTRODUCTION

Bimetallic Vacuum Switching Valve (BVSV)
TVV
Thermal Vacuum Valve
TWC
Three-W ay Catalytic Converter
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
WU-OC
Warm Up Oxidation Catalytic Converter
WU-TWC
Warm Up Three-Way Catalytic Converter
3GR
Third Gear
4GR
Fourth Gear
Thermostatic Vacuum Switching Valve (TVSV)

Three-W ay Catalyst (TWC)
CCRO
Manifold Converter
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IN-1
INTRODUCTION
HOW TO USE THIS MANUAL

IN002-0J
To assist you in finding your way through the manual, the Section Title and major heading are given
at the top of every page.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended 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 begin with an overview illustration. It identifies the components and shows how
the parts fit together.
Example:
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IN-2
INTRODUCTION
The

procedures are presented in a step-by-step format:

The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST 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 stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they are required you are given the page
to refer to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave
the procedure to look up your specifications. They are also found at the back of AT section, for quick
reference.
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IN-3
INTRODUCTION
CAUTIONS, NOTICES, HINTS:

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility 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
The UNITS given 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 Nm (310 kgfcm, 22 ftlbf)
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AUTOMATIC TRANSMISSION
DESCRIPTION
DESCRIPTION
AT0A4-04
GENERAL
The A43D is a 4-speed automatic transmission.
The A43D automatic transmission is mainly composed of a torque converter clutch, a overdrive (hereafter called O/D) planetary gear unit, a 3-speed planetary gear unit and a hydraulic control system.
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DESCRIPTION
GENERAL SPECIFICATIONS
Type of Transmission
A43D
Type of Engine
22R-E
Torque Converter Clutch Stall Torque Ratio
1.75 : 1
Lock-up Mechanism
Gear Ratio
Equipped
1st Gear
2.452
2nd Gear
1.452
3rd Gear
1.000
O/D Gear
0.688
Reverse Gear
2.212
Number of Discs and Plates

O/D Direct Clutch (C0)
1/0
Forward Clutch (C1)
4/4
Rear Clutch (C2)
3/3
No.2 Brake (B2)
3/3
No.3 Brake (B3)
5/4
O/D Brake (B0)
3/3
No.1 Brake (B1)
Capacity (US qts, Imp.qts)
1/1
ATF DEXRON II
ATF Type
Total
6.3 (6.7,5.5)
Drain and Refill
2.4 (2.5, 2.1)
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OPERATION
OPERATION
1.
OPERATING CONDITIONS
AT0A5-02
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2.
AT-5
FUNCTION OF COMPONENTS
OPERATION
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OPERATION
The conditions of operation for each gear position are shown in the following illustrations:
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OPERATION
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3.
OPERATION
HYDRAULIC CONTROL SYSTEM

The hydraulic control system is composed of the oil pump, the valve body, the governor body, the accumulators, the clutches and brakes as well as the fluid passage which connect all of these components.
Based in the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter, clutches and brakes in accordance with the vehicle driving conditions.
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PREPARATION
PREPARATION
AT0A6-03
SST (SPECIAL SERVICE TOOLS)

09350-20015
TOYOTA Automatic Transmission

Tool Set
(09350-06120)
No.2 Measure Terminal
(09361-3001 1)
Manual Valve Lever Shaft Oil

Seal Replacer
(09362-3001 1)
Guide Bolt
(09369-20040)
Piston Spring Compressor Set
(09370-12010)
Clutch Drum Thrust Play Gauge
09350-30020
TOYOTA Automatic Transmission

Tool Set
(09350-07080)
Brake Reaction Sleeve Puller
(09350-07090)
Brake No.1 Piston Puller
09610-20012
Pitman Arm Puller
AT0A7-02
RECOMMENDED TOOLS
09031-00030
Pin Punch .
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PREPARATION
AT0A8-03
EQIPMENT
Feeler gauge
Vernier calipers
Dial indicator or dial indicator with magnetic base
Dial indicator
Straight edge
Torque wrench
Cylinder gauge
AT0A9-03
LUBRICANT
Item
Capacity
Dry fill
6.3 liters (6.7 US qts, 5.5 lmp. qts)
Drain and refill
2.4 liters (2.5 US qts, 2.1 lmp. qts)
Classification
ATF DEXRON II
AT0AA-03
SSM (SPECIAL SERVICE MATERIALS)

08833-00080
Adhesive 1344,
THREE BOND 1344,
LOCTITE 242 or equivalent
Oil pump set bolt

Extension housing set bolt
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COMPONENT PARTS REMOVAL

AT0AB-04
COMPONENTS
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AT0AC-02
BASIC SUBASSEMBLY SEPARATION

1.
REMOVE WIRE HARNESS CLAMP AND THROTTLE

CABLE CLAMP
2.
REMOVE CONTROL SHAFT LEVER
3.
(a)
(b)
(c)
(d)
REMOVE PARK/NEUTRAL POSITION SWITCH

Unstake the lock washer.
Remove the nut and bolt.
Remove the lock washer and grommet.
Remove the park/neutral position switch.
4. REMOVE NO.1 VEHICLE SPPEED SENSOR

(a) Remove the bolt and pull out the No.1 vehicle speed sensor.
(b) Remove the O-ring from the sensor.
5. REMOVE UNIONS
(a) Remove the 2 unions.
(b) Remove the O-ring from both unions.
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6. REMOVE OVERDRIVE SOLENOID

(a) Remove the 2 bolts and overdrive solenoid.
(b) Remove the 2 O-rings.
7. REMOVE OIL PUMP

(a) Remove the 7 bolts holding the oil pump to the transmission case.
(b) Using SST, remove the oil pump.

SST 09610-20012
NOTICE: Do not damage the stator shaft bushing surface.
(c)
Remove the O-ring from it.
(d) Remove the assembled bearing and race from the oil
pump rear side.
8. REMOVE TRANSMISSION HOUSING

(a) Remove the 6 bolts.
(b) While holding the input shaft, remove the transmission
housing.
(c) Remove the O-ring from the overdrive case.
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9. REMOVE EXTENSION HOUSING AND GASKET

(b) Remove the extension housing and gasket.
(c)
Remove the oil apply tube and gasket from the extension
housing.
10. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR

AND BALL
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the vehicle speed sensor drive gear and ball.
(c) Using a snap ring expander, remove the snap ring.
11. REMOVE GOVERNOR BODY

(a) Using a screwdriver, loosen the staked part of the lock
plate.
(b) Remove the governor body lock bolt.
(c)
While lifting the retaining clip with a screwdriver, slide off

the governor body.
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12. REMOVE GOVERNOR OIL SEAL STRAINER

(a) Remove the 3 screws, cover and gasket.
(b) Remove the oil strainer from the transmission case.
13. REMOVE OIL PAN

NOTICE: Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the pan.

(b) Remove the oil pan with lifting the transmission case.
(c) Remove the oil pan gasket.
14. EXAMINE PARTICLES IN PAN

Remove the magnets and use them to collect steel particles.
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 wear
Brass (non-magnetic) ... bushing wear
15. REMOVE OIL TUBE
(a) Turn over the transmission.
(b) Pry up both tube ends with a large screwdriver and remove the 2 tubes.
16. REMOVE OIL STRAINER AND GASKET

(a) Remove the 5 bolts holding the oil strainer to the valve
body.
(b) Remove the oil strainer and gasket.
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17. REMOVE VALVE BODY

(b) Disconnect the throttle cable from the cam and remove
the valve body.
18. REMOVE THROTTLE CABLE

(a) Using a 10 mm socket driver, push the throttle cable end
to remove it.
(b) Remove the O-ring.
19. REMOVE ACCUMULATOR PISTONS AND SPRINGS

CAUTION: Keep face away to avoid injury. Do not use regular high-pressure air.
(a) Position a rag to catch each piston.

(b) Applying compressed air to the oil holes shown, and remove the 3 pistons and springs.
(c) Remove the 2 O-rings from each piston.
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20. REMOVE PARKING LOCK ROD AND PAWL

(a) Remove the 2 bolts and wave washers.
(b) Remove the parking lock pawl bracket.
(c)
Disconnect the parking lock rod from the manual valve lever.
(d) Pull out the shaft and remove the spring and lock pawl.
(e) Remove the E-ring from the shaft.
21. MEASURE INSTALLATION DISTANCE OF OVERDRIVE DIRECT CLUTCH

HINT: Make a note of the distance for reassembly.
(a) Push the input shaft and drum toward the rear to make
sure the overdrive direct clutch is installed correctly.
(b) Place SST on the overdrive case.

SST 09350-20015 (09370-12010)
(c) Using calipers, measure distance between the tops of
SST and the clutch drum.
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22. REMOVE OVERDRIVE PLANETARY GEAR, WITH OVERDRIVE DIRECT CLUTCH AND OVERDRIVE ONEWAY CLUTCH
(a) Remove the overdrive planetary gear with the overdrive
direct clutch and overdrive one-way clutch from the overdrive case.
(d) Remove the race and thrust washer.
23. REMOVE OVERDRIVE CASE

(a) Remove the overdrive case from the transmission case.
HINT: When the overdrive case is removed, the front
clutch sometimes adheres to it.
(b) Remove the 2 races.
24. MEASURE INSTALLATION DISTANCE OF FRONT

CLUTCH
HINT: Make a note of the distance for reassembly.
(a) Push the input shaft and drum toward the rear to make
sure the front clutch is installed correctly.
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(b) Place SST on the transmission case.

SST 09350-20015 (09370-12010)
(c) Using calipers, measure distance between the tops of
25. REMOVE FRONT CLUTCH

(a) Remove the front clutch from the transmission case.
(b) Remove the 2 bearings and a race.
26. REMOVE REAR CLUTCH

(a) Remove the rear clutch from the transmission case.
(b) Remove the race.
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27. REMOVE CENTER SUPPORT

(a) Remove the 2 bolts and wave washers.
(b) Remove the center support from the transmission case.
28. REMOVE FRONT PLANETARY GEAR UNIT

(a) Using 2 screwdrivers, remove the snap ring.
(b) Insert 2 wires into the planetary gear and remove it.
29. CHECK PACK CLEARANCE OF NO.3 BRAKE

Using calipers, measure the clearance between the disc
and transmission case.
Clearance:
0.61-2.64 mm (0.0240-0.1039 in.)
If the values are nonstandard, inspect the discs.
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30. REMOVE NO.3 BRAKE PACK AND PRESSURE PLATE

(a) Remove the 5 discs and 4 plates.
(b) Remove the pressure plate.
31. REMOVE REAR PLANETARY GEAR UNIT AND OUTPUT SHAFT

(a) Remove the rear planetary gear unit and output shaft.
(b) Remove the 2 bearings.
32. REMOVE BRAKE APPLY TUBE
33. REMOVE RACE

Remove the race from the transmission case.
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34. CHECK NO.3 BRAKE PISTONS MOVING

Make sure the No.3 brake pistons move smoothly when
applying and releasing the compressed air into the transmission case.
35. REMOVE COMPONENTS OF NO.3 BRAKE PISTON

(a) Set SST on the spring retainer, and compress the return
springs.
SST 09350-20015 (09362-20040)
(b) Using a snap ring expander, remove the snap ring.
(c)
Remove the piston return spring.
(d) Hold outer piston with hand, apply compressed air to the
transmission case to the remove the outer piston.
If the piston does not pop out with compressed air, lift the
piston out with needle-nose pliers.
(e) Remove the O-ring from the outer piston.
(f)
Insert SST behind the reaction sleeve and gradually lift it

out of the transmission case.
SST 09350-30020 (09350-07080)
(g) Remove the 2 O-rings from the reaction sleeve.
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(h) Insert SST behind the inner piston and gradually lift it out
of the transmission case.
SST 09350-30020 (09350-07090)
(i) Remove the 2 O-rings from the inner piston.
36. REMOVE MANUAL VALVE LEVER, SHAFT AND OIL

SEALS
(a) Using a chisel, cut off the spacer and slide it toward the
lever.
(b) Using a pin punch and hammer, drive out the pin.
(c)
Pull the lever shaft out through the case and remove the
lever.
(d) Remove the spacer from the lever.
(e) Using a screwdriver, remove the 2 oil seals.
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COMPONENT PARTS
COMPONENT PARTS
AT0AD-03
GENERAL NOTES
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep
all parts of that group in a separate container while proceeding with disassembly, inspection, repair and
assembly of other component groups.
Recommended ATF:
DEXRON II
GENERAL CLEANING NOTES:

1. All disassembled parts should be washed clean and any fluid passages and holes blown through with
compressed air.
2. When using compressed 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 should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in correct order to allow efficient inspection, repairs, and
reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New discs for the brakes and clutches that are to be used for replacement must be soaked in transmission fluid for at least 15 minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must also be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
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OIL PUMP
OIL PUMP
AT0AE-03
COMPONENTS
OIL PUMP DISASSEMBLY
AT0AF-03
1.
USE TORQUE CONVERTER CLUTCH AS WORK

STAND
2.
REMOVE OIL SEAL RINGS

Remove the 2 oil seal rings.
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OIL PUMP
3.
REMOVE STATOR SHAFT

Remove the 6 bolts, and then remove the stator shaft
from the oil pump body.
4.
REMOVE OIL PUMP DRIVE GEAR AND DRIVEN GEAR
AT0AG-03
OIL PUMP INSPECTION

1.
CHECK OIL PUMP BODY BUSHING

Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Maximum inside diameter:
38.19 mm (1.5035 in.)
If the inside diameter is greater than the maximum, replace the oil pump body.
2.
CHECK STATOR SHAFT BUSHING

stator shaft bushings.
Front side 21.58 mm (0.8496 in.)
Rear side 21.58 mm (0.8496 in.)
If the inside diameter is greater than the maximum, replace the stator shaft.
3.
CHECK BODY CLEARANCE OF DRIVEN GEAR

Push the driven gear to one side of the body.
Using a feeler gauge, measure the clearance.
Standard body clearance:
0.07-0.15 mm (0.0028-0.0059 in.)
Maximum body clearance:
0.3 mm (0.012 in.)
If the body clearance is greater than the maximum, replace the drive gear, driven gear or pump body.
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4.
OIL PUMP
CHECK TIP CLEARANCE OF DRIVEN GEAR

Measure between the driven gear teeth and the crescent-shaped part of the pump body.
Standard tip clearance:
0.11-0.14 mm (0.0043-0.0055 in.)
Maximum tip clearance:
0.3 mm (0.012 in.)
If the tip clearance is greater than the maximum, replace

the drive gear, driven gear or pump body.
5.
CHECK SIDE CLEARANCE OF BOTH GEARS

Using a steel straight edge and a feeler gauge, measure
the side clearance of both gears.
Standard side clearance:
0.02-0.05 mm (0.0008-0.0020 in.)
Maximum side clearance:
0.1 mm (0.004 in.)
If the side clearance is greater than the maximum, replace

the drive gear, driven gear or pump body.
6. IF NECESSARY, REPLACE OIL SEAL
(a) Pry off the oil seal with a screwdriver.
(b) Using SST, install a new oil seal.

The oil seal end should be flushed with the outer edge of
the pump body.
SST 09350-20015 (09388-20010)
(c) Coat the oil seal lip with MP grease.
AT0AH-03
OIL PUMP ASSEMBLY

1.
INSTALL DRIVEN GEAR AND DRIVE GEAR TO OIL

PUMP BODY
(a) Place the oil pump body on the torque converter clutch.
(b) Coat the driven gear and drive gear with ATF.
(c) Install the driven gear and drive gear.
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OIL PUMP
2. INSTALL STATOR SHAFT TO OIL PUMP BODY

(a) Align the stator shaft with each bolt bole.
(b) Temporarily install the 6 bolts.
(c)
Install SST around the pump body and stator shaft.

SST 09350-20015 (09363-20010)
(d) Tighten SST to align the pump body and stator shaft.
(e) Tighten the 6 bolts.

Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
(f)
Remove SST.
3. INSTALL OIL SEAL RINGS

(a) Coat the 2 oil seal rings with ATF.
(b) Install 2 oil seal rings to the stator shaft, then snug them
down by squeezing their ends together.
NOTICE: Do not spread the ring ends too much.
HINT: After installing the oil seal rings, check that they rotate smoothly.
4.
CHECK OIL PUMP DRIVE GEAR ROTATION

Make sure the drive gear rotates smoothly.
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OVERDRIVE DIRECT CLUTCH

AT0AJ-02
COMPONENTS
OVERDRIVE PLANETARY GEAR,

OVERDRIVE DIRECT CLUTCH AND
OVERDRIVE ONE-WAY CLUTCH
DISASSEMBLY
1.
AT0AK-03
CHECK OPERATION OF ONE-WAY CLUTCH

Hold the O/D direct clutch drum and turn the input shaft.
The input shaft turns freely clockwise and locks counter
clockwise.
2. REMOVE OVERDRIVE DIRECT CLUTCH ASSEMBLY
FROM OVERDRIVE PLANETARY GEAR
(a) Remove the overdrive direct clutch from the overdrive
planetary gear.
WWW.ALL-TRANS.BY
AT-32
(b) Remove the bearing and race from the planetary carrier.
3.
CHECK PISTON STROKE OF OVERDRIVE DIRECT

CLUTCH
(a) Place the O/D direct clutch assembly onto the oil pump.
(b) Using a dial indicator, measure the O/D direct clutch piston stroke while applying and releasing compressed air
(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
1.77-2.58 mm (0.0697-0.1016 in.)
(c)
If the values are nonstandard, inspect the discs.

Remove the O/D direct clutch assembly from the oil
pump.
4. REMOVE OVERDRIVE BRAKE HUB

(a) Using a screwdriver, remove the snap ring.
(b) Remove the O/D brake hub.
WWW.ALL-TRANS.BY
AT-33
5.
REMOVE DISC
6. REMOVE FLANGE AND CUSHION PLATE

(b) Remove the flange and cushion plate.
7. REMOVE PISTON RETURN SPRINGS

(a) Place SST on the spring seat and compress the return
springs with a shop press.
SST 09350-20015 (09369-20040)
(c)
Remove the spring seat and 18 springs.
8. REMOVE OVERDRIVE DIRECT CLUTCH PISTON

(a) Place the O/D direct clutch onto the oil pump.
(b) Hold the O/D direct clutch piston and apply compressed
air to the oil pump to remove the O/D direct clutch piston.
HINT: Make sure the direct clutch piston is square in the
drum before applying compressed air.
(c) Remove the 2 O-rings from the piston.
WWW.ALL-TRANS.BY
AT-34
9. REMOVE THRUST WASHER

(b) Remove the thrust washer.
10. REMOVE ONE-WAY CLUTCH ASSEMBLY
11. DISASSEMBLE ONE-WAY CLUTCH

(a) Remove the 2 retainers from both sides.
(b) Remove the one-way clutch from the outer race.
12. REMOVE THRUST WASHER
WWW.ALL-TRANS.BY
AT-35

AT0AL-02
OVERDRIVE PLANETARY GEAR AND

OVERDRIVE DIRECT CLUTCH INSPECTION
1.
INSPECT DISC AND FLANGE

Check to see if the sliding surface of the disc and flange
are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a parts of the printed numbers are defaced,
replace disc.

Before assembling new disc, soak it in ATF for at
least 15 minutes.
2. CHECK OVERDRIVE DIRECT CLUTCH PISTON
(a) Check that check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying low-pressure compressed air.
3.
CHECK OVERDRIVE DIRECT CLUTCH DRUM BUSHINGS

clutch drum bushings.
23.14 mm (0.9110 in.)
If the inside diameter is greater than the maximum, replace the clutch drum.
4.
CHECK OVERDRIVE PLANETARY GEAR BUSHING

planetary gear bushing.
11.27 mm (0.4437 in.)
If the inside diameter is greater than the maximum, replace the planetary gear.
5.
MEASURE PLANETARY PINION GEAR THRUST

CLEARANCE
Using a feeler gauge, measure the planetary pinion gear
thrust clearance.
Standard clearance:
0.20-0.50 mm (0.0079-0.0197 in.)
If the clearance is non-standard, inspect the planetary

gear thrust washer.
If necessary, replace the planetary gear assembly.
WWW.ALL-TRANS.BY
AT-36

AT0AM-03
OVERDRIVE PLANETARY GEAR,

OVERDRIVE DIRECT CLUTCH AND
OVERDRIVE ONE-WAY CLUTCH ASSEMBLY
1.
INSTALL THRUST WASHER

Install the thrust washer to the overdrive planetary gear,
the grooved side facing upward.
2. ASSEMBLE ONE-WAY CLUTCH

(a) Install the one-way clutch into the outer race, the open
end of the retainers facing upward.
(b) Install the 2 retainers to both sides.
3.
INSTALL ONE-WAY CLUTCH ASSEMBLY
4. INSTALL THRUST WASHER

(a) Install the thrust washer.
(b) Using a screwdriver, install the snap ring.
5. INSTALL OVERDRIVE DIRECT CLUTCH PISTON

(a) Coat new O-rings with ATF and install them on the O/D
direct clutch piston.
(b) Place SST on the direct clutch piston.
SST 09350-20015 (09369-20040)
(c) Being careful not to damage the O-rings, press in the direct clutch piston into the clutch drum with both hands.
WWW.ALL-TRANS.BY
AT-37
6. INSTALL PISTON RETURN SPRINGS

(a) Install the 18 springs and spring seat.
(b) Place SST on the spring seat, and compress the return
SST 09350-20015 (09369-20040)
(c) Install the snap ring with a snap ring expander. Be sure
the end gap of the snap ring is not aligned with the spring
seat claw.
7.
(a)
(b)
(c)
INSTALL CUSHION PLATE AND FLANGE

Install the cushion plate.
Install flange, the rounded edge facing upward.
Install the snap ring. Be sure the end gap of the snap ring
is not aligned with the cutout portion of the drum.
8.
INSTALL DISC
9. INSTALL OVERDRIVE BRAKE HUB

(a) Install the O/D brake hub.
(b) Using a screwdriver, install the snap ring. Be sure the end
gap of the snap ring is not aligned with the cutout portion
of the drum.
WWW.ALL-TRANS.BY
AT-38
10. CHECK PISTON STROKE OF OVERDRIVE DIRECT

CLUTCH
(a) Place the O/D direct clutch assembly onto the oil pump.
(b) Using dial indicator, measure the overdrive direct clutch
piston stroke while applying and releasing compressed
air (392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
1.77-2.58 mm (0.0697-0.1016 in.)
If the piston stroke is less than the limit, parts may have
been assembled incorrectly, check and reassemble
again.
11. INSTALL OVERDRIVE DIRECT CLUTCH ASSEMBLY
(a) Coat the race and bearing with petroleum jelly and install
them onto the O/D planetary gear.
Bearing and race diameter
mm (in.)
Inside
Outside
Bearing
24.9 (0.980)
37.5 (1.476)
Race
25.0 (0.984)
37.4 (1.472)
(b) Install the direct clutch assembly onto the O/D planetary
gear.
HINT: Mesh the splines of the O/D planetary gear with the
flukes of the disc by rotating and pushing the O/D planetary gear.
12. CHECK OPERATION OF ONE-WAY CLUTCH

Hold the O/D direct clutch drum and turn the input shaft.
The input shaft turns freely clockwise and locks counterclockwise.
WWW.ALL-TRANS.BY
AT-39
OVERDRIVE BRAKE
OVERDRIVE BRAKE
AT0AN-02
COMPONENTS
OVERDRIVE BRAKE DISASSEMBLY
AT0AP-02
1. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place the O/D case assembly onto the transmission case,
facing the cutout portion of the O/D case to the down side
HINT: Make sure that the oil hole of the O/D case is
aligned with the oil hole of the transmission case.
(b) Using a dial indicator, measure the O/D brake piston

stroke while applying and releasing compressed air
(392-785 kPa, 4-8 kgf/cm2, 57-114 psi)
Piston stroke:
0.65-2.21 mm (0.0256-0.0870 in.)
(c)
If the values are non-standard, inspect the discs.

Remove the O/D case from the transmission case.
WWW.ALL-TRANS.BY
AT-40
OVERDRIVE BRAKE
2.
REMOVE FLANGE, DISCS, PLATES AND CUSHION

PLATE
(b) Remove the flange.
(c) Remove the 3 discs and 3 plates.

(d) Remove the cushion plate.
3. REMOVE OVERDRIVE PLANETARY RING GEAR

(a) Remove the O/D planetary ring gear.
(b) Remove the bearing and 2 races.

(b) Remove the spring seat and 12 springs.
WWW.ALL-TRANS.BY
AT-41
OVERDRIVE BRAKE
5. REMOVE OVERDRIVE BRAKE PISTON

(a) Hold the O/D brake piston by hand, apply compressed air
into the passage to remove the O/D brake piston.
6.

AT0AQ-03
OVERDRIVE BRAKE INSPECTION

INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
HINT:

replace all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.
AT0AR-02
OVERDRIVE BRAKE ASSEMBLY

(b) Install 2 oil seal rings to the O/D case, then snug them
NOTICE: Do not spread the ring ends more than necessary.
WWW.ALL-TRANS.BY
AT-42
OVERDRIVE BRAKE
2. INSTALL OVERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF and install them on the O/D
brake piston.
(b) Being careful not to damage the O-rings, press in the
brake piston into the O/D case with both hands.

(a) Install the 12 piston return springs, as shown.
(b) Install the spring seat.

(c) Pushing the spring seat, install the snap ring. Be sure the
end gap of the snap ring is not aligned with the cutout portion of the O/D case.
HINT: Make sure that the snap ring is inserted in its
groove.
4. INSTALL OVERDRIVE PLANETARY RING GEAR

(a) Coat the bearing and races with petroleum jelly and install
them onto the overdrive case.
Bearing and races diameter
mm (in.)
Inside
Outside
Race (Front)
30.1 (1.185)
48.5 (1.909)
Bearing
28.4 (1.118)
46.3 (1.823)
Race (Rear)
27.6 (1.087)
44.5 (1.752)
(b) Install the O/D planetary ring gear.

5.
INSTALL CUSHION PLATE
WWW.ALL-TRANS.BY
AT-43
6.
OVERDRIVE BRAKE
INSTALL PLATES AND DISCS

Install the 3 plates and 3 discs.
Install in order: P=Plate D=Disc
P-D-P-D-P-D
7. INSTALL FLANGE
(a) Install the flange, the rounded edge facing upward.
of the O/D case.
8. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place the O/D case assembly onto the transmission case,
facing the cutout portion of the O/D case to the down side
HINT: Make sure that the oil hole of the O/D case is
aligned with the oil hole of the transmission case.
(b) Using a dial indicator, measure the O/D brake piston

stroke whileapplying and releasing compressed air
(392-785 kPa, 4-8 kgf/cm2, 57-114 psi)
Piston stroke:
0.65-2.21 mm (0.0256-0.0870 in.)
again.
WWW.ALL-TRANS.BY
AT-44
FRONT CLUTCH
FRONT CLUTCH
AT0AS-03
COMPONENTS
FRONT CLUTCH DISASSEMBLY

1.
2.
AT0AT-03
INSTALL FRONT CLUTCH ASSEMBLY TO OVERDRIVE CASE
REMOVE REAR CLUTCH HUB AND FRONT CLUTCH

HUB
(b) Remove the rear clutch hub and front clutch hub.
WWW.ALL-TRANS.BY
AT-45
(c)
FRONT CLUTCH
Remove the bearing and 2 races.
3. CHECK PISTON STROKE OF FRONT CLUTCH

(a) Before cheking the piston stroke, install the rear clutch
hub.
(b) Install the snap ring.
(c)
Using SST and a dial indicator, measure the front clutch

air (392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
SST 09350-20015 (09350-06120)
Piston stroke:
1.32-2.66 mm (0.0520-0.1047 in.)

(d) Remove the snap ring and rear clutch hub.
4. REMOVE DISCS AND PLATES

(d) Remove the 4 discs and 4 plates.
WWW.ALL-TRANS.BY
AT-46
FRONT CLUTCH

SST 09350-20015 (09369-20040)
(c)
6. REMOVE FRONT CLUTCH PISTON

(a) Place the front clutch drum onto the O/D case.
(d) Hold the front clutch piston with hand, apply compressed
air to the O/D case to remove the front clutch piston.
FRONT CLUTCH INSPECTION

1.
AT0AU-03
INSPECT DISC AND PLATE

Check to see if the sliding surface of the disc and plate are
worn or burnt. If necessary, replace them.
HINT:

replace all discs.

Before assembling new discs. soak them in ATF for
2. CHECK FRONT CLUTCH PISTON
(a) Check that check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying low pressure compressed air.
WWW.ALL-TRANS.BY
AT-47
FRONT CLUTCH
AT0AV-03
FRONT CLUTCH ASSEMBLY

1. INSTALL FRONT CLUTCH PISTON
(a) Coat new O-rings with ATF and install them on the front
clutch piston.
(b) Place SST on the front clutch piston.
SST 09350-20015 (09369-20040)
(c) Being careful not to damage the O-rings, press the clutch
piston into the front clutch drum with both hands.
2. INSTALL PISTON RETURN SPRING
(a) Install the piston return spring.
SST 09350-20015 (09369-20040)
seat claw.
3. INSTALL PLATES AND DISCS

(a) Install the 4 plates and 3 discs.
Install in order: P=Plate D= Disc
P-D-P-D-P-D-P
(b) Install the snap ring. Be sure the end gap of the snap ring
is not aligned with the cutout portion of the front clutch
drum.
(c) Install the disc.
WWW.ALL-TRANS.BY
AT-48
FRONT CLUTCH
4. CHECK PISTON STROKE OF FRONT CLUTCH

(a) Before checking the piston stroke, install the rear clutch
hub.
(b) Install the snap ring.
(c) Using SST and a dial indicator, measure the front clutch
air (392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
SST 09350-20015 (09350-06120)
Piston stroke:
1.32-2.66 mm (0.0520-0.1047 in.)
again.
If the piston stroke is nonstandard, select another plate.
HINT: There are 2 different thicknesses for the plate.
Plate thicknness
1.8 mm (0.071 in.)
2.0 mm (0.079 in.)
(d) Remove the snap ring and rear clutch hub.

5. INSTALL FRONT CLUTCH HUB
(a) Coat the bearing and races with petroleum jelly and install
them onto the front clutch drum.
Bearing and races diameter
mm (in.)
Inside
Outside
Race (Rear)
21.4 (0.843)
37.3 (1.469)
Bearing
23.4 (0.921)
37.5 (1.476)
Race (Front)
24.1 (0.949)
37.3 (1.469)
(b) Install the front clutch hub into the front clutch drum.
HINT: Mesh the splines of the front clutch hub with the
flukes of the discs by rotating and pushing the front clutch
hub.
6. INSTALL REAR CLUTCH HUB

(a) Install the rear clutch hub.
(b) Install the snap ring. Be sure the end gap of the snap ring
is not aligned with the cutout portion of the front clutch
drum.
WWW.ALL-TRANS.BY
AT-49
REAR CLUTCH
REAR CLUTCH
AT0AW-03
COMPONENTS
REAR CLUTCH DISASSEMBLY
AT0AX-02
1. CHECK PISTON STROKE OF REAR CLUTCH

(a) Place the rear clutch assembly onto the center support.
(b) Using a dial indicator, measure the rear clutch piston

(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
0.91-1.99 mm (0.0358-0.0783 in.)
WWW.ALL-TRANS.BY
AT-50
REAR CLUTCH
2. REMOVE FLANGE
3.
REMOVE DISCS AND PLATES

Remove the 3 discs and 3 plates.

SST 09350-20015 (09369-20040)
(c)
WWW.ALL-TRANS.BY
AT-51
REAR CLUTCH
5. REMOVE REAR CLUTCH PISTON

(a) Place the rear clutch drum onto the center support.
(b) Hold the rear clutch piston with hand, apply compressed
air to the center support to remove the rear clutch piston.
AT0AY-03
REAR CLUTCH INSPECTION

1.

HINT:

replace all discs.

2. CHECK REAR CLUTCH PISTON
(a) Check that check balls are free by shaking the piston.
(b) Check that the valves do not leak by applying lowpressure compressed air.
REAR CLUTCH ASSEMBLY
AT0AZ-02
1. INSTALL REAR CLUTCH PISTON

(a) Coat new O-rings with ATF and install them on the rear
clutch piston.
(b) Place SST on the rear clutch piston.
SST 09350-20015 (09369-20040)
(c) Being careful not to damage the O-rings, press in the rear
clutch piston into the clutch drum with both hands.

WWW.ALL-TRANS.BY
AT-52
REAR CLUTCH
SST 09350-20015 (09369-20040)
seat claw.
3.

P-D-P-D-P-D
4. INSTALL FLANGE
(a) Install the flange, the flat end facing downward.
of the rear clutch drum.
5. CHECK PISTON STROKE OF REAR CLUTCH

(a) Plate the rear clutch assembly onto the center support.
(b) Using a dial indicator, measure the rear clutch piston
(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
0.91-1.99 mm (0.0358-0.0783 in.)
again.
WWW.ALL-TRANS.BY
AT-53
NO.1 BRAKE
NO.1 BRAKE
AT0B0-03
COMPONENTS
NO.1 BRAKE DISASSEMBLY
AT0B1-03
1.
REMOVE PLANETARY SUN GEAR AND NO.1 ONEWAY CLUTCH

(a) Using a snap ring expander, remove the snap ring.
(b) Remove the planetary sun gear with No.1 one- way
clutch.
WWW.ALL-TRANS.BY
AT-54
2.
NO.1 BRAKE
CHECK PISTON STROKE OF NO.1 BRAKE

Using a dial indicator, measure the No.1 brake piston
(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
0.78-1.50 mm (0.0307-0.0591 in.)
If the values are non-standard, inspect the disc.
3. REMOVE FLANGE
4.
REMOVE DISC AND PLATE
5. REMOVE PISTON RETURN SPRING

SST 09350-20015 (09369-20040)
WWW.ALL-TRANS.BY
AT-55
(c)
NO.1 BRAKE
6. REMOVE NO.1 BRAKE PISTON

(a) Hold the No.1 brake piston with hand, apply compressed
air to the center support to remove the No.1 brake piston.
(b) Remove the 2 O-rings from the piston.
7.

NO.1 BRAKE INSPECTION

1.
2.
AT0B2-03

HINT:

replace disc.

Before assembling new disc, soak it in ATF for at
least 15 minutes.
CHECK CENTER SUPPORT BUSHING
center support bushing.
36.46 mm (1.4354 in.)
If the inside diameter is greater than the maximum, replace the center support.
WWW.ALL-TRANS.BY
AT-56
NO.1 BRAKE
AT0B3-03
NO.1 BRAKE ASSEMBLY

(b) Contract the oil seal rings and install them onto the center
support.
2. INSTALL NO.1 BRAKE PISTON

(a) Coat new O-rings with ATF and install them on the No.1
brake piston.
(b) Place SST on the No.1 brake piston.
SST 09350-20015 (09369-20040)
(c) Being careful not to damage the O-rings, press in the
No.1 brake piston into the center support with both hands.

SST 09350-20015 (09369-20040)
seat claw.
4.
INSTALL PLATE AND DISC
WWW.ALL-TRANS.BY
AT-57
NO.1 BRAKE
5. INSTALL FLANGE
(a) Install the flange, the rounded edge facing downward.
of the center support.
6.

(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
0.78-1.50 mm (0.0307-0.0591 in.)
again.
7.
INSTALL PLANETARY SUN GEAR AND NO.1 ONEWAY CLUTCH

(a) While turning the one-way clutch, install the planetary
sun gear.
(b) Using a snap ring expander, install the snap ring.
WWW.ALL-TRANS.BY
AT-58
NO.2 BRAKE
NO.2 BRAKE
AT0B4-03
COMPONENTS
NO.2 BRAKE DISASSEMBLY

1.
2.
AT0B5-03

(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
1.01-2.25 mm (0.0398-0.0886 in.)

3. REMOVE FLANGE
WWW.ALL-TRANS.BY
AT-59
NO.2 BRAKE
4.
REMOVE DISCS AND PLATES

Remove the 3 discs and 3 plates.
5. REMOVE PISTON RETURN SPRING

SST 09350-20015 (09369-20040)
(c)
6. REMOVE NO.2 BRAKE PISTON

(a) Hold the No.2 brake piston with hand, apply compressed
air to the center support to remove the No.2 brake piston.
(b) Remove the O-ring from the piston.
WWW.ALL-TRANS.BY
AT-60
(c)
NO.2 BRAKE
Remove the O-ring from the center support.
AT0B6-03

HINT:

replace all discs.

NO.2 BRAKE ASSEMBLY
AT0B7-03
1. INSTALL NO.2 BRAKE PISTON

(a) Coat a new O-ring with ATF and install it on the center
support.
(b) Coat a new O-ring with ATF and install it on the No.2
brake piston.
(c) Place SST on the No.2 brake piston.
SST 09350-20015 (09369-20040)
(d) Being careful not to damage the O-rings, press in the
No.2 brake piston into the center support with both hands.
WWW.ALL-TRANS.BY
AT-61
NO.2 BRAKE

SST 09350-20015 (09369-20040)
seat claw.
3.

P-D-P-D-P-D
4. INSTALL FLANGE
(a) Install the flange, the flat end facing downward.
of the center support.
WWW.ALL-TRANS.BY
AT-62
5.
NO.2 BRAKE

(392-785 kPa, 4-8 kgf/cm2, 57-114 psi).
Piston stroke:
1.01-2.25 mm (0.0398-0.0886 in.)
6.
again.
WWW.ALL-TRANS.BY
AT-63
PLANETARY SUN GEAR
PLANETARY SUN GEAR

AT0B8-03
COMPONENTS
AT0B9-03
PLANETARY SUN GEAR AND NO.1

ONE-W AY CLUTCH DISASSEMBLY
1.
2.
3.

CHECK OPERATION OF NO.1 ONE-WAY CLUTCH
Hold No.1 one-way clutch and turn the planetary sun
gear. The planetary sun gear turns freely counterclockwise and locks clockwise.
REMOVE NO.1 ONE- WAY CLUTCH FROM PLANETARY SUN GEAR
4. DISASSEMBLE NO.1 ONE-WAY CLUTCH

(a) Using a screwdriver, loosen the staked parts of the rear
side retainer.
(b) Remove the retainer.
WWW.ALL-TRANS.BY
AT-64
(c)
PLANETARY SUN GEAR
Remove the one-way clutch and 2 retainers from the outer race.
(d) Using a pin punch and hammer, remove the front side retainer.
5.

PLANETARY SUN GEAR INSPECTION
AT0BA-03
CHECK PLANETARY SUN GEAR BUSHINGS

planetary sun gear bushings.
21.58 mm (0.8496 in.)
If the inside diameter is greater than the maximum, replace the planetary sun gear.
WWW.ALL-TRANS.BY
AT-65
PLANETARY SUN GEAR

AT0BB-03
PLANETARY SUN GEAR AND NO.1

ONE-W AY CLUTCH ASSEMBLY
(b) Install the oil seal rings to the planetary sun gear, then
snug them down by squeezing their ends together.
2. ASSEMBLE NO.1 ONE-WAY CLUTCH
(a) Install the one-way clutch into the outer race, the open
end of the retainers facing rearward.
(b) Install the 2 retainers into both sides.
(c) Install 2 new retainers to the outer race.

(d) Using a pin punch and hammer, stake the claws.
3.
INSTALL NO.1 ONE-WAY CLUTCH TO PLANETARY

SUN GEAR
4.

Hold No.1 one-way clutch and turn the planetary sun
gear. The planetary sun gear turns freely counterclockwise and locks clockwise.
5.
WWW.ALL-TRANS.BY
AT-66
FRONT PLANETARY GEAR

AT0BC-03
COMPONENTS
AT0BD-03
FRONT PLANETARY GEAR AND NO.2

ONE-W AY CLUTCH DISASSEMBLY
1.
REMOVE THRUST WASHER FROM FRONT PLANETARY CARRIER
2.

Hold the one-way clutch inner race and turn the planetary
gear. The planetary gear turns freely counterclockwise
and locks clockwise.
3.
REMOVE ONE-WAY CLUTCH INNER RACE
WWW.ALL-TRANS.BY
AT-67
4. REMOVE NO.2 ONE-WAY CLUTCH

(b) Remove the one-way clutch and 2 retainers from the

planetary gear.
5.
REMOVE THRUST WASHER
FRONT PLANETARY GEAR INSPECTION
AT0BE-03

CLEARANCE
thrust clearance.
Standard clearance:
0.20-0.50 mm (0.0079-0.0197 in.)

gear thrust washer.
WWW.ALL-TRANS.BY
AT-68

AT0BF-03
FRONT PLANETARY GEAR AND NO.2

ONE-W AY CLUTCH ASSEMBLY
(a) Coat the thrust washer with petroleum jelly.
(b) Install the thrust washer into the front planetary gear.
HINT: Make sure that the lug shapes match the cutout
portions on the front planetary gear.
2. INSTALL NO.2 ONE-WAY CLUTCH

(a) Install the one-way clutch and two retainers into the front
planetary gear.
HINT: Make sure that the open end of the retainers on the
one-way clutch are faced upward.
(b) Using a screwdriver, install the snap ring.
3.
INSTALL ONE-WAY CLUTCH INNER RACE

Install the inner race while turning it counterclockwise.

(b) Install thrust washer onto the front planetary gear.
HINT: Make sure that the lug shapes match the holes on
the front planetary gear.
WWW.ALL-TRANS.BY
AT-69
5.

Hold the one-way clutch inner race and turn the planetary
gear. The planetary gear turns freely counterclockwise
and locks clockwise.
WWW.ALL-TRANS.BY
AT-70
REAR PLANETARY GEAR
REAR PLANETARY GEAR

AT0BG-03
COMPONENTS
REAR PLANETARY GEAR AND OUTPUT

SHAFT DISASSEMBLY
1.
AT0BH-03
REMOVE THRUST WASHER FROM FRONT PLANETARY RING GEAR
2. REMOVE FRONT PLANETARY RING GEAR

(a) Using a snap ring expander, pull out the ring gear while
compressing the snap ring.
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AT-71
REAR PLANETARY GEAR
(b) Using a screwdriver, remove the snap ring from the ring
gear.
3.
REMOVE REAR PLANETARY GEAR ASSEMBLY

FROM OUTPUT SHAFT
(a) Pull out the rear planetary gear assembly.
(b) Remove the bearing and race.
4.
REMOVE REAR PLANETARY CARRIER AND ASSEMBLED THRUST WITH RACE BEARING AND RACE
FROM PLANETARY RING GEAR
5. REMOVE PLANETARY RING GEAR

(a) Using a screwdriver, remove the set ring.
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AT-72
REAR PLANETARY GEAR
(b) Remove the planetary ring gear.
(c)
Remove the race from the ring gear.
6.
REMOVE OIL SEAL RING FROM INTERMEDIATE

SHAFT
Using a screwdriver, remove the oil seal ring.
7.
REMOVE OIL SEAL RINGS FROM OUTPUT SHAFT

AT0BJ-03

SHAFT INSPECTION
1.
CHECK OUTPUT SHAFT BUSHING

output shaft bushing.
18.08 mm (0.7118 in.)
If the inside diameter is greater than the maximum, replace the output shaft.
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AT-73
2.
REAR PLANETARY GEAR

CLEARANCE
thrust clearance.
Standard clearance:
0.20-0.50 mm (0.0079-0.0197 in.)

gear thrust washer.
AT0BK-03

SHAFT ASSEMBLY
(b) Install the oil seal rings to the output shaft, then snug them
2.
INSTALL NEW OIL SEAL RING

Coat a new oil seal ring with ATF and install it to the intermediate shaft.
NOTICE: Do not spread the ring too much.
HINT: After installing the oil seal ring, check that it rotates
smoothly.
3. INSTALL PLANETARY RING GEAR

(a) Coat the race with petroleum jelly and install it onto the intermediate shaft.
Race diameter
mm (in.)
Race
Inside
Outside
21.4 (0.843)
41.4 (1.630)
(b) Install the ring gear to the intermediate shaft.
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AT-74
REAR PLANETARY GEAR
(c)
Install the set ring.
4.
INSTALL ASSEMBLED THRUST WITH RACE BEARING AND REAR PLANETARY CARRIER TO PLANETARY RING GEAR
5.
INSTALL REAR PLANETARY GEAR ASSEMBLY TO

OUTPUT SHAFT
(a) Coat the bearing and race with petroleum jelly and install
them onto the ring gear.
mm (in.)
Inside
Outside
Race
30.1 (1.185)
48.5 (1.909)
Bearing
28.4 (1.118)
46.3 (1.823)
(b) Install the rear planetary gear assembly to the output

shaft.
6. INSTALL FRONT PLANETARY RING GEAR

(a) Install the snap ring.
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AT-75
REAR PLANETARY GEAR
(b) Align the snap ring end with the wide cutout portion of the
output shaft.
(c) Using a snap ring expander, install the ring gear while
compressing the snap ring.
(d) Check that the snap ring is installed into the groove of the
output shaft.

(b) Install the thrust washer onto the rear planetary carrier.
HINT: Make sure that the lug shapes match the cutout
portions on the rear planetary carrier.
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AT-76
NO.3 BRAKE
NO.3 BRAKE
AT0BL-03
COMPONENTS
AT0BM-03
INSPECT DISC AND PLATE

Check to see if the sliding surface of the disc and plate are
worn or burnt. If necessary, replace them.
HINT:

replace all discs.

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AT-77
VALVE BODY
VALVE BODY
AT0BN-03
COMPONENTS
VALVE BODY DISASSEMBLY

1.
REMOVE DETENT SPRING
2.
REMOVE MANUAL VALVE
AT0BP-02
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AT-78
VALVE BODY
3. REMOVE LOWER VALVE BODY COVER

(a) Remove the 8 bolts and lower valve body cover.
(b) Remove the 2 gaskets and plate.
(c)
Remove the 4 check balls.
(d) Remove the retainer and 3 pins.
4.
REMOVE LOWER VALVE BODY PLATE
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AT-79
5.
VALVE BODY
REMOVE BOLTS FROM LOWER VALVE BODY

Remove the 3 bolts.
6.
REMOVE BOLTS FROM FRONT AND REAR UPPER

VALVE BODIES
(a) Turn over the valve body.
(b) Remove the 5 bolts from the front upper valve body, and
remove the 5 bolts from the rear upper valve body.
7.
LIFT OFF FRONT AND REAR UPPER VALVE BODIES

AND PLATE AS A SINGLE UNIT
(a) Hold the valve body plate to the upper valve bodies and
lift off the upper valve bodies.
HINT: Be careful that the check balls and retainers do not
fall out.
(b) Remove the 2 gaskets and plate.
AT0BQ-02
VALVE BODY ASSEMBLY

1.
POSITION NEW NO.2 GASKET AND PLATE ON LOWER VALVE BODY

(a) Place a new No.2 gasket and plate on the lower valve
body.
HINT: Since No.1 gasket and No.2 gasket look similar,
use the illustrations below to differentiate between them.
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AT-80
VALVE BODY
(b) Temporarily secure the plate with the 2 bolts.

HINT: Use the two bolts for the oil strainer.
2.
POSITION NEW NO.1 GASKET ON PLATE
3.
PLACE LOWER VALVE BODY WITH PLATE AND GASKETS ON REAR UPPER VALVE BODY
Hold the lower valve body, plate and gaskets securely so
they do not separate.
Align each bolt hole in the valve bodies with the gaskets
and plate.
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AT-81
VALVE BODY
4.
INSTALL AND FINGER TIGHTEN BOLTS IN LOWER

VALVE BODY TO SECURE REAR UPPER VALVE
BODY
(a) Install and finger tighten the bolt.
HINT: Bolt length (mm, in.) is indicated in the illustration.
(b) Hold the rear upper valve body and lower valve body, turn
over the assembly.
(c) Install and finger tighten the 5 bolts.
HINT: Each bolt length (mm, in.) is indicated in the illustration.
(d) Remove the temporarily installed bolts.
5.
6.
PLACE LOWER VALVE BODY AND REAR UPPER

VALVE BODY ON FRONT UPPER VALVE BODY
Align each bolt hole in the valve bodies with the gaskets
and plate.
INSTALL AND FINGER TIGHTEN BOLTS IN LOWER

VALVE BODY TO SECURE FRONT UPPER VALVE
BODY
(a) Install and finger tighten the 2 bolts.
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AT-82
VALVE BODY
(b) Hold the front upper valve body and lower valve body, turn
over the assembly.
(c) Install and finger tighten the 5 bolts.
7.
TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES

(a) Tighten the 10 bolts in the upper valve bodies.
(b) Tighten the 3 bolts in the lower valve body.

8.
INSTALL LOWER VALVE BODY PLATE

9. INSTALL LOWER VALVE BODY COVER

(a) Install the retainer and 3 pins.
Retainer:
Height 8.5 mm (0.335 in.)
Width 5.0 mm (0.197 in.)
Thickness 3.2 mm (0.126 in.)
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AT-83
VALVE BODY
(b) Install the 4 check balls.

Check ball:
Rubber ball diameter
5.5 mm (0.217 in.)
(c)
Place a new No.3 and No.4 gaskets and plate on the lower valve body.
HINT: Since No.3 gasket and No.4 gasket look similar,
use the illustrations below to differentiate between them.
(d) Install the lower valve body cover.

(e) Install and tighten the 8 bolts.
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AT-84
VALVE BODY
10. INSTALL MANUAL VALVE
11. INSTALL DETENT SPRING

HINT: Bolt length (mm, in.) is indicated in the illustration.
12. MAKE SURE MANUAL VALVE MOVES SMOOTHLY
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FRONT UPPER VALVE BODY

AT0BR-03
COMPONENTS
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AT-86

AT0BS-03
VALVE BODY SPRINGS SPECIFICATIONS

HINT: During reassembly, please refer to the spring specifications below to help you to differentiate between the different springs.
Mark
Name (Color)
(A)
Down-shift plug (Purple)
(B)
(C)
Free length / Outer diameter

mm (in.)
Total No. of coils
39.8 (1.567) / 10.8 (0.425)
13.5
Throttle valve (None)
21.9 (0.862) / 8.6 (0.339)
10.0
Secondary regulator valve (Green)
71.3 (2.807) / 17.4 (0.685)
17.0
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AT-87

AT0BT-02
RETAINER, STOPPER AND CHECK BALL LOCATION

1.
RETAINER AND STOPPER
Retainer
Cut-back valve
2.
Height / Width / Thickness

mm (in.)
19.0 (0.748) / 5.0 (0.197) / 3.2 (0.126)
CHECK BALL
Check ball
Rubber ball
Diameter
mm (in.)
5.54 (0.2181)
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REAR UPPER VALVE BODY

AT0BU-03
COMPONENTS
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AT-89

AT0BV-03

Mark
Name (Color)
mm (in.)
Total No. of coils
(A)
2-3 shift valve (White)
35.1 (1.382) / 9.0 (0.354)
13.7
(B)
Detent regulator valve (Red)
29.1 (1.146) / 8.9 (0.350)
15.0
(C)
Intermediate modulator valve (Green)
27.3 (1.075) / 9.0 (0.354)
11.5
(D)
Reverse clutch sequence valve (None)
37.6 (1.480) / 9.2 (0.362)
16.5
(E)
Low coast modulator valve
42.4 (1.669) / 9.2 (0.362)
17.0
(None)
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AT-90

AT0BW-03
RETAINERS AND CHECK BALLS LOCATION

1.
RETAINER
Mark
2.
Retainer

mm (in.)
(A)
Detent regulator valve
21.2 (0.835) / 5.0 (0.197) / 3.2 (0.126)
(B)
2-3 shift valve
14.0 (0.551) / 5.0 (0.197) / 3.2 (0.126)
(C)
Intermediate shift valve
14.0 (0.551) / 5.0 (0.197) / 3.2 (0.126)
CHECK BALL
Mark
Check ball
Diameter
mm (in.)
(A)
Rubber ball
5.54 (0.2181)
(B)
Steel ball
5.56 (0.2189)
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LOWER VALVE BODY
LOWER VALVE BODY

AT0BX-03
COMPONENTS
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LOWER VALVE BODY

AT0BY-03

Mark
Name (Color)

mm (in.)
(A)
Check ball (None)
13.7 (0.539) / 10.5 (0.413)
Total No. of coils

10.0
(B)
Cooler by-pass valve (Orange)
28.9 (1.138) / 13.8 (0.543)
8.5
(C)
Check ball (None)
20.0 (0.787) / 5.0 (0.197)
18.0
(D)
1-2 shift valve (None)
34.6 (1.362) / 7.6 (0.299)
15.0
(E)
3-4 shift valve (Orange)
33.7 (1.327) / 10.6 (0.417)
16.5
(F)
Pressure relief valve (None)
32.1 (1.264) / 13.1 (0.516)
11.0
(G)
Primary regulator valve (White)
55.2 (2.173) / 17.0 (0.669)
12.5
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LOWER VALVE BODY

AT0BZ-03
RETAINERS, CHECK BALLS AND SPRINGS LOCATION

1.
RETAINER
Mark
2.
Retainer

mm (in.)
(A)
Primary regulator valve
17.5 (0.689) / 14.0 (0.551) / 3.2 (0.126)
(B)
1-2 shift valve
19.0 (0.748) / 14.0 (0.551) / 3.2 (0.126)
CHECK BALL AND SPRING
Mark
Check ball
Diameter
mm (in.)
(A)
Rubber ball
6.35 (0.2500)
(B)
Plastic ball
9.53 (0.3752)
(C)
Rubber ball
5.54 (0.2181)
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AT-94
GOVERNOR BODY
GOVERNOR BODY
AT0C0-02
COMPONENTS
AT0C1-02
GOVERNOR BODY DISASSEMBLY

1.
REMOVE RETAINING CLIP

Using a screwdriver, remove the retaining clip.
2.
(a)
(b)
(c)
DISASSEMBLE GOVERNOR VALVE

Using a screwdriver, remove the E-ring.
Remove the governor weight.
Remove the governor valve shaft, spring and governor
valve.
AT0C2-02
GOVERNOR BODY ASSEMBLY

1. ASSEMBLE GOVERNOR VALVE
(a) Insert the governor valve into the governor body.
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AT-95
GOVERNOR BODY
(b) Insert the spring and governor valve shaft into the governor body.
(c)
Install the governor weight and E-ring.
2.
INSTALL RETAINING CLIP
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AT-96
TRANSMISSION CASE
TRANSMISSION CASE
AT0C3-03
TRANSMISSION CASE INSPECTION

INSPECT TRANSMISSION CASE BUSHING
Using a cylinder gauge, measure the inside diameter of
the transmission case rear bushing.
38.19 mm (1.5035 in.)
If the inside diameter is greater than the maximum, replace the transmission case.
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AT-97
EXTENSION HOUSING
EXTENSION HOUSING
AT0C4-03
EXTENSION HOUSING INSPECTION

INSPECT EXTENSION HOUSING BUSHING
Using a cylinder gauge, measure the inside diameter of
the extension housing bushing.
38.09 mm (1.4996 in.)
If the inside diameter is greater than the maximum, replace the extension housing.
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AT-98
COMPONENT PARTS INSTALLATION

AT08X-03
Disassembly, inspection and assembly of each component group have been indicated in the preceding
chapter. Before assembly, make sure again that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this group
immediately.
Recommended ATF:
DEXRON II
GENERAL INSTALLATION NOTES

1.
2.
3.
4.
5.
6.
7.
AT0C5-02
The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage and affect performance.
Before assembling new clutch discs, soak them in automatic transmission fluid for at least 15 minutes.
Apply automatic transmission fluid on sliding or rotating surfaces of parts before assembly.
Use petroleum jelly to keep small parts in their places.
Do not use adhesive cements on gaskets and similar parts.
When assembling the transmission, be sure to use new gaskets and O-rings.
Dry all parts with compressed air, never use shop rags.
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AT-99
Bearing and Race Diameters
Mark
Front Race Diameter
Thrust Bearing Diameter
Inside / Outside mm (in.)
( A)
24.3 (0.957) / 43.2 (1.701)
Rear Race Diameter

24.3 (0.957) / 39.1 (1.539)
(B)
24.1 (0.949) / 37.3 (1.469)
23.4 (0.921) / 37.5 (1.476)
(C)
30.1 (1.185) / 48.5 (1.909)
28.4 (1.118) / 46.4 (1.827)
27.6 (1.087) / 44.5 (1.752)
(D)
24.1 (0.949) / 44.3 (1.744)
(E)
38.2 (1.504) / 55.2 (2.173)
39.2 (1.543) / 57.5 (2.264)
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AT-100

AT0C6-02
BASIC SUBASSEMBLY REASSEMBLY

1.
INSTALL MANUAL VALVE LEVER, SHAFT AND OIL

SEALS
(a) Using SST, drive in 2 new oil seals as far as they will go.
SST 09350-20015 (09361-30010)
(b) Coat the oil seal lips with MP grease.
(c) Assemble a new spacer to the manual valve lever.

(d) Install the manual valve lever shaft to the transmission
case through the manual valve lever.
(e) Drive in the pin to the shaft.
(f)
Match the spacer hole to the lever calking hollow and calk
the spacer to the lever.
(g) Make sure the manual valve lever shaft turns smoothly.
2. INSTALL COMPONENTS OF NO.3 BRAKE PISTON

(a) Coat 5 new O-rings to the inner piston, reaction sleeve
and outer piston.
NOTICE: The thinner O-ring goes on the outside of the
reaction sleeve.
(c)
Assemble the inner piston, reaction sleeve and outer piston.
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(d) Stand the transmission case up.

(e) Being careful not to damage the O-rings, press in the assembled pistons into the transmission case with hand.
(f)
Place the piston return spring onto the outer piston.
(g) Set SST as shown, and compress the return springs with
SST.
SST 09350-20015 (09369-20040)
(h) Install the snap ring with a snap ring expander. Be sure
seat claw.
3.
CHECK NO.3 BRAKE PISTONS MOVING

Make sure the No.3 brake pistons move smoothly when
applying and releasing the compressed air into the transmission case.
4.
INSTALL RACE
Coat the race with petroleum jelly and install it onto the
transmission case.
Race diameter
mm (in.)
Race
Inside
Outside
39.2 (1.543)
57.5 (2.264)
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5.
INSTALL BRAKE APPLY TUBE

Install the tube, aligning its locking tab with the cutout of
the case.
HINT: Make sure that the lips of the tube end are completely inserted into the outer piston.
6.
INSTALL REAR PLANETARY GEAR UNIT AND OUTPUT SHAFT

(a) Coat the 2 bearings with petroleum jelly and install them
onto the rear planetary gear unit.
Bearings diameter
mm (in.)
Bearing
Inside
Outside
38.2 (1.504)
55.2 (2.173)
(b) Install the rear planetary gear unit to the transmission

case.
7. INSTALL PRESSURE PLATE, DISCS AND PLATES

(a) Install the pressure plate, the flat surface facing forward.
(b) Install the 5 discs and 4 plates.
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D
8.
CHECK PACK CLEARANCE OF NO.3 BRAKE

Using calipers, measure the clearance between the disc
and transmission case.
Clearance:
0.61 - 2.64 mm (0.0240 - 0.1039 in.)
If the values are non-standard, check for an improper

installation.
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9. INSTALL FRONT PLANETARY GEAR UNIT

(a) Remove the one-way clutch inner race from the planetary
gear unit.
(b) Install the front planetary gear unit.
HINT: Mesh the splines of the planetary gear with the
flukes of the discs by rotating and pushing the planetary
gear.
(c)
Position the notched tooth of the inner race toward the

valve body side of the case. Push it into place.
HINT: The inner race is correctly installed if the snap ring
groove is fully visible.
(d) Using a screwdriver, install the snap ring.
10. INSTALL CENTER SUPPORT

(a) Aim the bolt and oil holes of the center support toward the
valve body side, and align them with the bolt and oil holes
of the transmission case and insert.
(b) Install the 2 bolts with the wave washers, and tighten the
bolts.
HINT: First tighten the accumulator piston side.
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11. INSTALL REAR CLUTCH

(a) Coat the race with petroleum jelly and install it onto the
rear clutch.
Race diameter
mm (in.)
Race
Inside
Outside
27.6 (1.087)
44.5 (1.752)
(b) Install the rear clutch.

HINT:

Mesh the splines of the rear clutch with the flukes of
the disc by rotating and pushing the rear clutch.

If the rear clutch is fully meshed with the center support, the splined center of the clutch will be flush with
the end of the sun gear shaft.
12. INSTALL FRONT CLUTCH

(a) Coat the bearings and race with petroleum jelly and install
them onto the front clutch.
mm (in.)
Inside
Outside
Bearing (Front)
23.4 (0.921)
37.5 (1.476)
Race
30.1 (1.185)
48.5 (1.909)
Bearing (Rear)
28.4 (1.118)
46.4 (1.827)
(b) Install the front clutch.

HINT: Mesh the splines of the front clutch with the flukes
of the discs by rotating and pushing the front clutch.
13. MEASURE INSTALLATION DISTANCE OF FRONT

CLUTCH
(a) Place SST on the transmission case.
SST 09350-20015 (09370-12010)
(b) Using calipers, measure the distance between the tops of
If the distance corresponds to that during disassembly,
the front clutch is installed correctly.
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14. INSTALL OVERDRIVE CASE

(a) Finger tighten the 2 SSTs on the transmission case.
SST 09350-20015 (09362-30011)
HINT: Remove the SST after installation of the oil pump.
(b) Coat the races with petroleum jelly and install them onto
the overdrive case.
Races diameter
mm (in.)
Inside
Outside
Race (Front)
23.0 (0.906)
48.0 (1.890)
Race (Rear)
24.1 (0.946)
37.3 (1.469)
(c)
Insert the overdrive case gently through the 2 guide bolts

(SST) with cutout portion of the case facing the valve
body side.
15. INSTALL OVERDRIVE PLANETARY GEAR UNIT WITH

OVERDRIVE DIRECT CLUTCH AND ONE- WAY
CLUTCH
(a) Coat the thrust washer with petroleum jelly and install it
onto the overdrive planetary gear.
(b) Coat the race with petroleum jelly and install it onto the overdrive planetary gear.
Race diameter
mm (in.)
Race
(c)
Inside
Outside
24.3 (0.957)
39.1 (1.539)
Install the overdrive planetary gear with the overdrive direct clutch and one-way clutch.
HINT: Mesh the splines of the overdrive planetary gear
with the flukes of the discs by rotating and pushing the overdrive planetary gear.
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16. MEASURE INSTALLATION DISTANCE OF OVERDRIVE DIRECT CLUTCH

(a) Place SST on the overdrive case.
SST 09350-20015 (09370-12010)
(b) Using calipers, measure distance between the tops of
If the distance corresponds to that during disassembly,
the overdrive direct clutch is installed correctly.
17. INSTALL TRANSMISSION HOUSING

(a) Coat a new O-ring with ATF and install it around the overdrive case.
(b) Install the transmission housing and 6 bolts.
(c) Tighten the bolts.
Torque:
10 mm bolt 34 Nm (345 kgfcm, 25 ftlbf)
12 mm bolt 57 Nm (580 kgfcm, 42 ftlbf)
18. INSTALL OIL PUMP

(a) Coat the assembled bearing and race with petroleum jelly
and install it onto the oil pump.
Assembled bearing and race diameter
mm (in.)
Bearing and race
Inside
Outside
24.3 (0.957)
43.2 (1.701)
(b) Coat a new O-ring with ATF and install it around the pump
body.
(c) Install the oil pump gently through the 2 guide bolts (SST).
(d) Apply sealant to the bolt heads.

Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(e) Finger tighten the 5 bolts.

(f) Using a screwdriver, remove the 2 SST.
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(g) Finger tighten the 2 bolts.

19. CHECK INPUT SHAFT ROTATION

Make sure the input shaft rotates smoothly.
20. CHECK OUTPUT SHAFT

(a) Using a dial indicator, measure the end play of the output
shaft with hand.
End play:
0.3 - 0.9 mm (0.012 - 0.035 in.)
If the values are non-standard, check for an improper

installation.
(b) Check to see that output shaft rotates smoothly.
21. INDIVIDUAL PISTON OPERATION INSPECTION

Check for the sound of operation while applying compressed air into the oil holes indicated in the illustration.
(1) O/D direct clutch
(2) O/D brake
(3) Rear clutch
(4) Front clutch
(5) No.1 brake
(6) No.2 brake
(7) No.3 brake
If there is no noise, disassemble and check the installation condition of the parts.
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22. INSTALL PARKING LOCK PAWL AND ROD

(a) Install the E-ring to the shaft.
(b) Install the parking lock pawl, shaft and spring.
(c)
Connect the parking lock rod to the manual valve lever.
(d) Install the parking lock pawl bracket.

(e) Install and tighten the 2 bolts with the wave washer.
(f)
Shift the manual valve lever to the P position, and confirm

the planetary ring gear is correctly locked up by the lock
pawl.
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AT-109
23. INSTALL ACCUMULATOR SPRINGS AND PISTONS

(a) Coat new O-rings with ATF and install them to the pistons.
(b) Install the 3 springs and 3 accumulator pistons to the
bore.
Piston
mm (in.)
Piston
Outer diameter
C1
31.8 (1.252)
C2
31.8 (1.252)
B2
34.8 (1.370)
Spring dimensions
mm (in.)
Piston (Color)
Free length
Outer diameter
C1
(None)
64.7 (2.547)
17.5 (0.689)
C2
(White)
55.2 (2.173)
15.9 (0.626)
B2
(Purple)
66.7 (2.626)
16.4 (0.646)
24. INSTALL THROTTLE CABLE

(a) Coat a new O-ring with ATF and install it to the cable.
(b) Install the cable to the case.
25. INSTALL VALVE BODY

(a) Align the groove of the manual valve to the pin of the lever.
(b) Connect the throttle cable to the cam.
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AT-1 10
(c)
Install the 17 bolts.

HINT: Each bolt length (mm, in.) is indicated below.
Bolt length:
A bolt 20 mm (0.79 in.)
B bolt 25 mm (0.98 in.)
C bolt 30 mm (1.18 in.)
D bolt 36 mm (1.42 in.)
E bolt 40 mm (1.57 in.)
F bolt 47 mm (1.85 in.)
G bolt 55 mm (2.17 in.)
26.
(a)
(b)
(c)
INSTALL OIL STRAINER

Install new gasket to the oil strainer.
Install the oil strainer to the valve body.
Install and tighten the 5 bolts.
27. INSTALL OIL TUBE

Using a plastic hammer, install the 2 tubes into position.
NOTICE: Be careful not to bend or damage the tube.
28. INSTALL OIL PAN

(a) Install the 2 magnets in the oil pan.
NOTICE: Make sure that the magnets do not interfere with
the oil tubes.
(b) Install a new gasket to the transmission case.

HINT: Align the cut part of the gasket and case.
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AT-1 11
(c)
Install and tighten the 14 bolts.

29.
(a)
(b)
(c)
INSTALL GOVERNOR OIL STRAINER

Insert the oil strainer into the transmission case.
Install a new gasket and cover.
Install and tighten the 3 screws.
30. INSTALL GOVERNOR BODY ON OUTPUT SHAFT

(a) While lifting the retaining clip with a screwdriver, slide the
governor body and insert the retaining clip end into the
hole on the output shaft.
(b) Install a new lock plate and bolt, and tighten the bolt.
(c)
Stake the lock plate.
31. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR

AND BALL
(a) Using a snap ring expander, install the snap ring.
(b) Install the ball into the hole on the output shaft.
(c) Align the groove of the drive gear with the ball, install the
drive gear.
(d) Using a snap ring expander, install the snap ring.
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AT-1 12
32. INSTALL EXTENSION HOUSING

(a) Install the oil apply tube and a new gasket to the extension
housing.
(b) Install the extension housing with a new gasket to the

case.
(c) Apply sealant to the bolt A.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(d) Install and tighten the 6 bolts.

HINT: The 2 lower bolts are shorter.
33. INSTALL OVERDRIVE SOLENOID

(a) Coat 2 new O-rings with ATF and install them to the overdrive solenoid.
(b) Install the overdrive solenoid with the 2 bolts.
(c) Tighten the bolts.
34. INSTALL UNIONS

(a) Coat new 2 O-rings with ATF and install them to each
unions.
(b) Install and tighten the 2 unions.
35.
(a)
(b)
(c)
INSTALL NO.1 VEHICLE SPEED SENSOR

Coat a new O-ring with ATF and install it to the sleeve.
Install the No.1 vehicle speed sensor with the bolt.
Tighten the bolt.
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AT-1 13
36. INSTALL PARK/NEUTRAL POSITION SWITCH

(a) Using the control shaft lever, fully turn the manual valve
lever shaft back and return 2 notches. It is now in neutral.
(b) Insert the park/neutral position switch onto the manual

valve lever shaft and temporarily tighten the adjusting
bolt.
(c) Install the grommet and a new lock washer. Install and
tighten the nut.
(d) Align the neutral basic line and the switch groove, and
tighten the adjusting bolt.
(e) Bend the tabs of the lock washer.

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

(a) Install the control shaft lever with the spring washer and
nut.
(b) Tighten the nut.
Torque:6.9 Nm (70 kgfcm, 61 in.lbf)
38. INSTALL WIRE HARNESS CLAMP AND THROTTLE

CABLE CLAMP
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IN-4
INTRODUCTION
GENERAL REPAIR INSTRUCTIONS

1.
2.
3.
4.
5.
6.
IN022-06
Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.
During disassembly, keep parts in the appropriate order
to facilitate reassembly.
Observe the following:
(a) Before performing electrical work, disconnect the
negative (-) terminal cable from the battery.
(b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehicle body.
(c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
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, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive (+) terminal is properly in place.
Check hose and wiring connectors to make sure that they
are secure and correct.
Non-reusable parts
(a) Always replace cotter pins, gaskets, O-rings and oil
seals etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the symbol.
Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(b) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
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IN-5
INTRODUCTION
7.
8.
9.
the specified seal lock adhesive to the bolt, nut or

threads.
(c) Precoated parts are indicated in the component illustrations by the symbol.
When necessary, use a sealer on gaskets to prevent
leaks.
Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST
and SSM can be found at the preparation of AT section.
10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use
one with a lower rating.
11. To pull apart electrical connectors, pull on the connector

itself, not the wires.
12. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
a vehicle raised on a jack alone, even for a small job
that can be finished quickly.
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AT-14
SERVICE SPECIFICATIONS
AT06P-0A
SERVICE DATE
Oil Pump
Body clearance
STD
Maximum
Tip clearance
STD
Maximum
Side clearance
Pump body bushing inside diameter
STD
0.07 - 0.15 mm
0.3 mm
0.11 - 0.14 mm
0.3 mm
0.02 - 0.05 mm
0.0028 - 0.0059 in.

0.012 in.
0.0043 - 0.0055 in.
0.012 in.
0.0008 - 0.0020 in.
Maximum
0.1 mm
0.004 in.
Maximum
38.19 mm
1.5035 in.
Stator shaft bushing inside diameter

Front side
Maximum
Rear side
Maximum
21.58 mm
0.8496 in.
21.58 mm
0.8496 in.
23.14 mm
0.9110 in.
1.77 - 2.58 mm
0.0697 - 0.1016 in.
Overdrive Direct Clutch

Clutch drum bushing inside diameter
Maximum
Overdrive direct clutch piston stroke

Overdrive planetary gear bushing
Maximum
11.27 mm
Planetary pinion gear thrust clearance
Standard
0.20 - 0.50 mm
0.0079 - 0.0197 in.
0.4437 in.
0.65 - 2.21 mm
0.0256 - 0.0870 in.
1.32 - 2.66 mm
0.0520 - 0.1047 in.
Overdrive Brake
Piston stroke
Front Clutch
Piston stroke
Flange thickness
1.8 mm
0.071 in.
2.0 mm
0.079 in.
Rear Clutch
Piston stroke
0.91 - 1.99 mm
0.0358 - 0.0783 in.
0.78 - 1.50 mm
0.0307 - 0.0591 in.
No.1 Brake
Piston stroke
Center support bushing inside diameter
Maximum
36.46 mm
1.4354 in.
No.2 Brake
Piston stroke
1.01 - 2.25 mm
0.0398 - 0.0886 in.
21.58 mm
0.8496 in.
0.20 - 0.50 mm
0.0079 - 0.0197 in.
Planetary Sun Gear

Maximum inside diameter
Front Planetary Gear

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AT-15
Rear Planetary Gear

0.20 - 0.50 mm
0.0079 - 0.0197 in.
0.61 - 2.64 mm
0.0240 - 0.1039 in.
No.3 Brake
Pack clearance
Valve Body Spring

Free length and Coil outer
Spring
diameter
Total No. of coils and Color
mm (in.)
Front upper valve body

Secondary regulator valve
71.3 (2.807)
17.4 (0.685)
17.0
Green
Down shift plug
39.8 (1.567)
10.8 (0.425)
13.5
Purple
Throttle valve
21.9 (0.862)
8.6 (0.339)
10.0
None
Rear upper valve body

2-3 shift valve
35.1 (1.382)
9.0 (0.354)
13.7
White
29.1 (1.146)
8.9 (0.350)
15.0
Red
Intermediate modulator valve
27.3 (1.075)
9.0 (0.354)
11.5
Green
Reverse clutch sequence valve
37.6 (1.480)
9.2 (0.362)
16.5
None
Low coast modulator valve
42.4 (1.669)
9.2 (0.362)
17.0
None
13.7 (0.539)
10.5 (0.413)
10.0
None
Lower valve body

Check ball (Cooler return)
Cooler by-pass valve
28.9 (1.138)
13.8 (0.543)
8.5
Check ball (Damping check ball)
20.0 (0.787)
5.0 (0.196)
18.0
Orange
1-2 shift valve
34.6 (1.362)
7.6 (0.299)
15.0
None
3-4 shift valve
33.7 (1.327)
10.6 (0.417)
16.5
Orange
Pressure relief valve
32.1 (1.264)
13.1 (0.516)
11.0
None
55.2 (2.173)
17.0 (0.669)
12.5
White
None
Valve Body Key

Height
Width
Thickness
mm (in.)
mm (in.)
mm (in.)
19.0 (0.748)
5.0 (0.197)
3.2 (0.126)
21.2 (0.835)
5.0 (0.197)
3.2 (0.126)
2-3 shift valve
14.0 (0.551)
5.0 (0.197)
3.2 (0.126)
Intermediate shift valve
14.0 (0.551)
10.0 (0.394)
3.2 (0.126)
1 - 2 shift valve
19.0 (0.748)
5.0 (0.197)
3.2 (0.126)
17.5 (0.689)
5.0 (0.197)
3.2 (0.126)
Retainer
Front upper valve body
Cut-back valve
Rear upper valve body
Lower valve body
Transmission Case
Transmission case bushing
Maximum
38.19 mm
1.5035 in.
Maximum
38.09 mm
1.4996 in.
Extension Housing
Extension housing bushing
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AT-16
Output Shaft
End play
0.3 - 0.9 mm
0.012 - 0.035 in.
Accumulator Spring
Spring
Free length mm (in.)
Color
C1
64.7 (2.547)
None
C2
55.2 (2.173)
White
B2
66.7 (2.626)
Purple
AT06Q-0A
TORQUE SPECIFICATION
Part tightened
Nm
kgfcm
ftlbf
Stator shaft x Oil pump body
7.4
75
65 in.lbf
Throttle cam x Front upper valve body
7.4
75
65 in.lbf
Valve body cover x Front upper valve body
5.4
55
48 in.lbf
Valve body cover x Rear upper valve body
5.4
55
48 in.lbf
Valve body cover x Lower valve body
5.4
55
48 in.lbf
Upper valve body x Lower valve body
5.4
55
48 in.lbf
Lower valve body cover x Lower valve body
5.4
55
48 in.lbf
Detent spring x Valve body
5.4
55
48 in.lbf
Center support x Transmission case

Transmission housing x Transmission case
25
260
19
10 mm bolt
34
345
25
12 mm bolt
57
580
42
Oil pump x Transmission case
21
215
16
Parking lock pawl bracket
7.4
75
65 in.lbf
Valve body x Transmission case
10
100
Oil strainer x Valve body
5.4
55
48 in.lbf
Oil pan x Transmission case
4.4
45
39 in.lbf
Governor body lock plate
3.9
40
35 in.lbf
Extension housing x Transmission case
34
345
25
Overdrive solenoid x Transmission case
13
130
Union
34
350
25
Park/Neutral position switch
5.4
55
48 in.lbf
Park/Neutral position switch adjusting bolt
3.9
40
35 in.lbf
Control shaft lever
6.9
70
61 in.lbf
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IN-12
INTRODUCTION
STANDARD BOLT TORQUE SPECIFICATIONS
IN008-02
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IN-13
INTRODUCTION

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ABBREVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN THIS

Automatic Transmission Fluid

Overdrive Direct Clutch

O/D One-way Clutch

No.1 One-way Clutch

No.2 One-way Clutch

Special Service Materials

Special Service Tools

GLOSSARY OF SAE AND TOYOTA TERMS

GLOSSARY OF SAE AND TOYOTA TERMS

Secondary Air Injection

Air Injection (AI)

Battery Positive Voltage

Charge Air Cooler

Continuous Fuel Injection

Clutch Pedal Position

Continuous Trap Oxidizer

Closed Throttle Position

Direct Fuel Injection (Diesel)

Data Link Connector 1

Data Link Connector 2

2: Toyota Diagnosis Communication Link (TDCL)

Data Link Connector 3

3: OBD II Diagnostic Connector

Diagnostic Trouble Code

Diagnostic Test Mode

Engine Control Level

Engine Control Module

Engine ECU (Electronic Control Unit)

Engine Coolant Temperature

Coolant Temperature, Water Temperature (THW)

Electrically Erasable Programmable Read Only

+B, Battery Voltage

Direct Injection (DI)

Electrically Erasable Programmable Read Only Memory

Early Fuel Evaporation

Cold Mixture Heater (CMH), Heat Control Valve (HCV)

Exhaust Gas Recirculation

Exhaust Gas Recirculation (EGR)

Toyota Distributorless Ignition (TDI)

Engine Modification (EM)

Erasable Programmable Read Only Memory

Programmable Read Only Memory (PROM)

Evaporative Emission Control (EVAP)

Flash Electrically Erasable Programmable

Read Only Memory

Flash Erasable Programmable Read Only Memory

Heated Oxygen Sensor

Heated Oxygen Sensor (HO2S)

GLOSSARY OF SAE AND TOYOTA TERMS

Idle Air Control

Idle Speed Control (ISC)

Intake Air Temperature

Intake or Inlet Air Temperature

Ignition Control Module

Indirect Fuel Injection