Part 2

15. CHECK PISTON STROKE OF O/D BRAKE
a. Place SST and a dial indicator onto the O/D brake piston.
SST 09350-30020 (09350-06120)





b. Measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).

Piston Stroke:
1UZ-FE: 1.40 - 1.70 mm (0.055 - 0.067 inch)
2JZ-GE: 1.32 - 1.62 mm (0.052 - 0.064 inch)

If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again. If the piston stroke is non-standard, select another flange.

HINT: There are 7 different thickness for the flange.





Flange thickness: mm (inch)





16. INSTALL O/D PLANETARY GEAR UNIT WITH O/D DIRECT CLUTCH & O/D ONE-WAY CLUTCH
a. Coat the race with petroleum jelly and install it onto the O/D planetary ring gear.





Race diameter: mm (inch)





b. Install the O/D planetary ring gear.





c. Install the bearing and race onto the O/D planetary ring gear.





Bearing and race diameter: mm (inch)





d. Coat the race with petroleum jelly and install it onto the O/D planetary gear.





Race diameter: mm (inch)





e. Install the O/D planetary gear with the O/D direct clutch & O/D one-way clutch.





f. Install the assembled bearing & race onto the O/D direct clutch.





Assembled bearing & race diameter: mm (inch)





17. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the oil pump.





Race diameter: mm (inch)

b. Coat a new O-ring with ATF and install it around the pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

NOTICE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.





e. Install the 7 bolts.

Torque: 21 Nm (215 kgf.cm, 16 ft. lbs.)





18. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.





19. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil holes indicated in the illustration.

HINT: When inspecting the O/D direct clutch, check with the C0 accumulator piston hole closed. If there is no noise, disassemble and check the installation condition of the parts.
(1) Forward clutch
(2) Direct clutch
(3) O/D brake
(4) 3rd coast brake
(5) 3rd brake
(6) 2nd brake
(7) 1st & reverse brake





20. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEAL
a. Using SST, drive in a 2 new oil seals.
SST 09350-30020 (09350-07110)
b. Coat the oil seal lip with MP grease.





c. Install 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. Using a hammer, drive in a new spring pin.





f. Match the manual valve lever indentation with the spacer hole and stake them together with the punch.
g. Make sure the shaft rotates smoothly.





21. 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. Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.

Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)





e. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly locked up by the lock pawl.