Part 2
16. INSTALL SECOND COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING
a. Coat the 2 new O-rings with ATF and install them to the cover.
b. Install the spring, piston assembly and cover to the case.
c. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
17. CHECK PISTON ROD STROKE OF SECOND COAST BRAKE
a. Place a mark on the second coast brake piston rod.
b. Using SST, measure the stroke while applying and releasing compressed air (392-785 kPa, 4-8 kgf/ cm', 57-114 psi).
SST 09240-00020
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)
If it is still more than standard value, replace the brake band with a new one.
18. INSTALL OVERDRIVE SUPPORT ASSEMBLY
a. Coat the race with petroleum jelly and install it onto the overdrive support assembly.
Race diameter
b. Using 2 bolts of SST, aim the bolt and oil holes of the overdrive support toward the valve body side, and align them with the bolt holes of the transmission case and insert.
SST 09350-30020 (09350-07020)
c. Temporarily tighten the 2 bolts.
d. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
HINT: Install the snap ring open end toward the valve body.
e. Torque the 2 bolts.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
19. CHECK OUTPUT SHAFT
a. Using a dial indicator, measure the end play of the output shaft with hand.
End play: 0.27 - 0.86 mm (0.0106 - 0.0339 inch)
If the values are non-standard, check for an improper installation.
b. Check to see that output shaft rotates smoothly.
20. INSTALL FLANGES, PLATES AND DISCS OF OVERDRIVE BRAKE
a. Install the 4.0 mm (0.157 inch) thick flange (flat ring) with the rounded edge side of the flange facing the discs.
b. Install the plates and discs.
Install in order: P = Plate D = Disc
Tacoma, 4Runner: D-P-D-P-D
Previa, T100: D-P-D-P-D-P-D
Land Cruiser: D-P-D-P-D-P-D-P-D
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.
d. Using a screwdriver, install the snap ring.
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
a. Place SST and a dial indicator onto the overdrive brake piston.
SST 09350-30020 (09350-06120)
b. Measure the stroke while applying and releasing compressed air (392-785 kPa, 4-8 kg f/cm2, 57-114 psi).
Piston stroke:
Tacoma, 4Runner: 1.32 - 1.62 mm (0.0520 - 0.0638 inch)
Previa, T100: 1.40 - 1.70 mm (0.0551 - 0.0669 inch)
Land Cruiser: 1.75 - 2.05 mm (0.0689 - 0.0807 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again. If the piston stroke is nonstandard, select another flange.
HINT: There are 7 different thicknesses for the flange.
Flange thickness
22. INSTALL OVERDRIVE PLANETARY GEAR UNIT WITH OVERDRIVE DIRECT CLUTCH AND ONE-WAY CLUTCH
a. Coat the assembled bearing and race with petroleum jelly and install it onto the overdrive support.
Assembled bearing and race diameter
b. Install the overdrive planetary ring gear.
c. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
Bearing and race diameter
d. Coat the race with petroleum jelly and install it onto the planetary gear.
Race diameter
e. Install the overdrive planetary gear with the overdrive direct clutch and one-way clutch.
f. Place SST on the transmission case.
SST 09350-36010 (09350-06090)
g. Using calipers, measure distance between the tops of SST and the clutch drum.
Standard distance: 15.5 - 16.5 mm (0.610 - 0.650 inch)
If the values are non-standard, check for an improper installation.
h. Coat the assembled bearing and race with petroleum jelly and install it onto the O/D direct clutch.
Assembled bearing and race diameter
23. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the oil pump.
Bearing diameter
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 O/D 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: 22 Nm (220 kgf-cm, 16 ft. lbs.)
24. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.
25. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil hole indicated in the illustration.
HINT: When inspecting the O/D direct clutch, check with the Co accumulator piston hole closed. If there is no noise, disassemble and check the installation condition of the parts.
1) O/D direct clutch
2) Direct clutch
3) Forward clutch
4) O/D brake
5) Second coast brake
6) Second brake
7) First and reverse brake
26. INSTALL SPEED SENSOR ROTOR AND KEY
a. Install the key on the output shaft.
b. Align the groove of the sensor rotor with the key, install the sensor rotor.
c. Using snap ring pliers, install the snap ring.
27. INSTALL TRANSFER CASE
a. Clean contacting surface of any residual packing material using gasoline alcohol.
b. Apply Formed In Place Gasket (FIPG) to the case.
Part No. 08826 - 00090, THREE BOND 1281 or equivalent
A340F
c. Install the case and torque the 7 bolts.
Torque: 34 Nm (345 kgf-cm, 25 ft. lbs.)
HINT: Each bolt length is indicated in the illustration.
A343F
c. Install the case and torque the 8 bolts.
Torque: 34 Nm (345 k9f.cm, 25 ft. lbs.)
HINT: Each bolt length is indicated in the illustration.
28. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEALS
a. Using SST and a hammer, drive in the 2 new oil seals.
SST 09350-30020 (09350-07110)
b. Coat the oil seal lip with Multipurpose (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 now spring pin.
f. Match the manual valve lever indentation with the spacer hole and caulk them the punch.
g. Make sure the shaft rotates smoothly.