Part 1

COMPONENT PARTS INSTALLATION
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 NOTES:
1. The automatic transmission is; composed of highly precision -finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least 15 minutes.
3. Apply automatic transmission fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. When working with FIPG material, you must observe the following.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the packing Formed In Place Gasket (FIPG) material must be removed and reapplied.

A340F: BEARINGS AND RACES INSTALLATION POSITION AND DIRECTION

A343F: BEARINGS AND RACES INSTALLATION POSITION AND DIRECTION

TRANSMISSION ASSEMBLY
1. INSTALL COMPONENTS OF FIRST AND REVERSE BRAKE PISTON
a. Coat the 3 new O-rings with Automatic Transmission Fluid (ATF).
b. Install the 2 O-rings on the No.1 piston.
c. Install the O-ring on the reaction sleeve.

d. Install the No.1 piston to the reaction sleeve.

e. Coat a new O-ring with ATF and install it on the No.2 piston.
f. Install the No.1 piston with the reaction sleeve onto the No.2 piston.

g. Align the teeth of the No.2 piston into the proper grooves.
h. Being careful not to damage the O-rings, press in the No.2 and No.1 first and reverse brake pistons into the transmission case.
i. Place the piston return spring onto the No.2 piston.
j. Set Special Service Tool (SST) as shown, and compress the return spring with SST.
SST 09350-30020 (09350-07050)

k. Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

2. CHECK PISTON STROKE OF FIRST AND REVERSE BRAKE

Make sure the first and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

3. INSTALL LEAF SPRING

4. INSTALL REAR PLANETARY GEAR UNIT WITH SECOND BRAKE DRUM. FIRST AND REVERSE BRAKE PACK AND OUTPUT SHAFT

a. Install the flange, the rounded edge facing forward.
b. Reinstall the plates and discs.
Install in order: P = Plate D = Disc
Tacoma, 4Runner: D-P-D-P-D-P-D-P-D-P
Previa, T100: D-P-D-P-D-P-D-P-D-P-D-P
Land Cruiser: D-P-D-P-D-P-D-P-D-P-D-P-D-P

c. Install the second brake drum assembly.

d. Coat the assembled bearing and race with petroleum jelly and install it onto the case.

Assembled bearing and race diameter

e. Align the teeth of the second brake drum, flange, discs and plates.

f. Align the splines of the transmission case and the assembled rear planetary gear, second brake drum, first and reverse brake pack and output shaft, indicated by A.
g. Hold the output shaft with wooden blocks or equivalents.

h. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)

5. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE

Using a feeler gauge, measure the clearance between the plate and second brake drum.

Clearance:
Tacoma, 4Runner: 0.50 - 1.02 mm (0.0197 - 0.0402 inch)
Previa, TOYOTA: T100 0.60 - 1.12 mm (0.0236 - 0.0441 inch)
Land Cruiser: 0.70 - 1.22 mm (0.0276 - 0.0480 inch)

If the values are non -standard, select another flange.

HINT: There are 6 different thicknesses for the flange.

Flange thickness

6. INSTALL SECOND BRAKE PISTON SLEEVE

7. INSTALL NEW BRAKE DRUM GASKET

8. INSTALL NO.1 ONE-WAY CLUTCH
9. INSTALL FLANGE, PLATES AND DISCS OF SECOND BRAKE
a. Install the 1.8 mm (0.071 inch) thick plate with the rounded edge side of the plate facing the disc.

b. Install the plates and discs.

Plate thickness: 2.5 mm (0.098 inch)

Install in order: P = Plate D = Disc
Tacoma, 4Runner: D-P-D-P-D-P-D-P
Previa, T100, Land Cruiser: D-P-D-P-D-P-D-P-D-P

c. Using a screwdriver, install the snap ring.

10. CHECK PACK CLEARANCE OF SECOND BRAKE

Using a feeler gauge, measure the clearance between the snap ring and flange.

Clearance:
Tacoma, 4Runner: 0.50 - 1.76 mm (0.0197 - 0.0693 inch)
Previa, T100, Land Cruiser: 0.62 - 1.98 mm (0.0244 - 0.0780 inch)

If the values are non -standard, check for an improper installation.

11. INSTALL PLANETARY SUN GEAR
While turning the planetary sun gear clockwise, install it into the No. 1 one-way clutch.

HINT: Confirm the thrust washer is installed correctly.

12. INSTALL FRONT PLANETARY GEAR

a. Coat the bearing and race with petroleum jelly and install them onto the front planetary gear.

Bearing and race diameter

b. Install the front planetary gear to the sun gear.

c. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)

d. Remove the wooden blocks or equivalent under the output shaft.

e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.

Race diameter

13. INSTALL SECOND COAST BRAKE BAND

a. Install the second coast brake band to the case.

b. Install the pin through the brake band.

c. Using needle-nose pliers, install the E-ring to the pin.

14. INSTALL FRONT PLANETARY RING GEAR TO FORWARD AND DIRECT CLUTCH

a. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.

Bearing and race diameter

b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.

Race diameter

c. Align the flukes of the discs in the forward clutch.

d. Align the splines of the front planetary ring gear with the flukes of the discs and install the front planetary ring gear to the forward clutch.

15. INSTALL ASSEMBLED DIRECT CLUTCH, FORWARD CLUTCH AND FRONT PLANETARY RING GEAR INTO CASE

a. Coat the bearing and race with petroleum jelly and install them onto the ring gear.

Bearing and race diameter

b. Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission case.

c. Using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum.

Height: 5.3 - 7.3 mm (0.209 - 0.287 inch)

If the values are non-standard, check for an improper installation.

d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.

Assembled bearing and race diameter