Part 1

A750E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION
(a) Check bearing position.

Bearing diameter:

2. ASSEMBLE NO. 4 BRAKE PISTON AND BRAKE REACTION SLEEVE

(a) Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
(b) Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
(c) Install the No. 4 brake piston to the reaction sleeve.

3. INSTALL NO. 4 BRAKE PISTON WITH BRAKE REACTION SLEEVE
(a) Install the No. 4 brake piston with brake reaction sleeve to the transmission case.
NOTICE:
- Do not damage the O-rings.
- Make sure the No. 4 brake piston is underneath the brake reaction sleeve.

4. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat a new O-ring with ATF.
(b) Install the O-ring on the 1st and reverse brake piston.
(c) With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.
NOTE: Be careful not to damage the O-ring.

(d) Place the piston return spring onto the No. 4 brake piston.
5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place SST on the spring retainer, and compress the return spring.
SST: 09350-30020
09350-07050
(b) Using SST, install the snap ring.
SST: 09350-30020
09350-07070
6. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the thrust needle roller bearing.
Thrust needle roller bearing diameter:

(b) Install the thrust needle roller bearing.
(c) Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear.
Bearing and race diameter:

(d) Install the rear planetary gear assembly.
7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

(a) Make sure the 1st and reverse brake piston moves smoothly when applying and releasing the compressed air into the transmission case.

(b) Using a vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.
NOTE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.
HINT: Length A = 36.35 to 37.09 mm (1.43 to 1.46 in.)

(c) Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, 7 No. 4 brake plates and 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.
HINT: Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.00984 to 0.0709 in.)
Length B = 36.04 to 37.14 mm (1.42 to 1.46 in.)

Standard pack clearance:
0.8 to 1.1 mm (0.0315 to 0.0433 in.)
If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.
H thickness:

8. INSTALL NO. 4 BRAKE DISC

(a) Install the 2 flanges, 8 discs and 7 plates.
Install in order:
F - D - P - D - P - D - P - D - P - D - P - D - P - D - P - D - F
HINT: F = Flange
D = Disc
P = Plate

9. INSTALL BRAKE PLATE STOPPER SPRING
10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

(a) Install the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange to the intermediate shaft.
Bearing and race diameter:

11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

(a) Install the 1-way clutch and 1-way clutch inner race to the intermediate shaft.
12. INSTALL INTERMEDIATE SHAFT

(a) Install the intermediate shaft with No. 3 1-way clutch assembly to the case.

(b) Using SST, install the snap ring.
SST: 09350-30020
09350-07050
09350-07060
13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

(a) Install the planetary sun gear and center planetary gear to the case.
(b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear.
Race diameter:

14. INSTALL NO. 2 BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the brake piston.
(b) Press the brake piston into the brake cylinder with both hands.
NOTE: Be careful not to damage the O-rings.

(c) Install the brake piston to the case.
15. INSTALL NO. 2 BRAKE DISC

(a) Install the brake piston return spring.
(b) Install the 3 plates, 3 discs and flange.
Install in order:
D - P - D - P - D - P - F
HINT: D = Disc
P = Plate
F = Flange

(c) Using SST and press, compress the return spring and install the No. 2 brake spring snap ring.
SST: 09351-40010
16. INSTALL NO. 1 BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them on the brake piston.
(b) Press the brake piston into the brake cylinder with both hands.
NOTE: Be careful not to damage the O-rings.

17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder on the transmission case.
18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

(a) Using SST and a press, compress the return spring and install the brake piston return spring snap ring.
SST: 09351-40010
19. INSTALL NO. 1 BRAKE DISC

(a) for 1GR-FE:
Install the 3 plates, 3 discs and flange.
Install in order:
P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

(b) for 2UZ-FE:
Install the 4 plates, 4 discs and flange.
Install in order:
P - D - P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

20. INSTALL CENTER PLANETARY RING GEAR

(a) Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear.

(b) Using a screwdriver, install the snap ring.
21. INSTALL FRONT PLANETARY RING GEAR

(a) Install the front planetary ring gear and thrust needle roller bearing on the case.
Thrust needle roller bearing diameter:

22. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the thrust needle roller bearing and thrust washer.
(b) Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear.
Thrust needle roller bearing and race diameter:

(a) Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.

(b) Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.
Standard piston stroke:
0.42 to 0.72 mm (0.0165 to 0.0283 in.)
If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange.
HINT: There are 4 different thicknesses for the flange.

Flange thickness:

24. INSTALL 2ND BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
(b) Press the 2nd brake cylinder into the 2nd brake piston with both hands.
NOTE: Be careful not to damage the O-rings.

(c) Using SST and a press, compress the return spring and install the snap ring.
SST: 09351-40010
NOTE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

25. INSTALL 2ND BRAKE CYLINDER

(a) Install the 2nd brake cylinder to the case.
26. INSTALL 1-WAY CLUTCH ASSEMBLY

(a) Install the thrust washer and 1-way clutch to the case.
27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

(a) Using SST, install the snap ring.
SST: 09350-30020
09350-07060
28. INSTALL NO. 3 BRAKE DISC

(a) Install the cushion plate, 4 plates, 4 discs and flange to the case.
Install in order:
C - P - D - P - D - P - D - P - D - F
HINT: C = Cushion
P = Plate
D = Disc
F = Flange

29. INSTALL NO. 3 BRAKE SNAP RING

(a) Using a screwdriver, install the snap ring.
30. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

(a) Coat 2 new O-rings with ATF, and install them to the direct clutch piston.

(b) Install the No. 2 clutch balancer and direct clutch return spring to the direct clutch piston.

(c) Coat a new O-ring with ATF, and install it on the clutch drum.
(d) Press the direct clutch piston into the clutch drum with both hands.
NOTE: Be careful not to damage the O-rings.

(e) Place SST on the direct clutch piston, and compress the return spring with a press.
SST: 09320-89010
SST: 09350-30020
09350-07070
NOTE: Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

(f) Install the snap ring with a snap ring expander.
NOTE: Do not expand the snap ring excessively.

(g) Set the end gap of the snap ring in the piston as shown in the illustration.
NOTE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

31. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

(a) Coat a new O-ring with ATF, and install it on the clutch drum.

(b) Coat a new O-ring with ATF, and install it on the reverse clutch piston.

(c) Press the clutch drum sub-assembly into the reverse clutch piston with both hands.
NOTE: Be careful not to damage the O-ring.

32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Coat a new O-ring with ATF, and install it on the reverse clutch piston.
(b) Install the reverse clutch return spring onto the reverse clutch piston.
33. INSTALL NO. 3 CLUTCH BALANCER

(a) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.
SST: 09387-00070
SST: 09350-30020
09350-07070
NOTE: Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

(b) Install the snap ring with a snap ring expander.
NOTE: Do not expand the snap ring excessively.

(c) Set the end gap of the snap ring in the piston as shown in the illustration.
NOTE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

34. INSTALL DIRECT CLUTCH DISC

(a) for 1GR-FE:
Install the 5 plates, 5 discs and reverse clutch flange on the clutch drum.
Install in order:
P - D - P - D - P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

(b) for 2UZ-FE:
Install the 6 plates, 6 discs and reverse clutch flange on the clutch drum.
Install in order:
P - D - P - D - P - D - P - D - P - D - P - D - F
HINT: P = Plate
D = Disc
F = Flange

(c) Using a screwdriver, install the 2 hole snap rings on the clutch drum.
35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transmission Unit
36. INSTALL REVERSE CLUTCH FLANGE

(a) Install the reverse clutch flange to the clutch drum.
37. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the 5 reverse clutch discs, 4 clutch plates, reverse clutch flange, clutch cushion plate and reverse clutch reaction sleeve to the reverse clutch hub.
Install in order:
D - P - D - P - D - P - D - P - D - F - C - S
HINT: D = Disc
P = Plate
F = Flange
C = Cushion
S = Sleeve

(b) Using a screwdriver, install the hole snap ring.
38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Transmission Unit
39. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Using a screwdriver, remove the snap ring from the clutch drum.

(b) Remove the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs, and 4 clutch plates from the reverse clutch hub.
40. INSTALL FORWARD CLUTCH PISTON

(a) Coat 2 new O-rings with ATF, and install them on the forward clutch piston.