Transmission A761e Overhaul

A761E Overhaul - LS430
HOW TO USE THIS AUTOMATIC TRANSMISSION REPAIR INFORMATION;

GENERAL INFORMATION
1. GENERAL DESCRIPTION
a. This manual was created in accordance with SAE J2008.
b. Generally repair operations can be separated in the following 3 main processes:
1. Diagnosis
2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting
3. Final Inspection
c. This manual explains" Removing and Installing, Replacing, Disassembling, Installing and
Checking, Adjusting", but" Final inspection" is omitted.
cardiagn.com
d. The following essential operations are not written in this manual, however these operations must be
done in the practical situation.
1. Operation with a jack or lift
2. Cleaning of a removed part if necessary
3. Visual check
2. INDEX
a. An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to
be repaired.
3. PREPARATION
a. Use of special service tools (SST) and special service materials (SSM) may be required, depending
on the repairing condition. Be sure to use SST and SSM when they are required and follow the
working procedure properly. A list of SST and SSM is in the Preparation section in this manual.
4. REPAIR PROCEDURES
a. Component drawing is placed as the section or title if necessary.
b. Illustrations of the parts catalog are placed as the" disassembled parts drawing" so that it enables
you to understand the fitting condition of the components.
c. Non-reusable parts, grease applied parts, precoated parts and torque are specified in the components
drawing.
Example:
Fig. 1: Identifying Components Nonreusable Parts
cardiagn.com
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Torque, oil applying position, and non-reusable parts are described as important points in the
procedure.
NOTE: There are cases where such information can only be indicated by an
illustration. In those cases, all the information such as torque, oil,
etc. is described in the illustration.
e. Installing procedure of operation item is performed in the reverse order of the removal, and only
the important points are described.
f. Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value
and notice are placed.
g. There may be cases where the illustrations of similar models are used. In those cases, the details
may be different from the actual vehicle.
h. The procedures are presented in a step-by-step format:
1. The illustration shows what to do and where to do.
2. The task heading tells what to do.
3. The detailed text tells how to perform the task and gives other information such as
specifications and warnings.
Example:
Fig. 2: Installing Front Differential Case Tapered
HINT:
cardiagn.com
This format provides an experienced technician with a FAST TRACK to the necessary information. The
task heading can be read at a glance when necessary, and the text below provides detailed information.
Important specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
a. Specifications are presented in bold type throughout the manual. You never have to leave the
procedure to look up your specifications. The specifications are also found in the Service
Specifications section for a quick reference.
6. TERMS DEFINITION
TERMS DEFINITION
CAUTION Indicate the possibility of injury to you or other people.
NOTICE Indicate the possibility of damage to the components being
repaired.
HINT Provide additional information to help you perform the repair
efficiently.
7. SI UNIT
a. The UNITS used 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 N m (310 kgf.cm, 22 ft.lbf)
REPAIR INSTRUCTION FOR AUTOMATIC TRANSMISSION REPAIR MANUAL
PRECAUTION
1. BASIC REPAIR HINT
a. PRECOATED PARTS
1. Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory.
2. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated
with the specified adhesive.
3. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then
apply the specified seal lock adhesive to the bolt, nut or threads.
cardiagn.com
Fig. 3: Sealing Lock Adhesive
NOTE: Do the torque checking with the lower limit value of the torque
tolerance.
4. Depending on the seal lock agent to apply, there may be a case where it is necessary to leave '
it for a specified time until it hardens.
b. GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
c. BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
d. TORQUE WHEN USING EXTENSION TOOL WITH TORQUE WRENCH
1. In case of tightening by extending the entire length of the torque wrench combined with SST
or tool, if you tighten until the reading of the torque wrench reached the specified torque
value, the actual torque becomes excessive.
2. In this text, only the specified torque is described. In case of using SST or extension tool,
find the reading of the torque wrench by the formula.
3. Formula T'=T x L2/(L1 + L2)
FORMULA REFERENCE
T' Reading of torque wrench {N.m (kgf.cm, ft.lbf)}
T Torque {N.m (kgf.cm, ft.lbf)}
L1 Length of SST or tool (cm)
L2 Length of torque wrench (cm)
Fig. 4: Measuring Length Of Torque Wrench cardiagn.com

cardiagn.com
Fig. 5: Measuring Length
Fig. 6: Measuring Length Of Torque Wrench
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN MANUAL

Abbreviations Meaning
ASSY Assembly
AT Automatic Transmission
ATF Automatic Transmission Fluid
B0 Overdrive Brake
B2 3rd Brake
C0 Overdrive Clutch
C2 Direct Clutch
cardiagn.com
D Disc
F Flange
FIPG Formed in Place Gasket
MP Multipurpose
O/D Overdrive
P Plate
SSM Special Service Materials
SST Special Service Tools
w/ With
w/o Without
GLOSSARY OF SAE AND LEXUS TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE
recommendations, as well as their LEXUS equivalents.
GLOSSARY OF SAE AND LEXUS TERMS

SAE
ABBREVIATIONS SAE TERMS LEXUS TERMS ()-ABBREVIATIONS
A/C Air Conditioning Air Conditioner
ACL Air Cleaner Air Cleaner
AIR Secondary Air Injection Air Injection (Al)
AP Accelerator Pedal -
B+ Battery Positive Voltage +B, Battery Voltage
BARO Barometric Pressure -
CAC Charge Air Cooler Inter cooler
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 Potion -
DFI Direct Fuel Injection (Diesel) Direct Injection (DI)
DI Distributor Ignition -
DLC1 Data Link Connector 1 1: Check Connector
DLC2 Data Link Connector 2 2: Total Diagnosis Communication Link
(TDCL)
DLC3 Data Link Connector 3 3: OBD II Diagnostic Connector
DTC Diagnostic Trouble Code Diagnostic Code
DTM Diagnostic Test Mode -
cardiagn.com
ECL Engine Control Level -
ECM Engine Control Module Engine ECU (Electronic Control Unit)
ECT Engine Control Temperature Coolant Temperature, Water Temperature
(THW)
EEPROM Electrically Erasable Electrically Erasable Programmable Read
Programmable Read Only Only memory (EEPROM),
memory 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 Distributorless Ignition (DI)
EM Engine Modification Engine Modification (EM)
EPROM Erasable Programmable Read Programmable Read Only Memory (PROM)
Only Memory
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)
IAC Idol Air Control Idol Speed Control (ISC)
IAT Intake Air Temperature Intake or Inlet Air Temperature
ICM Ignition Control Module -
IFI Indirect Fuel Injection Indirect 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 Manifold Pressure
Intake Vacuum
MC Mixture Control Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDP Manifold Differential Pressure -
MFI Multiport Fuel Injection Electronic Fuel Injection (EFI)
MIL Malfunction Indicator Lamp Check Engine Light
cardiagn.com
MST Manifold Surface temperature -
MVZ Manifold Vacuum Zone -
NVRAM Non-Volatile 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), CC0
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 Diesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAM Random Access Memory Random Access Memory (RAM)
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 Electronic Fuel Injection (EFI), Sequential
Injection Injection
SPL Smoke Puff Limiter -
SRI Service Reminder Indicator -
SRT System Readiness Test -
ST Scan Tool -
TB Throttle Body Throttle Body
TBI Throttle Body Fuel Injection Single Point Injection
Central Fuel Injection (Ci)
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 -
TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve
(TVSV)
TWC Three-Way Catalytic Converter Three-Way Catalytic (TWC)
CCRO
TWC+OC Three-Way + Oxidation CCR + CCO
cardiagn.com
Catalytic Converter
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 Manifold Converter
Converter
3GR Third Gear -
GR Fourth Gear -
PREPARATION
AUTOMATIC TRANSMISSION/TRANS;
PREPARATION
SST (Special Service Tools)
SPECIAL SERVICE TOOLS

09309- Transmission Bearing AUTOMATIC TRANSMISSION
37010 Replacer ASSY(A761E)
09320- Transfer Clutch Spring CLUTCH DRUM & INPUT
89010 Compressor SHAFT ASSY(A761E)
09350- TOYOTA Automatic AUTOMATIC TRANSMISSION

30020 Transmission Tool Set ASSY(A761E)
OIL PUMP ASSY(A761E)
CLUTCH DRUM & INPUT
SHAFT ASSY(A761E)
cardiagn.com
(09350- No.2 Measure Terminal AUTOMATIC TRANSMISSION
06120) ASSY(A761E)
(09350- No.2 Piston Spring CLUTCH DRUM & INPUT

07040) Compressor SHAFT ASSY(A761E)
(09350- No.3 Piston Spring AUTOMATIC TRANSMISSION

07050) Compressor ASSY(A761E)
(09350- No.1 Snap Ring AUTOMATIC TRANSMISSION
07060) Expander ASSY(A761E)
cardiagn.com
(09350- No.2 Snap Ring AUTOMATIC TRANSMISSION
07070) Expander ASSY(A761E)
CLUTCH DRUM & INPUT
SHAFT ASSY(A761E)
(09350- Brake Reaction Sleeve AUTOMATIC TRANSMISSION

07080) Puller ASSY(A761E)
(09350- Brake No.1 Piston AUTOMATIC TRANSMISSION

07090) Puller ASSY(A761E)
cardiagn.com
(09350- Oil Seal Replacer AUTOMATIC TRANSMISSION
07110) ASSY(A761E)
(09351- Oil Seal Replacer OIL PUMP ASSY(A761E)

32140)
09351- Tool Set, TOYOTA AUTOMATIC TRANSMISSION

40010 Automatic ASSY(A761E)
Transmission
(09351- Pipe AUTOMATIC TRANSMISSION

04010) ASSY(A761E)
cardiagn.com
(09351- Spring Compressor AUTOMATIC TRANSMISSION
04020) No.1 ASSY(A761E)

04030) No.2 ASSY(A761E)
(09351- Plate AUTOMATIC TRANSMISSION
04040) ASSY(A761E)
(09351- Bolt AUTOMATIC TRANSMISSION

04050) ASSY(A761E)

04060) No.3 ASSY(A761E)
cardiagn.com
(09351- Bolt Set AUTOMATIC TRANSMISSION
04070) ASSY(A761E)
09387- First & Reverse Brake CLUTCH DRUM & INPUT

00070 Wrench SHAFT ASSY(A761E)
09950- Replacer Set AUTOMATIC TRANSMISSION
60010 ASSY(A761E)
(09951- Replacer 35 AUTOMATIC TRANSMISSION

00350) ASSY(A761E)
cardiagn.com
09950- Handle Set AUTOMATIC TRANSMISSION
70010 ASSY(A761E)
(09951- Handle 100 AUTOMATIC TRANSMISSION

07100) ASSY(A761E)
Recommended Tools
RECOMMENDED TOOLS
09031-00030 Pin Punch AUTOMATIC TRANSMISSION
ASSY(A761E)
SSM
SSM REFERENCE
08826-00090 "Seal Packing 1281," AUTOMATIC TRANSMISSION ASSY
THREE BOND 1281 or (A761E)
equivalent
(FIPG)
Equipment
EQUIPMENT
Feeler gauge
Cylinder Gauge
Vernier calipers
Dial indicator
Micrometer
Feeler gauge
Straight edge
Torque wrench
Angle gauge
V block
cardiagn.com
Lubricant
LUBRICANT SPECIFICATION
Automatic transmission fluid Dry 8.5 liters (9.0 US qts, 7.5 Imp. ATF TYPE WS or equivalent
fill qts)
rain and refill 2.3 liters (2.4 US qts, 2.0 Imp.
qts)
SSM (Special Service Materials)
SPECIAL SERVICE MATERIALS

08826-00090 "Seal Packing 1281," AUTOMATIC TRANSMISSION ASSY
THREE BOND 1281 or (A750E/A750F)
equivalent
(FIPG)
SERVICE SPECIFICATIONS
STANDARD BOLT; HOW TO DETERMINE BOLT STRENGTH
cardiagn.com
Fig. 7: Standard Bolt - How To Determine Bolt Strength
SPECIFIED TORQUE FOR STANDARD BOLTS
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Hexagon head bolt Hexagon flange bolt
Class Diameter mm Pitch mm N.m kgf.cm ft.lbf N.m kgf.cm ft.lbf
4T 6 1 5 55 48 in.lbf 6 60 52 in.lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
5T 6 1 6.5 65 56 in.lbf 7.5 75 65 in.lbf
8 1.25 15.5 160 12 17.5 175 13
10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 - - -
6T 6 1 8 80 69 in.lbf 9 90 78 in.lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
12 1.25 71 730 53 80 810 59
cardiagn.com
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 - - -
7T 6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166 - - -
8T 8 1.25 29 300 22 33 330 24
10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
9T 8 1.25 34 340 25 37 380 27
10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
10T 8 1.25 38 390 28 42 430 31
10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
11T 8 1.25 42 430 31 47 480 35
10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
HOW TO DETERMINE NUT STRENGTH

cardiagn.com
Fig. 8: Standard Bolt - How To Determine Nut Strength
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength
classification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
AUTOMATIC TRANSMISSION / TRANSAXLE; SERVICE DATA
AUTOMATIC TRANSMISSION / TRANSAXLE SERVICE DATA

OIL PUMP
STD 0.10 to 0.17 mm (0.0039 to 0.0067
Body clearance in.)
MAX 0.17 mm (0.0067 in.)
STD 0.07 to 0.15 mm (0.0028 to 0.0059
Tip clearance in.)
Max 0.15 mm (0.0059 in.)
STD 0.03 to 0.05 mm (0.0012 to 0.0020
Side clearance in.)
Max 0.05 mm (0.0020 in.)
Mark
cardiagn.com
0 10.736 to 10.742 mm (0.442268 to
0.42291 in.)
1 10.743 to 10.749 mm (0.442296 to
0.42319 in.)
2 10.750 to 10.756 mm (0.442323 to
0.42346 in.)
Drive gear thickness 3 10.757 to 10.763 mm (0.442350 to
0.42374 in.)
4 10.764 to 10.770 mm (0.442378 to
0.42401 in.)
5 10.771 to 10.777 mm (0.442405 to
0.42429 in.)
6 10.778 to 10.784 mm (0.442433 to
0.42457 in.)
Mark
0 10.736 to 10.742 mm (0.442268 to
0.42291 in.)
1 10.743 to 10.749 mm (0.442296 to
0.42319 in.)
2 10.750 to 10.756 mm (0.442323 to
0.42346 in.)
Driven gear thickness 3 10.757 to 10.763 mm (0.442350 to
0.42374 in.)
4 10.764 to 10.770 mm (0.442378 to
0.42401 in.)
5 10.771 to 10.777 mm (0.442405 to
0.42429 in.)
6 10.778 to 10.784 mm (0.442433 to
0.42457 in.)
Pump body bushing inside Max 38.188 mm (1.50349 in.)
diameter
Stator shaft bushing inside Max (Front side) 21.577 mm (0.850 in.)
diameter Max. (Rear side) 32.08 mm (1.263 in.)
STATOR SHAFT BUSHING INSIDE DIAMETER REFERENCE

FRONT PLANETARY GEAR
Planetary gear bushing inside Maximum 57.48 mm (2.263 in.)
diameter
STD 0.20 to 0.60 mm (0.008 to 0.024
Planetary pinion gear thrust in.)
clearance
Maximum 0.65 mm (0.026 in.)
CLEARANCE REFERENCE
CENTER PLANETARY GEAR
STD 0.12 to 0.68 mm (0.005 to 0.027
cardiagn.com
Planetary pinion gear thrust in.)
clearance
Maximum 0.73 mm (0.029 in.)
THRUST CLEARANCE
RR PLANETARY RING GEAR FLANGE
Planetary ring gear flange bushing Maximum 32.175 mm (1.267 in.)
inside diameter
DIAMETER REFERENCE
COAST AND FORWARD CLUTCH
STD 26.037 to 26.062 mm (1.0251 to
Forward clutch hub inside 1.0261 in.)
diameter
Max. 26.112 mm (1.028 in.)
Forward clutch return spring free STD 24.64 mm (0.9701 in.)
length Min. 13.67 mm (0.538 in.)
Coast clutch 0.3 to 0.6 mm (0.012 to 0.024 in.)
Pack clearance Forward clutch 0.56 to 0.86 mm (0.0220 to 0.339
in.)
Mark
0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
Flange thickness (Coast clutch) 3 3.3 mm (0.130 in.)
4 3.4 mm (0.134 in.)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
9 3.9 mm (0.154 in.)
Mark
0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
3 3.3 mm (0.130 in.)
4 3.4 mm (0.134 in.)
Flange thickness (Coast clutch)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
9 3.9 mm (0.154 in.)
A 4.0 mm (0.158 in.)
FLANGE THICKNESS
cardiagn.com
DIRECT AND REVERSE CLUTCH
STD 35.812 to 35.837 mm (1.4099 to
Reverse clutch hub inside diameter 1.4109 in.)
Max. 35.887 mm (1.4129 in.)
Reverse clutch return spring free STD 21.04 mm (0.828 in.)
Direct clutch return spring free STD 19.51 mm (0.768 in.)
Direct clutch 0.5 to 0.8 mm (0.020 to 0.031 in.)
Pack clearance
Reverse clutch 0.5 to 0.8 mm (0.020 to 0.031 in.)
Piston return spring free length (Direct clutch) 32.9 mm (1.2953 in.)
Mark
0 3.0 mm (0.118 in.)
1 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.)
3 3.3 mm (0.130 in.)
Flange thickness (Direct clutch)
4 3.4 mm (0.134 in.)
5 3.5 mm (0.138 in.)
6 3.6 mm (0.142 in.)
7 3.7 mm (0.146 in.)
8 3.8 mm (0.150 in.)
Mark
0 2.8 mm (0.110 in.)
1 2.9 mm (0.114 in.)
2 3.0 mm (0.118 in.)
3 3.1 mm (0.122 in.)
4 3.2 mm (0.126 in.)
5 3.3 mm (0.130 in.)
6 3.4 mm (0.134 in.)
7 3.5 mm (0.138 in.)
Flange thickness (Reverse clutch)
8 3.6 mm (0.142 in.)
9 3.7 mm (0.146 in.)
A 3.8 mm (0.150 in.)
FLANGE THICKNESS
NO.4 BRAKE
Pack clearance 0.4 to 0.7 mm (0.016 to 0.028 in.)
STD 23.74 mm (0.935 in.)
Piston return spring free length
Min. 14.42 mm (0.5677 in.)
Mark
0 0 mm (0 in.)
2 0.2 mm (0.00787 in.)
4 0.4 mm (0.01575 in.)
cardiagn.com
Flange thickness 6 0.6 mm (0.02362 in.)
8 0.8 mm (0.03150 in.)
10 0.6 mm (0.03937 in.)
12 0.6 mm (0.04724 in.)
14 0.6 mm (0.05512 in.)
FLANGE THICKNESS
NO.2 BRAKE
Piston stroke 0.6 to 0.9 mm (0.024 to 0.035 in.)
STD 22.66 mm (0.8921 in.)
Piston return spring free length
Min. 14.21 mm (0.5594 in.)
Mark
0 2.0 mm (0.079 in.)
1 2.1 mm (0.083 in.)
2 2.2 mm (0.087 in.)
4 2.4 mm (0.094 in.)
5 2.5 mm (0.098 in.)
6 2.6 mm (0.102 in.)
7 2.7 mm (0.106 in.)
FLANGE THICKNESS
NO.1 BRAKE
Piston stroke 0.42 to 0.72 mm (0.017 to 0.028
in.)
Mark
0 2.0 mm (0.079 in.)
1 2.2 mm (0.087 in.)
3 2.6 mm (0.102 in.)
FLANGE THICKNESS
INTERMEDIATE SHAFT
Intermediate shaft run out Maximum 0.08 mm (0.003 in.)
STD A: 25.962 to 25.975 mm (1.022 to
1.023 in.)
B: 25.962 to 25.975 mm (1.022 to
1.023 in.)
C: 32.062 to 32.075 mm (1.262 to
1.263 in.)
Intermediate shaft diameter
D: 32.062 to 32.075 mm (1.262 to
1.263 in.)
Min A: 25.912 mm (1.020 in.)
cardiagn.com
B: 25.912 mm (1.020 in.)
C: 32.012 mm (1.260 in.)
D: 32.012 mm (1.260 in.)
INTERMEDIATE SHAFT DIAMETER

ACCUMULATOR
Free length/Outer
Spring diameter mm (in.) Color
B1 Inner 44.98 (1.7709) / 11.30 Natural
(0.445)
Outer 46.36 (1.8252) / 17.10 Natural
(0.6732)
C2 63.14 (2.4858) / 16.0 Light Gray
(0.6299)
B3 64.5 (2.539) / 19.5 (0.768) Orange
C3 inner 44.0 (1.732) / 14.0 (0.551) Yellow
outer 76.65 (3.0178) / 20.10 Natural
(0.7913)
OUTPUT SHAFT BEARING
Clearance 0.02 to 0.12 mm (0.0008 to 0.0047 in.)
No. 1 3.80 mm (0.1496 in.)
No. 2 3.85 mm (0.1516 in.)
No. 3 3.90 mm (0.1555 in.)
Flange thickness No. 4 3.95 mm (0.1575 in.)
No. 5 4.00 mm (0.1575 in.)
No. 6 4.05 mm (0.1594 in.)
No. 7 4.10 mm (0.1614 in.)
No. 8 4.15 mm (0.1634 in.)
No. 9 4.20 mm (0.1653 in.)
No. 10 4.25 mm (0.1673 in.)
No. 11 4.30 mm (0.1693 in.)
No. 12 4.35 mm (0.1713 in.)
TORQUE SPECIFICATION
TORQUE SPECIFICATION
Part tightened N.m kgf.cm ft.lbf
Transmission housing 14 mm 34 345 25
at Transmission case 17 mm 57 581 42
Automatic transaxle breather tube at 5.4 55 48 in.lbf
Transmission case
Park/Neutral position Bolt 13 130 9
switch assy Nut 6.9 70 61 in.lbf
cardiagn.com
Transmission wire at Transmission case 5.4 55 48 in.lbf
Oil cooler tube union at Transmission case 29 296 21
Transmission control shaft lever RH 16 163 12
Transmission revolution sensor at 5.4 55 48 in.lbf
Transmission case
Extension housing assy at Transmission 34 345 25
case
Oil pan at Transmission case 4.4 45 39 in.lbf
Valve body oil strainer assy at 10 100 7
Transmission valve body assy
Transmission valve body assy at 11 110 8
Transmission case
Parking lock pawl bracket at Transmission 7.4 75 65 in.lbf
case
Drain plug 20 204 15
Over flow plug 20 204 15
Flange yoke at Output shaft 126 1,280 92
Oil pump at Transmission case 21 214 15
Oil pump body at Stator shaft assy 12 122 9
Detent spring at Transmission valve body 11 110 8
assy
Lock plate at Transmission valve body 6.4 65 57 in.lbf
assy
Shift solenoid valve SR at Transmission 10 100 7
valve body assy
Shift solenoid valve S1 at Transmission 10 100 7
valve body assy
Shift solenoid valve S2 at Transmission 10 100 7
valve body assy
ATF Temperature sensor at Transmission 10 100 7
valve body assy
Transmission wire at Transmission valve 10 100 7
body assy
AUTOMATIC TRANSMISSION/TRANS
AUTOMATIC TRANSMISSION ASSY (A761E)
PRECAUTION
NOTE:  The automatic transmission is composed of highly precision-finished

parts, necessitating careful inspection before reassembly because even a
small nick could cause fluid leakage or affect its performance. The
instructions here are organized so that you work on only one component
cardiagn.com
group at a time. This avoids the possibility of switching similar-looking
parts from different sub-assy. The component groups are inspected and
repaired from the converter housing side. As much as possible, complete
the inspection, repair and reassembly before proceeding to the next
component group. If a defective part is found in a component group during
reassembly, inspect and repair the part immediately. If a component group
cannot be assembled because parts are being ordered, be sure to keep all
parts of the group in a separate container while proceeding with
disassembly, inspection, repair and reassembly of other component
groups.
Recommended ATF: WS
 All disassembled parts should be washed clean, and any fluid passages
and holes should be blown out with compressed air.
 Dry all parts with compressed air-never use a shop rag.
 When using compressed air, always aim away from yourself to prevent
accidentally spraying ATF or kerosene on your face.
 The recommended automatic transmission fluid or kerosene should be
used for cleaning.
 After cleaning, the parts should be arranged in the correct order for
efficient inspection, repairs, and reassembly.
When disassembling a valve body, be sure to match each valve together

with the corresponding spring.
 New replacement discs for brakes and clutches replacement must be

soaked in ATF for at least 15 minutes before reassembly.
 All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding
surfaces should be coated with ATF prior to reassembly.
 All gaskets and rubber O-rings should be replaced.
 Do not apply adhesive cements to gaskets and similar parts.
 Make sure that the ends of a snap ring are not aligned with any of the
cutouts and are installed in the groove correctly.
 If a worn bushing is replaced, the sub-assembly containing the bushing
must also be replaced.
 Check thrust bearings and races for wear or damage. Replace if
necessary.
 Use petroleum jelly to keep parts in place.
 When working with FIPG material, you must do the following.
Using a razor blade and a gasket scraper, remove all the old packing
(FIPG) material from the gasket surface.
cardiagn.com
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise,

the packing (FIPG) material must be removed and reapplied.
SYSTEM DESCRIPTION
1. OPERATION
cardiagn.com
Fig. 9: System Description Automatic Transmission
OPERATION
One-way
Shift
Solenoid Valve Clutch Brake Clutch
Lever
Position S1 S2 S3 S4 SR SL1 SL2 SLU C1 C2 C3 C4 B1 B2 B3 B4 F1 F2 F3 F4
P ON ON ON ON
R (1) ON ON ON ON
N ON ON ON ON
D, S 1st ON ON ON ON
(6) 2nd ON ON ON ON ON ON
3rd ON ON ON ON ON
4th ON ON ON ON
5th ON ON ON ON
6th ON ON ON ON ON
S 1st ON ON ON ON
3rd ON ON ON ON ON
4th ON ON ON ON
5th ON ON ON ON
S 1st ON ON ON ON
3rd ON ON ON ON ON
4th ON ON ON ON
(1)
S 1st ON ON ON ON
3rd ON ON ON ON
(1)
S 1st ON ON ON ON
(1)
S 1st ON ON ON
(1) (1)
: Operation
: Operate but is not related to power transmission
cardiagn.com
(1) with Engine Brake
2. FUNCTION OF COMPONENTS
Fig. 10: Function Of Components A/T

FUNCTION OF COMPONENTS
Component Function
C1 No.1 Clutch Connects input shaft and intermediate shaft.
C2 No.2 Clutch Connects input shaft and center planetary carrier.
C3 No.3 Clutch Connects input shaft and front sun gear.
C4 No.4 Clutch Connects input shaft and intermediate shaft.
B1 No.1 Brake Prevents front planetary carrier from turning both clockwise and
counterclockwise.
B2 No.2 Brake Prevents front and center ring gear from turning both clockwise and
counterclockwise.
B3 No.3 Brake Prevents outer race of F2 from turning both clockwise and
counterclockwise.
B4 No.4 Brake Prevents rear ring gear from turning both clockwise and
counterclockwise.
F1 No.1 One-Way Prevents front planetary carrier from turning counterclockwise.
Clutch
F2 No.2 One-Way When B3 is operating, prevents planetary sun gear from turning
Clutch counterclockwise.
F3 No.3 One-Way Prevents center planetary carrier and rear ring gear from turning
Clutch counterclockwise.
F4 No.4 One-Way Prevents intermediate shaft from turning counterclockwise.
cardiagn.com
Clutch
AUTOMATIC TRANSMISSION ASSY (A761E)
COMPONENTS
cardiagn.com
Fig. 11: Identifying Components Automatic Transmission Assy (A761E) (1 Of 5)
cardiagn.com

cardiagn.com

cardiagn.com

cardiagn.com

OVERHAUL
1. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

a. Remove the nut and the transmission control shaft lever RH.
cardiagn.com
Fig. 16: Removing Nut Transmission Control Shaft Lever RH
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY

a. Using a screwdriver, unstake the lock washer.
b. Remove the lock washer, the nut and the bolt.
c. Remove the park/neutral position switch.
cardiagn.com
Fig. 17: Removing Park/Neutral Position Switch Assy
3. REMOVE OIL COOLER TUBE UNION

a. Remove the 2 oil cooler tube unions.
b. Remove the O-rings from the oil cooler tube unions.
cardiagn.com
Fig. 18: Removing Oil Cooler Tube Union
4. REMOVE TRANSMISSION REVOLUTION SENSOR

a. Remove the 2 bolts and the 2 transmission revolution sensors.
b. Remove the O-ring from each sensor.
cardiagn.com
Fig. 19: Removing Transmission Revolution Sensor

5. REMOVE AUTOMATIC TRANSMISSION BREATHE TUBE
a. Remove the 2 bolts.
b. Remove the breather tube.
cardiagn.com
Fig. 20: Removing Automatic Transmission Breathe Tube
6. REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSY

b. Remove the transmission housing.
cardiagn.com
Fig. 21: Removing Automatic Transmission Flange Yoke Assy
7. REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSY

a. Using a hammer and chisel, loosen the staked part of the nut.
b. Remove the nut and flange yoke assy.
cardiagn.com
Fig. 22: Removing Automatic Transmission Flange Yoke Assy
c. Remove the oil seal from the flange yoke assy.

cardiagn.com
Fig. 23: Removing Oil Seal From Flange Yoke Assy
8. REMOVE EXTENSION (ATM) HOUSING SUB-ASSY

cardiagn.com
Fig. 24: Removing Bolts
b. Using a snap ring expander, remove the snap ring.

c. Remove the thrust needle roller bearing and the 2 bearing race.
cardiagn.com
Fig. 25: Removing Thrust Needle Roller Bearing
d. Use a screwdriver to remove the extension housing sub-assy.

cardiagn.com
Fig. 26: Removing Extension Housing Sub-Assy
9. REMOVE RR COVER SLEEVE

a. Remove the 2 washers and RR cover sleeve.
10. REMOVE TRANSMISSION CASE ADAPTOR RADIAL BALL BEARING
a. Remove the transmission case adaptor radial ball bearing from the extension housing sub-assy.
cardiagn.com
Fig. 27: Removing Transmission Case Adaptor Radial Ball Bearing
11. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using a screwdriver, remove the oil seal.
cardiagn.com
Fig. 28: Removing Oil Seal
12. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSY

a. Install the transmission case on the overhaul attachment.
13. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSY
NOTE: Do not turn the transmission over as this will contaminate the valve body
with foreign matter located at the bottom of the pan.
a. Remove the drain plug and the gasket.

b. Remove the 20 bolts, oil pan and gasket.
cardiagn.com
14. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSY

a. Remove the magnets, and use them to collect steel particles.
b. 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

cardiagn.com
Fig. 30: Removing Magnets
15. REMOVE VALVE BODY OIL STRAINER ASSY

a. Turn over the transmission.
b. Remove the 4 bolts holding the valve body oil strainer assy to the valve body.
c. Remove the O-ring from the valve body oil strainer assy.
cardiagn.com
Fig. 31: Removing O-Ring
16. REMOVE TRANSMISSION WIRE

a. Remove the ATF temperature sensor.
b. Remove the 2 bolts and disconnect the 2 clamps.
c. Disconnect the 9 connectors from the shift solenoid valves.
cardiagn.com
Fig. 32: Disconnecting Connectors
d. Remove the bolt from the case.

e. Pull the transmission wire out of the transmission case.
f. Remove the O-ring from the transmission wire.
cardiagn.com
17. REMOVE TRANSMISSION VALVE BODY ASSY

a. Remove the bolt and detente spring.
cardiagn.com
Fig. 34: Removing Bolt And Detente Spring
b. Remove the 20 bolts.

c. Remove the valve body assy.
cardiagn.com
18. REMOVE TRANSAXLE CASE GASKET

a. Remove the 3 transaxle case gaskets.
cardiagn.com
Fig. 36: Removing Transaxle Case Gaskets
19. REMOVE BRAKE DRUM GASKET

a. Remove the 3 brake drum gaskets.
cardiagn.com
Fig. 37: Removing Brake Drum Gaskets
20. REMOVE CHECK BALL BODY

a. Remove the check ball body and the spring.
cardiagn.com
Fig. 38: Removing Check Ball Body And Spring
21. REMOVE C-2 ACCUMULATOR PISTON

a. While bowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.
b. Remove the 2 O-rings from the piston.
NOTE: Take care as the C-3 and B-3 accumulator piston may eject.
22. REMOVE B-3 ACCUMULATOR PISTON

a. Applying compressed air to the oil hole, remove the B-3 accumulator piston and the spring.
NOTE: Take care as the C-3 accumulator piston may jump out.
cardiagn.com
Fig. 39: Removing O-Rings
23. REMOVE C-3 ACCUMULATOR PISTON

a. While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2
springs.
cardiagn.com
24. REMOVE B-1 ACCUMULATOR VALVE

a. Remove the B-1 accumulator valve and the 2 springs.
cardiagn.com
Fig. 41: Removing B-1 Accumulator Valve
25. REMOVE PARKING LOCK PAWL BRACKET

a. Remove the 3 bolts and the parking lock pawl bracket.
cardiagn.com
26. REMOVE PARKING LOCK ROD SUB-ASSY

a. Disconnect the parking lock rod from the manual valve lever.
cardiagn.com
Fig. 43: Disconnecting Parking Lock Rod
27. REMOVE PARKING LOCK PAWL SHAFT

a. Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.
b. Remove the E-ring from the shaft.
cardiagn.com
Fig. 44: Removing E-Ring From Shaft
28. REMOVE MANUAL VALVE LEVER SUB-ASSY

a. Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.
cardiagn.com
Fig. 45: Cutting Off Spacer
b. Using a pin punch and a hammer, drive out the spring pin.
HINT:
Slowly drive out the spring pin so that it does not fall into the transmission case.
c. Pull the manual valve lever shaft out through the case, and remove the manual valve lever.
cardiagn.com
Fig. 46: Pulling Manual Valve Lever Shaft
29. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

a. Using a screwdriver, remove the 2 oil seals.
cardiagn.com
Fig. 47: Removing Oil Seals
30. REMOVE OIL PUMP ASSY

a. Remove the 10 bolts from the transmission case.
cardiagn.com
b. Using screwdriver, pull out the oil pump.

cardiagn.com
Fig. 49: Pulling Out Oil Pump
c. Remove the thrust bearing race No.1 from the oil pump.
cardiagn.com
Fig. 50: Removing Thrust Bearing Race
31. REMOVE CLUTCH DRUM & INPUT SHAFT ASSY

a. Remove the clutch drum & input shaft assy from the transmission case.
cardiagn.com
Fig. 51: Removing Clutch Drum & Input Shaft Assy
b. Remove the clutch drum thrust washer, 2 thrust needle roller bearings and bearing race.
cardiagn.com
Fig. 52: Removing Clutch Drum Thrust Washer
32. INSPECT 1 WAY N0.2 CLUTCH ASSY

a. Hold the reverse clutch hub and turn the 1 way clutch assy No.2.
b. The 1 way clutch assy No.2 turns freely clockwise and locks counterclockwise.
If there is a problem with the 1 way clutch, replace the 1 way clutch.
cardiagn.com
Fig. 53: Inspecting Way N0.2 Clutch Assy
33. REMOVE 1 WAY NO.2 CLUTCH ASSY

a. Remove the 1 way clutch assy No.2 and clutch drum thrust washer from the clutch drum and input
shaft assy.
cardiagn.com
Fig. 54: Removing Way Clutch Assy
34. REMOVE BRAKE NO.3 SNAP RING

a. Using a screwdriver, remove the brake No.3 snap ring from the case.
cardiagn.com
Fig. 55: Removing Brake Snap Ring
35. REMOVE 2ND BRAKE DISC SET

a. Remove the flange, cushion plate, 4 discs and the 4 plates from the case.
cardiagn.com
Fig. 56: Removing Flange
36. INSPECT 2ND BRAKE DISC SET

a. Check whether the sliding surface of the disc, the plate or the flange are worn or burnt.
If necessary, replace them.
NOTE:  If the lining of the disc is peeled off or discolored, or if any part of the
printed numbers is damaged, replace all discs.
 Before assembling new discs, soak them in ATF for at least 15
minutes.
cardiagn.com
Fig. 57: Inspecting 2Nd Brake Disc Set
37. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)

cardiagn.com
Fig. 58: Removing Snap Ring
38. REMOVE 1 WAY CLUTCH ASSY

a. Remove the 1 way clutch assy and the planetary carrier thrust washer No.1 from the case.
cardiagn.com
Fig. 59: Removing Way Clutch Assy
39. REMOVE 2ND BRAKE CYLINDER

a. Remove the 2nd brake cylinder from the case.
cardiagn.com
Fig. 60: Removing 2Nd Brake Cylinder
40. REMOVE 2ND BRAKE PISTON

a. Using SST and a press, remove the snap ring.
SST 09351-40010 (09351-04060, 09351-04070)
b. Remove the 2nd brake piston return spring.

cardiagn.com
Fig. 61: Removing 2Nd Brake Piston Return Spring
c. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd
brake cylinder to remove the 2nd brake piston.
cardiagn.com
Fig. 62: Removing 2Nd Brake Piston
d. Remove the 2 O-rings from the 2nd brake piston.

cardiagn.com
41. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSY NO.3

a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 15.72 mm (0.619 in.)
Minimum free length: 9.74 mm (0.383 in.)
If the inside diameter is shorter than the minimum free length, replace the brake piston return spring sub-
assy No.3.
cardiagn.com
Fig. 64: Measuring Free Length Of Spring Together With Spring Seat
42. REMOVE FRONT PLANETARY GEAR ASSY

a. Remove the front planetary gear assy and the 1 way clutch inner race from the case.
cardiagn.com
Fig. 65: Removing Front Planetary Gear Assy
b. Remove the thrust needle roller bearing, the thrust bearing race No.3 and the planetary carrier thrust
washer No.2 from the front planetary gear assy.
cardiagn.com
43. INSPECT FRONT PLANETARY GEAR ASSY

a. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.
Standard clearance:
0.20 to 0.60 mm (0.008 to 0.024 in.)
Maximum clearance: 0.65 mm (0.026 in.)
If the clearance is greater than the maximum clearance, replace the front planetary gear assembly.
cardiagn.com
Fig. 67: Measuring Front Planetary Pinion Gear Thrust Clearance
b. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.
Maximum inside diameter: 57.48 mm (2.263 in.)
If the inside diameter is greater than the maximum inside diameter, replace the front planetary gear
assy.
cardiagn.com
Fig. 68: Measuring Inside Diameter Of Front Planetary Gear Bushing
44. INSPECT 1 WAY CLUTCH ASSY

a. Install the 1 way clutch assy to 1 way clutch inner race.
b. Hold the 1 way clutch inner race and turn the 1 way clutch assy.
c. Check that the 1 way clutch assy turns freely counterclockwise and locks clockwise.
d. Remove the 1 way clutch assy from the 1 way clutch inner race.
cardiagn.com
Fig. 69: Removing 1 Way Clutch Assy
45. REMOVE FRONT PLANETARY RING GEAR

a. Remove the front planetary ring gear from the transmission case.
cardiagn.com
Fig. 70: Removing Front Planetary Ring Gear
46. REMOVE CTR PLANETARY RING GEAR

a. Using a screwdriver, remove the snap ring.
cardiagn.com
b. Remove the CTR planetary ring gear and the front planetary ring gear flange from the front
planetary ring gear.
cardiagn.com
Fig. 72: Removing CTR Planetary Ring Gear
47. REMOVE BRAKE DISC NO.1

a. Remove the flange, the 3 discs and the 3 plates from the case.
cardiagn.com
48. INSPECT BRAKE DISC NO.1

a. Check whether the sliding surface of the disc, the plate or the flange are worn or burnt.
NOTE:  If the lining of the disc is peeled off or discolored, if any part of the
groove is damaged, replace all discs.
minutes.
cardiagn.com
Fig. 74: Inspecting Brake Disc No.1
49. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

a. Using a screwdriver, remove the brake piston return spring snap ring from the case.
cardiagn.com
Fig. 75: Removing Brake Piston Return Spring Snap Ring
50. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSY

a. Remove the brake piston return spring and the brake piston No.1 with the brake cylinder No.1 from
the transmission case.
cardiagn.com
Fig. 76: Removing Brake Piston Return Spring
51. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSY

assy.
cardiagn.com
52. REMOVE BRAKE PISTON NO.1

a. Hold the brake piston No.1 and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the
transmission case to remove the brake piston No.1.
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
b. Remove the 2 O-rings from the brake piston No.1.

cardiagn.com
Fig. 78: Removing 2 O-Rings

a. Using a screwdriver, remove the snap ring from the case.
cardiagn.com
Fig. 79: Removing Snap Ring From Case
b. Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the case.
cardiagn.com
Fig. 80: Removing Flanges

a. Check whether the sliding surface of the disc, the plate and the flange are worn or burnt.
NOTE:  If the lining of the disc is peeled off or discolor, or if any part of the
minutes.
cardiagn.com
Fig. 81: Inspecting Brake Disc No.2
55. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSYNO.2

assy No.2.
cardiagn.com

a. Hold the brake piston No.2 and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the
transmission case to remove the brake piston No.2 with the cylinder.
HINT:
b. Remove the piston from the cylinder.

c. Remove the 2 O-rings from the brake piston No.2.
cardiagn.com
57. REMOVE CTR PLANETARY GEAR ASSY

a. Remove the CTR planetary gear assy, the planetary sun gear, thrust needle roller bearing and the
thrust bearing race No.4 from the case.
cardiagn.com
Fig. 84: Removing CTR Planetary Gear Assy
58. INSPECT CTR PLANETARY GEAR ASSY

a. Using a feeler gauge, measure the CTR planetary gear pinion thrust clearance.
Standard clearance:
0.12 to 0.68 mm (0.005 to 0.027 in.)
If the clearance is greater than the maximum clearance, replace the CTR planetary gear assy.
cardiagn.com
Fig. 85: Measuring CTR Planetary Gear Pinion Thrust Clearance
59. REMOVE INTERMEDIATE SHAFT

a. Using SST, remove the snap ring from the case.
SST 09350-30020 (09350-07060)

cardiagn.com
b. Remove the intermediate shaft with the 1 way clutch assy No.3 from the case.
cardiagn.com
Fig. 87: Removing Intermediate Shaft
60. INSPECT 1WAY NO.3 CLUTCH ASSY

a. Hold the RR planetary ring gear flange sub assy and turn the 1 way clutch assy.
b. Check that the 1 way clutch assy turns freely counterclockwise and locks clockwise.
cardiagn.com
Fig. 88: Inspecting 1Way No.3 Clutch Assy
61. REMOVE 1WAY NO.3 CLUTCH ASSY

a. Remove the 1 way clutch assy No.3 and the 1 way clutch inner race from the intermediate shaft.
cardiagn.com
Fig. 89: Removing 1 Way Clutch Assy
62. REMOVE RR PLANETARY RING GEAR FLANGE SUB-ASSY

a. Remove the thrust bearing race No.8, the thrust needle roller bearing, the thrust bearing race No.7
and the planetary ring gear flange from the intermediate shaft.
cardiagn.com
63. INSPECT RR PLANETARY RING GEAR FLANGE SUB-ASSY

a. Using a dial indicator, measure the inside diameter of the RR planetary ring gear bushing.
If the inside diameter is greater than the maximum inside diameter, replace the RR planetary ring gear.
cardiagn.com
Fig. 91: Measuring Inside Diameter Of RR Planetary Ring Gear Bushing
64. INSPECT INTERMEDIATE SHAFT

a. Using a dial indicator, check the intermediate shaft run out.
Maximum run out: 0.08 mm (0.003 in.)
If the bend exceeds the specification, replace the intermediate shaft with a new one.
cardiagn.com
Fig. 92: Checking Intermediate Shaft Run Out
b. Using a micrometer, check the outer diameter of the intermediate shaft positions shown in the
diagram.
Standard diameter:
A: 25.962 to 25.975 mm (1.022 to 1.023 in.)
B: 25.962 to 25.975 mm (1.022 to 1.023 in.)
C: 32.062 to 32.075 mm(1.262 to 1.263 in.)
D: 32.062 to 32.075 mm (1.262 to 1.263 in.)
Minimum diameter:
A: 25.912 mm (1.020 in.)
B: 25.912 mm (1.020 in.)
C: 32.012 mm (1.260 in.)

D: 32.012 mm (1.260 in.)
If the outer diameter is outside the standard, replace the intermediate shaft with the new one.
cardiagn.com
Fig. 93: Checking Outer Diameter Of Intermediate Shaft Positions

65. REMOVE BRAKE PLATE STOPPER SPRING
a. Remove the brake plate stopper spring from the case.
cardiagn.com
Fig. 94: Removing Brake Plate Stopper Spring

a. Remove the sleeve, 4 plates, 4 discs and flange from the case.
cardiagn.com
Fig. 95: Removing Sleeve


a. Check whether the sliding surface of the disc, the plate and the flange are worn or burnt.
NOTE:  If the lining of the disc is peeled off or discolor, or if any part of the
minutes.
Fig. 96: Inspecting Brake Disc No.4 cardiagn.com

68. REMOVE REAR PLANETARY GEAR ASSY

a. Remove the rear planetary gear assy from the case.
cardiagn.com
Fig. 97: Removing Rear Planetary Gear Assy
b. Remove the thrust bearing race No.9 and the thrust needle roller bearing from the rear planetary
gear assy.
cardiagn.com
c. Remove the thrust needle roller bearing from the case.

cardiagn.com
69. INSPECT REAR PLANETARY GEAR ASSY

a. Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.
Standard clearance: 0.2 to 0.6 mm (0.008 to 0.024 in.)
If the clearance is greater than the maximum clearance, replace the planetary gear assy.
cardiagn.com
Fig. 100: Measuring Rear Planetary Gear Pinion Thrust Clearance
b. Using a dial indicator, measure the inside diameter of the rear planetary gear bushing.
If the inside diameter is greater than the maximum inside diameter, replace the rear planetary gear assy.
cardiagn.com
Fig. 101: Measuring Inside Diameter Of Rear Planetary Gear Bushing
70. REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY

a. Place SST on the 1st & reverse brake return spring sub-assy and compress the brake return spring.
SST 09350-30020 (09350-07050)
b. Using SST, remove the snap ring and the brake return spring.
SST 09350-30020 (09350-07070)

cardiagn.com
71. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY

assy.
cardiagn.com
72. REMOVE 1ST & REVERSE BRAKE PISTON

a. Hold the 1st & reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2 , 57 psi) into the
transmission case to remove the brake piston.
HINT:
b. Remove the brake apply tube from the piston.

c. Remove the O-ring from brake piston.
cardiagn.com
73. REMOVE BRAKE REACTION SLEEVE

a. Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
b. Remove the 2 O-rings from the reaction sleeve.

cardiagn.com
Fig. 105: Removing Reaction Sleeve

a. Using SST, remove the brake piston No.4.
SST 09350-30020 (09350-07090)
b. Remove the 2 O-rings from the piston No.4.

cardiagn.com
Fig. 106: Removing Brake Piston
75. BEARING POSITION

cardiagn.com
Fig. 107: Identifying Bearing Position
BEARING POSITION REFERENCE

Front Race Diameter Inside/ Thrust Bearing Diameter Rear Race Diameter
Mark Outside Inside / Outside Inside/Outside
A 73.6 mm (2.898 in.) / 102.0 mm 71.9 mm (2.831 in.) / 85.6 mm -
(4.016 in.) (3.370 in.)
B 38.0 mm (1.496) / 57.0 mm 43.4 mm (1.709 in.) / 58.3 mm -
(2.244 in.) (2.295 in.)
C - 55.7 mm (2.193 in.) / 76.4 mm 53.7 mm (2.114 in.) / 74.0
(3.008 in.) mm (2.913 in.)
D 33.4 mm (1.315) / 49.0 mm 32.1 mm (1.264 in.) / 49.35 mm 32.1 mm (1.264 in.) / 49.0
(1.929 in.) (1.943 in.) mm (1.929 in.)
E - 21.5 mm (0.847 in.) / 40.8 mm -
(1.606 in.)
F 48.5 mm (1.909) / 62.7 mm 45.9 mm (1.807 in.) / 64.0 mm -
(2.469 in.) (2.520 in.)
G 37 mm (1.45 in.) / 52.3 mm 34.6 mm (1.362 in.) / 52.0 mm -
(2.059 in.) (2.047 in.)
H 36.9 mm (1.453 in.) / 49.7 mm 36.1 mm (1.421 in.) / 52.5 mm 36.1 mm (1.421 in.) / 51.0
(1.957 in.) (2.067 in.) mm (2.007 in.)
76. INSTALL BRAKE PISTON NO.4

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 brake piston No.4.
c. Install the brake piston No.4 to the reaction sleeve.
Fig. 108: Installing Brake Piston

cardiagn.com
77. INSTALL BRAKE REACTION SLEEVE
a. Coat a new O-ring with ATF, and install it to the reaction sleeve.
b. With the brake piston No.4 underneath (the rear side), install the brake reaction sleeve and the
brake piston No.4 to the transmission case.
NOTE: Be careful not to damage the O-rings.

cardiagn.com
Fig. 109: Installing Brake Reaction Sleeve
78. INSTALL 1ST & REVERSE BRAKE PISTON

a. Coat a new O-ring with ATF.
b. Install the O-ring on the 1st & 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.

cardiagn.com
Fig. 110: Installing O-Ring
d. Place the piston return spring onto the brake piston No.4.
cardiagn.com
Fig. 111: Placing Piston Return Spring
79. INSTALL 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY

a. Place SST on the brake return spring, and compress the return spring.
SST 09350-30020 (09350-07050)
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)

cardiagn.com
Fig. 112: Installing Snap Ring
80. INSTALL REAR PLANETARY GEAR ASSY

a. Install the thrust needle roller bearing.
Thrust needle roller bearing diameter:
THRUST NEEDLE ROLLER BEARING DIAMETER

Inside Outside
Thrust needle roller bearing 45.9 mm (1.807 in.) 64.0 mm (2.520 in.)
cardiagn.com
Fig. 113: Installing Thrust Needle Roller Bearing
b. Install the thrust needle roller bearing.

c. Coat the thrust bearing race No.9 with petroleum jelly, and install it onto the rear planetary ring
gear.
Bearing & race diameter:
BEARING & RACE DIAMETER

Inside Outside
Bearing 21.5 mm (0.847 in.) 40.8 mm (1.606 in.)
Race 48.5 mm (1.909 in.) 62.7 mm (2.469 in.)
cardiagn.com
d. Install the rear planetary gear assy.

cardiagn.com
Fig. 115: Installing Rear Planetary Gear Assy
81. INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE

a. Make sure that the 1st & reverse brake piston move smoothly when pulling and releasing the
compressed air gun lever while applying compressed air into the transmission case.
cardiagn.com
Fig. 116: Inspecting Pack Clearance Of First & Reverse Brake
b. Using vernier calipers, measure the level difference (length A) between the upper surface of the
brake apply tube and the hitting surface of the brake flange No.4 at both ends across the 1st &
reverse brake piston diameter, and calculate the average.
NOTE: The 1st & reverse brake piston must be securely installed to the end
face of the transmission case.
HINT:
Length A = 22.05 to 22.91 mm (0.8681 to 0.9020 in.)

cardiagn.com
Fig. 117: Measuring Level Difference Between Upper Surface Of Brake
c. Using vernier calipers, measure the thickness (length B) of the brake flanges the 4 brake plates
No.4 and the 4 brake discs No.4 altogether at the both ends across a diameter, and calculate the
average.
HINT:
Length B = 23.11 to 23.89 mm (0.9098 to 0.9405 in.)
Pack Clearance = Length A - Length B - 0.22 mm (0.0087 in.) + 1.8 mm (0.071 in.)
cardiagn.com
Fig. 118: Measuring Thickness Of Brake Flanges
Pack Clearance: 0.4 to 0.7 mm (0.016 to 0.028 in.)
d. If the pack clearance is outside the standard, select and install a brake flange that brings the pack
clearance to be within the standard.
HINT:
There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most
appropriate thickness.
Thickness H:
THICKNESS
No. Thickness H No. Thickness H
0 0 mm (0 in.) 8 0.8 mm (0.03150 in.)
2 0.2 mm (0.00787 in.) 10 1.0 mm (0.03937 in.)
4 0.4 mm (0.01575 in.) 12 1.2 mm (0.04724 in.)
6 0.6 mm (0.02362 in.) 14 1.4 mm (0.05512 in.)
82. INSTALL BRAKE DISC NO.4

a. Install the sleeve, 4 plates, the 4 discs and the flange.
Install in order: P = Plate, D = Disc, F = Flange, S = Sleeve F - D - P - D - P - D - P - D - P - S
cardiagn.com
cardiagn.com
Fig. 119: Installing Brake Disc

83. INSTALL BRAKE PLATE STOPPER SPRING

a. Install the brake plate stopper spring.
cardiagn.com
Fig. 120: Installing Brake Plate Stopper Spring
84. INSTALL RR PLANETARY RING GEAR FLANGE SUB-ASSY

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

Inside Outside
Thrust bearing race No.7 33.4 mm (1.315 in.) 49.0 mm (1.929 in.)
cardiagn.com
Fig. 121: Installing Thrust Bearing Race
85. INSTALL 1 WAY NO.3 CLUTCH ASSY

a. Install the 1 way clutch assy No.3 and the 1 way clutch inner race to the intermediate shaft.
cardiagn.com
Fig. 122: Installing Way Clutch Assy
86. INSTALL INTERMEDIATE SHAFT

a. Install the intermediate shaft with the 1 way clutch assy No.3 to the case.
cardiagn.com
Fig. 123: Installing Intermediate Shaft
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07050, 09350-07060)

cardiagn.com
87. INSTALL CTR PLANETARY GEAR ASSY

a. Install the center planetary gear assy and the planetary sun gear to the case.
b. Coat the thrust bearing race with petroleum jelly, and install it onto the CTR planetary ring gear.
Race diameter:
RACE DIAMETER
Inside Outside
Race 53.7 mm (2.114 in.) 74.0 mm (2.913 in.)
cardiagn.com
Fig. 125: Installing Center Planetary Gear Assy

a. Coat 2 new O-rings with ATF, and install them to the brake piston No.2.
b. Being careful not to damage the O-rings, press the brake piston No.2 into the brake cylinder No.2.
c. Install the brake piston No.2 to the case.
HINT:
Install the brake cylinder No.2 so that the projection protrudes from the upside of the transmission
case.
cardiagn.com
d. Check that the oil pressure apply hole of the brake cylinder No.2 aligns with the oil pressure apply
hole of the transmission case.
cardiagn.com
Fig. 127: Checking Oil Pressure

a. Install the flange, the 3 plates, 3 discs and brake piston return spring.
Install in order: P = Plate, D = Disc, F = Flange
F-P-D-P-D-P-D
cardiagn.com
Fig. 128: Installing Flange
b. Using SST and a press, install the brake No.2 spring snap ring.
SST 09351-40010 (09351-04010, 09351-04020, 09351-04040, 09351-04050)

cardiagn.com
Fig. 129: Installing Brake Spring Snap Ring
90. INSPECT PISTON STROKE OF BRAKE PISTON NO.2

a. Make sure that the brake piston No.2 moves smoothly when pulling and releasing the compressed
air gun lever while applying compressed air into the transmission case.
cardiagn.com
Fig. 130: Inspecting Piston Stroke Of Brake Piston
b. Using a SST and a dial gauge, measure the moving distance (distance A) of the clutch disc at the
both ends across a diameter while blowing air from the oil hole as shown in the illustration, and
calculate the average.
SST 09350-30020 (09350-06120)
Pack clearance: 0.6 to 0.9 mm (0.024 to 0.035 in.)
c. If the piston stroke is outside the standard, select & install a brake flange that brings the piston
stroke within the standard.
HINT:
There are 7 types of flanges that can be used to adjust the pack clearance. Select one with the most
Flange thickness:
FLANGE THICKNESS
No. Thickness No. Thickness
0 2.0 mm (0.079 in.) 4 2.4 mm (0.094 in.)
1 2.1 mm (0.083 in.) 5 2.5 mm (0.098 in.)
2 2.2 mm (0.087 in.) 6 2.6 mm (0.102 in.)
3 2.3 mm (0.091 in.) 7 2.7 mm (0.106 in.)
cardiagn.com
cardiagn.com
Fig. 131: Measuring Moving Distance Of Clutch Disc

a. Coat 2 new O-rings with ATF, and install them on the brake piston No.1
b. Be careful not to damage the O-rings. Press the brake piston No.1 into the brake cylinder No.1 by
hands.
cardiagn.com
92. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSY

a. Install the brake piston return spring and the brake piston No.1 with the brake cylinder No.1 to the
transmission case.
HINT:
Install the brake cylinder No.1 so that the projection protrudes from the upside of the transmission
case.
cardiagn.com
Fig. 133: Installing Brake Cylinder
b. Check that the oil pressure apply hole of the brake cylinder NO.2 aligns with the oil pressure apply
cardiagn.com
93. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

a. Using SST and press, install the brake piston return spring snap ring.
SST 09351-40010 (09351-04010, 09351-04030, 09351-04040, 09351-04050)

cardiagn.com
Fig. 135: Installing Brake Piston Return Spring Snap Ring
94. INSTALL CTR PLANETARY RING GEAR

a. Install the CTR planetary ring gear and the front planetary ring gear flange on the front planetary
ring gear.
cardiagn.com
Fig. 136: Installing CTR Planetary Ring Gear
b. Using a screwdriver, install the snap ring.
NOTE: Install the snap ring to the ring gear so that the both ends of the snap ring
come to the center of a protrusion on the ring gear.
cardiagn.com
95. INSTALL FRONT PLANETARY RING GEAR

a. Install the front planetary ring gear and the thrust needle roller bearing to the case.
THRUST NEEDLE ROLLER BEARING DIAMETER

Inside Outside
cardiagn.com
Fig. 138: Installing Front Planetary Ring Gear
96. INSTALL FRONT PLANETARY GEAR ASSY

a. Install the thrust needle roller bearing and the 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:
THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER

Inside Outside
Race 38.0 mm (1.496 in.) 57.0 mm (2.244 in.)
cardiagn.com
c. Install the front planetary gear assy and the 1 way clutch inner race to the case.
cardiagn.com
Fig. 140: Installing Front Planetary Gear Assy
97. INSPECT PISTON STROKE OF BRAKE PISTON NO.1

a. Make sure the brake piston No.1 moves smoothly when pulling and releasing the compressed air
gun lever while applying compressed air into the transmission case.
cardiagn.com
Fig. 141: Inspecting Piston Stroke Of Brake Piston
b. Using vernier calipers, measure the level difference (length A) between the upper surface of the
brake piston No.1 and the hitting surface of the brake flange No.1 at both ends across the brake
piston No.1 diameter.
c. Using vernier calipers, measure the thickness (length B) of the brake flange, the 3 brake plates No.1
and the 3 brake discs No.1 altogether at the both ends across a diameter, and calculate the average.
HINT:
Length A = 15.29 to 15.77 mm (0.6020 to 0.6209 in.)
Length B = 14.72 to 15.12 mm (0.5795 to 0.5953 in.)
Piston stroke = Length A - Length B
Piston stroke: 0.42 to 0.72 mm (0.017 to 0.028 in.)
If the piston stroke is outside the specification, parts may have been assembled incorrectly, so check and
reassemble again. If the piston stroke is not still outside the specification range, select another flange.
HINT:
There are 4 different thickness for the flange.
Flange thickness:
FLANGE THICKNESS
0 2.0 mm (0.079 in.) 2 2.4 mm (0.094 in.)
1 2.2 mm (0.087 in.) 3 2.6 mm (0.102 in.)
cardiagn.com
cardiagn.com
Fig. 142: Measuring Thickness Of Brake Flange


a. Install the 3 plates, the 3 discs and the flange.
Install in order: P = Plate, D = Disc, F = Flange
F-D-P-D-P-D-P
cardiagn.com
Fig. 143: Installing Plates
99. INSTALL 2ND BRAKE PISTON

a. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
b. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston by
hands.
cardiagn.com
Fig. 144: Installing 2Nd Brake Piston
c. Using SST and press, install the snap ring.
NOTE: Be sure that the end gap of the snap ring is not aligned with the
spring retainer claw.
SST 09351-40010 (09351-04060, 09351-04070)

cardiagn.com
100. INSTALL 2ND BRAKE CYLINDER

a. (a) Install the 2nd brake cylinder to the case.
cardiagn.com
Fig. 146: Installing 2Nd Brake Cylinder
b. Check that the oil pressure apply hole of the brake cylinder No.2 aligns with the oil pressure apply
cardiagn.com
101. INSTALL 1 WAY CLUTCH ASSY

a. Install the 1 way clutch assy and the thrust washer to the case.
cardiagn.com
Fig. 148: Installing 1 Way Clutch Assy
102. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

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

cardiagn.com
103. INSTALL 2ND BRAKE DISC SET

a. Install the flange, the 4 discs and the 4 plates to the case.
Install in order: P = Plate, D = Disc, F = Flange C = Cushion
F-D-P-D-P-D-P-D-P-C
cardiagn.com
Fig. 150: Installing 2Nd Brake Disc Set
104. INSTALL BRAKE NO.3 SNAP RING

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

cardiagn.com
105. INSTALL 1 WAY N0.2 CLUTCH ASSY

a. Coat the race with petroleum jelly and install it onto the clutch drum thrust washer No.2.
b. Install the 1 Way clutch assy No.2 and washer No.2.
cardiagn.com
Fig. 152: Installing 1 Way Clutch Assy
106. INSTALL CLUTCH DRUM & INPUT SHAFT ASSY

a. Install the thrust needle roller bearing.
b. Coat the race with petroleum jelly and install it onto the clutch drum & input shaft assy.
Thrust needle roller bearing and diameter:
THRUST NEEDLE ROLLER BEARING AND DIAMETER

Inside Outside
Thrust needle roller bearing A 71.9 mm (2.831 in.) 85.6 mm (3.370 in.)
Race A 73.6 mm (2.898 in.) 102.0 mm (4.016 in.)
Thrust needle roller bearing B 34.6 mm (1.362 in.) 52.0 mm (2.047 in.)
Race B 37.0 mm (1.457 in.) 52.3 mm (2.059 in.)
cardiagn.com
c. Install the input shaft sub assy with the clutch drum & input shaft assy onto the transmission case.
cardiagn.com
Fig. 154: Installing Input Shaft Sub Assy
107. INSTALL OIL PUMP ASSY

a. Install the thrust bearing race No.1 to the front oil pump
THRUST BEARING RACE REFERENCE

Inside Outside
Race 74.2 mm (2.921 in.) 87.74 mm (3.454 in.)
cardiagn.com
b. Coat a new O-ring with ATF, and install it around the oil pump assy.
c. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assy 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.
cardiagn.com
Fig. 156: Aligning Bolt Holes
e. Install the 10 bolts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

cardiagn.com
Fig. 157: Installing Bolts
108. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

a. Using SST, drive in 2 new oil seals.
SST 09350-30020 (09350-07110)
b. Coat the oil seal lips with MP grease.

cardiagn.com
Fig. 158: Installing Manual Valve Lever Shaft Oil Seal
109. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION

a. Check the operating sound while applying compressed-air into the oil holes indicated in the
illustration.
HINT:
When inspecting the O/D direct clutch, check with the C3 accumulator piston hole closed.
If there is no sound, disassemble and check the parts installation condition.
1. Clutch No.2 (C2 )

5. Brake No.3 (B3 )
6. Brake No.1 (B1 )
7. Brake No.2 (B2 )
8. Brake No.4 (B4 )
cardiagn.com
Fig. 159: Inspecting Individual Piston Operation Inspection

110. INSTALL MANUAL VALVE LEVER SUB-ASSY

a. Install a new spacer to the manual valve lever.
b. Install the manual valve lever shaft to the transmission case through the manual valve lever.
cardiagn.com
Fig. 160: Installing Manual Valve Lever Sub-Assy
c. Using a hammer, drive in a new spring pin.

cardiagn.com
Fig. 161: Installing Spring Pin
d. Align the manual valve lever indentation with the spacer hole, and stake them together with the
punch.
e. Make sure that the shaft rotates smoothly.
cardiagn.com
Fig. 162: Aligning Manual Valve Lever Indentation
111. INSTALL PARKING LOCK PAWL SHAFT

a. Install the E-ring to the shaft.
b. Install the parking lock pawl, the shaft and the spring.
cardiagn.com
Fig. 163: Installing E-Ring
112. INSTALL PARKING LOCK ROD SUB-ASSY

a. Connect the parking lock rod to the manual valve lever.
cardiagn.com
Fig. 164: Connecting Parking Lock Rod
113. INSTALL PARKING LOCK PAWL BRACKET

a. Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.
Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)

cardiagn.com
Fig. 165: Installing Parking Lock Pawl Bracket
b. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly
locked up by the lock pawl.
cardiagn.com
Fig. 166: Shifting Manual Valve Lever
114. INSTALL B-1 ACCUMULATOR VALVE

a. Install the spring and the accumulator valve to the hole.
cardiagn.com
Fig. 167: Installing Spring And Accumulator Valve
B-1 Accumulator spring:
Inner spring:
INNER SPRING REFERENCE

Free length Outer diameter Color
44.98 mm (1.7709 in.) 11.30 mm (0.445 in.) Natural
Outer spring:
OUTER SPRING
Free length Outer diameter) Color
cardiagn.com
Fig. 168: Installing Spring And Accumulator Piston To Hole
115. INSTALL C-3 ACCUMULATOR PISTON

a. Coat a new O-ring with ATF, and install it to the piston.
b. Install the spring and the accumulator piston to the hole.
cardiagn.com
Fig. 169: Installing Spring
C-3 Accumulator spring:
Inner spring:
INNER SPRING
44.0 mm (1.732 in.) 14.0 mm (0.551 in.) Yellow
Outer spring:
OUTER SPRING REFERENCE

cardiagn.com
116. INSTALL B-3 ACCUMULATOR PISTON

a. Coat 2 new O-rings with ATF, and install them to the piston.
cardiagn.com
Fig. 171: Installing Spring
Accumulator spring:
ACCUMULATOR SPRING
64.5 mm (2.539 in.) 19.5 mm (0.768 in.) Orange
cardiagn.com
117. INSTALL C-2 ACCUMULATOR PISTON

a. Coat 2 new O-rings with ATF, and install them to the piston.
cardiagn.com
Fig. 173: Installing Spring And Accumulator Piston
Accumulator spring:
ACCUMULATOR SPRING
63.14 mm (2.4858 in.) 16.0 mm (0.6299 in.) Light Gray
cardiagn.com
Fig. 174: Installing Check Ball Body And Spring
118. INSTALL CHECK BALL BODY

a. Install the check ball body and the spring.
cardiagn.com
Fig. 175: Installing Check Ball Body And Spring
119. INSTALL BRAKE DRUM GASKET

a. Install the 3 brake drum gaskets.
cardiagn.com
Fig. 176: Installing Brake Drum Gasket
120. INSTALL TRANSAXLE CASE GASKET

a. Install the 3 transaxle case gaskets.
cardiagn.com
Fig. 177: Installing Transaxle Case Gaskets
121. INSTALL TRANSMISSION VALVE BODY ASSY

a. Align the groove of the manual valve with the pin of the lever.
cardiagn.com
Fig. 178: Aligning Groove Of Manual Valve
b. Install the 20 bolts.
HINT:
Each bolt length is indicated below.
Blot length:
Bolt A: 25 mm (0.98 in.)
Bolt B: 36 mm (1.42 in.)
Bolt C: 45 mm (1.77 in.)
Bolt D: 50 mm (1.97 in.)

cardiagn.com
c. Install the detente spring with the bolt.

cardiagn.com
Fig. 180: Installing Detente Spring Bolt
122. INSTALL TRANSMISSION WIRE

a. Install a new O-ring to the transmission wire.
b. Install the transmission wire harness.
c. Install the bolt.

cardiagn.com
d. Connect the 9 solenoid connectors.

e. Install the ATF temperature sensor.
f. Install the clamp and the 2 bolts.

cardiagn.com
Fig. 182: Connecting Solenoid Connectors
123. INSTALL VALVE BODY OIL STRAINER ASSY

a. Coat new O-ring with ATF, and install them to the valve body oil strainer assy.
b. Install the oil strainer with the 4 bolts.

cardiagn.com
Fig. 183: Installing Oil Strainer
124. INSTALL TRANSMISSION OIL CLEANER MAGNET

a. Install the 3 transmission oil cleaner magnets.
cardiagn.com
Fig. 184: Installing Transmission Oil Cleaner Magnets
125. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSY

a. Install a new gasket on the oil pan.
b. Install and torque the 20 bolts.
Torque 4.4 N.m (45 kgf.cm, 39 in.lbf)
c. Install a new gasket and the drain plug.
Torque 20 N.m (204 kgf.cm, 15 ft.lbf)
d. Install a new gasket and the over flow plug.
Torque 20 N.m (204 kgf.cm, 15 ft.lbf)
126. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

a. Using SST and a hammer, install a new oil seal.
SST 09309-37010
127. INSTALL TRANSMISSION CASE ADAPTOR RADIAL BALL BEARING

cardiagn.com
Fig. 185: Installing Transmission Case Adaptor Radial Ball Bearing
128. INSTALL RR COVER SLEEVE

a. Install the 2 washers and RR cover sleeve to the output shaft.
cardiagn.com
Fig. 186: Installing Washers
129. INSTALL EXTENSION (ATM) HOUSING SUB-ASSY

a. Install the thrust needle roller bearing and the 2 bearing races.
b. Using a snap ring expander, install the snap ring.
cardiagn.com
c. Using feeler gauge, measure the clearance between the snap ring and the race.
Clearance: 0.02 to 0.12 mm (0.0008 to 0.0047 in.)
If the clearance is still standard, select another race.
HINT:
There are 12 different thickness for the race.
Flange thickness:
FLANGE THICKNESS
1 3.80 mm (0.1496 in.) 7 4.10 mm (0.1614 in.)
2 3.85 mm (0.1516 in.) 8 4.15 mm (0.1634 in.)
3 3.90 mm (0.1535 in.) 9 4.20 mm (0.1653 in.)
4 3.95 mm (0.1555 in.) 10 4.25 mm (0.1673 in.)
5 4.00 mm (0.1575 in.) 11 4.30 mm (0.1693 in.)
6 4.05 mm (0.1594 in.) 12 4.35 mm (0.1713 in.)
d. Clean the threads of the bolts and the case with whip gasoline.
cardiagn.com
Fig. 188: Measuring Clearance Between Snap Ring And Race
e. Apply FIPG to the extension housing as shown in the illustration.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent

cardiagn.com
Fig. 189: Applying FIPG To Extension Housing
f. Install the extension housing with new 6 bolts.
HINT:
Each blot length is indicated below.
Bolt length:
Bolt A: 45 mm (1.772 in.)
Bolt B: 35 mm (1.378 in.)

cardiagn.com
Fig. 190: Installing Extension Housing
130. INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSY

a. Using SST, install a new oil seal to the automatic transmission flange yoke.
SST 09950-60010 (09951-00350), 09950-70010 (09951-07100)
b. Install the automatic transmission flange yoke assy to the output shaft with a new nut.
Torque: 126 N.m (1,280 kgf.cm, 92 ft.lbf)
c. Using a hammer and chisel, stake the nut.

cardiagn.com
Fig. 191: Staking Nut
131. INSTALL AUTOMATIC TRANSMISSION HOUSING

a. Clean the threads of the bolts and the case with white gasoline.
b. Install the transmission housing with the 10 bolts.
Torque:
A (14 mm bolt): 34 N.m (347 kgf.cm, 25 ft.lbf)
B (17 mm bolt): 57 N.m (581 kgf.cm, 42 ft.lbf)

cardiagn.com
Fig. 192: Installing Transmission Housing Bolts
132. INSTALL TRANSMISSION REVOLUTION SENSOR

a. Coat 2 new O-rings with ATF, and install it to the transmission revolution sensor.
b. Install the 2 transmission revolution sensors.
c. Install the 2 bolts.

cardiagn.com
Fig. 193: Installing Transmission Revolution Sensor

133. INSTALL OIL COOLER TUBE UNION

a. Coat new O-ring with ATF, and install it to oil cooler tube union.
b. Install the oil cooler tube union as shown in the illustration.
cardiagn.com
Fig. 194: Installing Oil Cooler Tube Union
134. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY

a. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the
adjusting bolt
b. Install the new lock washer. Install and torque the nut.

cardiagn.com
Fig. 195: Installing Park/Neutral Position Switch Assy
c. Using the control shaft lever, turn the manual lever shaft back all the way and then forward 2
notches. It is now in neutral.
cardiagn.com
Fig. 196: Turning Manual Lever Shaft
d. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the
adjusting bolt.

cardiagn.com
Fig. 197: Aligning Neutral Basic Line
e. Using a screwdriver, bend the tabs of the lock washer.
HINT:
Bend at least 2 of the lock washer tabs.

cardiagn.com
Fig. 198: Bending Tabs Of Lock Washer
135. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH

a. Install the washer and the nut to the control shaft lever RH.

cardiagn.com
Fig. 199: Installing Transmission Control Shaft Lever
OIL PUMP ASSY (A761E)
COMPONENTS
cardiagn.com
Fig. 200: Identifying Oil Pump Assy (A761E) Components
OVERHAUL
1. REMOVE FRONT OIL PUMP BODY O-RING

a. Remove the O-ring from the oil pump assy.
cardiagn.com
2. FIX OIL PUMP ASSY

a. Place the oil pump body on the torque converter clutch.
cardiagn.com
Fig. 202: Placing Oil Pump Body
3. REMOVE CLUTCH DRUM OIL SEAL RING

a. Remove the 3 oil seal rings.
cardiagn.com
Fig. 203: Removing Oil Seal Rings
4. REMOVE STATOR SHAFT ASSY

a. Remove the 14 bolts, and then remove the stator shaft from the oil pump body.
cardiagn.com
5. REMOVE FRONT OIL PUMP BODY O-RING

a. Remove the O-ring from the oil pump body.
b. Remove the oil pump body from the torque converter clutch.
cardiagn.com
6. INSPECT FRONT OIL PUMP BODY SUB-ASSY

a. Using a dial indicator, measure the inside diameter of the oil pump body bushing.
If the inside diameter is greater than the maximum inside diameter, replace the oil pump body.
cardiagn.com
Fig. 206: Measuring Inside Diameter Of Oil Pump Body Bushing
7. INSPECT STATOR SHAFT ASSY

a. Using a dial indicator, measure the inside diameter of the stator shaft bushing.
Maximum inside diameter:
Front side: 21.577 mm (0.850 in.)
Rear side: 32.08 mm (1.263 in.)
If the inside diameter is grater than the maximum inside diameter, replace the stator shaft.
cardiagn.com
Fig. 207: Measuring Inside Diameter Of Stator Shaft Bushing
8. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY

a. Push the driven gear to one side of the body.
b. Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 to 0.17 mm (0.0039 to 0.0067 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum clearance, check the drive gear, the driven gear
and the pump body.
cardiagn.com
Fig. 208: Measuring Clearance
c. Using a feeler gauge, measure the clearance between the driven gear teeth and the drive gear teeth.
Standard tip clearance:
0.070 to 0.150 mm (0.0028 to 0.0059 in.)
Maximum tip clearance: 0.150 mm (0.0059 in.)
If the tip clearance is greater than the maximum clearance, check the drive gear, the driven gear and
the pump body.
cardiagn.com
Fig. 209: Measuring Clearance Between Driven Gear Teeth And Drive Gear Teeth
d. Using a steel straight edge and a feeler gauge, measure the side clearance of both gears.
Standard side clearance:
0.03 to 0.05 mm (0.0012 to 0.002 in.)
Maximum side clearance: 0.05 mm (0.002 in.)
e. There are 7 different thicknesses for the drive and driven gears.
Drive and driven gears thickness:
DRIVE AND DRIVEN GEARS THICKNESS

Mark Thickness
0 10.736 to 10.742 mm (0.42268 to 0.42291 in.)
1 10.743 to 10.749 mm (0.42296 to 0.42319 in.)
2 10.750 to 10.756 mm (0.42323 to 0.42346 in.)
3 10.757 to 10.763 mm (0.42350 to 0.42374 in.)
4 10.764 to 10.770 mm (0.42378 to 0.42401 in.)
5 10.771 to 10.777 mm (0.42405 to 0.42429 in.)
6 10.778 to 10.784 mm (0.42433 to 0.42457 in.)
If the side clearance is greater than the maximum thickness, check the drive gear, the driven gear and the
pump body.
cardiagn.com
Fig. 210: Measuring Side Clearance Of Both Gears
9. REMOVE FRONT OIL PUMP DRIVE GEAR

cardiagn.com
Fig. 211: Removing Front Oil Pump Drive Gear
10. REMOVE FRONT OIL PUMP DRIVEN GEAR

cardiagn.com
Fig. 212: Removing Front Oil Pump Driven Gear
11. REMOVE FRONT OIL PUMP OIL SEAL

a. Using a screwdriver, remove the oil seal.
NOTE: Be careful not to damage the bushing and the oil pump body.
cardiagn.com
Fig. 213: Removing Oil Seal
12. INSTALL FRONT OIL PUMP OIL SEAL

a. Using SST and a hammer, install a new oil seal.
HINT:
The oil seal end should be flush with the outer edge of the pump body.
SST 09350-30020 (09351-32140)
b. Coat the oil seal lip with MP grease.

cardiagn.com
Fig. 214: Installing New Oil Seal
13. FIX FRONT OIL PUMP BODY SUB-ASSY

a. Place the oil pump body on the torque converter clutch.
14. INSTALL FRONT OIL PUMP DRIVEN GEAR
a. Coat the driven gear with ATF.
b. Install the driven gear to the oil pump body.
cardiagn.com
Fig. 215: Installing Driven Gear To Oil Pump Body
15. INSTALL FRONT OIL PUMP DRIVE GEAR

a. Coat the drive gear with ATF.
b. Install the drive gear to the oil pump body.
cardiagn.com
Fig. 216: Installing Drive Gear To Oil Pump Body
16. INSTALL FRONT OIL PUMP BODY O-RING

a. Install the O-ring to the oil pump body.
cardiagn.com
17. INSTALL STATOR SHAFT ASSY

a. Align the stator shaft with each bolt hole.
Torque: 12 N.m (122 kgf.cm,9 ft.lbf)

cardiagn.com
18. INSTALL CLUTCH DRUM OIL SEAL RING

a. Coat the 3 oil seal rings with ATF.
b. Squeeze the ends of the 3 oil seal rings together with the wrap distance 8 mm or less, and then
install them to the starter shaft groove.
NOTE: Do not expand the ring ends excessively.
HINT:
After installing the oil seal rings, check that they rotate smoothly.
cardiagn.com
Fig. 219: Installing Clutch Drum Oil Seal Ring
19. INSPECT OIL PUMP DRIVE GEAR ROTATION

a. Make sure that the drive gear rotates smoothly.
b. Remove the oil pump assy from the torque converter.
cardiagn.com
Fig. 220: Removing Oil Pump Assy
20. INSTALL FRONT OIL PUMP BODY O-RING

a. Install the O-ring to the oil pump assy.
cardiagn.com
CLUTCH DRUM & INPUT SHAFT ASSY (A761E)
COMPONENTS
cardiagn.com
Fig. 222: Identifying Clutch Drum & Input Shaft Assy (A761E) Components
OVERHAUL
1. FIX CLUTCH DRUM & INPUT SHAFT ASSY

a. Place the oil pump onto the torque converter clutch, and then place the clutch drum & input shaft
assy onto the oil pump.
cardiagn.com
Fig. 223: Placing Oil Pump Onto Torque Converter Clutch
2. REMOVE REVERSE CLUTCH HUB SUB-ASSY

a. Using a screwdriver, remove the snap ring from the clutch drum and the input shaft assy.
cardiagn.com
b. Remove the reverse clutch hub sub assy with the reverse ' clutch reaction sleeve, the clutch cushion
plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates from the clutch
drum assy.
cardiagn.com
Fig. 225: Removing Reverse Clutch Hub Sub Assy
3. REMOVE REVERSE CLUTCH REACTION SLEEVE

a. Remove the reverse clutch reaction sleeve from the reverse clutch hub sub assy.
cardiagn.com
Fig. 226: Removing Reverse Clutch Reaction Sleeve
4. REMOVE REAR CLUTCH DISC

a. Remove the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs from the
reverse clutch hub.
cardiagn.com
Fig. 227: Removing Clutch Cushion Plate
5. INSPECT REAR CLUTCH DISC

a. Check whether the sliding surface of the disc, the plate and the flange are worn or burnt. If
necessary, replace them.
NOTE:  If the lining of the disc is peeled off or discolored, or even if only a
part of the printed numbers is damaged, replace all discs.
minutes.
cardiagn.com
Fig. 228: Inspecting Rear Clutch Disc
6. INSPECT REVERSE CLUTCH HUB SUB-ASSY

a. Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing.
Standard inside diameter:
35.812 to 35.837 mm (1.4099 to 1.4109 in.)
If the inside diameter is greater than the maximum inside diameter, replace the reverse clutch hub.
cardiagn.com
Fig. 229: Measuring Inside Diameter Of Reverse Clutch Hub Bushing
7. REMOVE FORWARD CLUTCH HUB SUB-ASSY

a. Remove the forward clutch hub sub assy and thrust washer from the clutch drum assy.
cardiagn.com
Fig. 230: Removing Forward Clutch Hub Sub Assy
b. Remove the 2 thrust needle roller bearings from the forward clutch hub sub assy.
cardiagn.com
Fig. 231: Removing Thrust Needle Roller Bearings
8. INSPECT FORWARD CLUTCH HUB SUB-ASSY

a. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter:
26.037 to 26.062 mm (1.0251 to 1.0261 in.)
If the inside diameter is greater than the maximum inside diameter, replace the forward clutch hub.
cardiagn.com
Fig. 232: Measuring Inside Diameter Of Forward Clutch Hub Bushing
9. REMOVE COAST CLUTCH HUB SUB-ASSY

a. Remove the coast clutch hub sub-assy from the clutch drum sub-assy.
cardiagn.com
Fig. 233: Removing Coast Clutch Hub Sub-Assy
10. INSPECT CLUTCH ASSY, 1 WAY NO.4

a. Hold the coast clutch hub and turn the 1 way clutch assy.
b. Check that the 1 way clutch assy turns freely counter-clockwise and locks clockwise.
If there is a problem with the 1 way clutch, replace the 1 w clutch.

cardiagn.com
Fig. 234: Inspecting Clutch Assy
11. REMOVE CLUTCH ASSY, 1 WAY NO.4

a. Remove the 1 way clutch No.4 and the 2 shaft thrust bearing races from the coast clutch hub.
cardiagn.com
Fig. 235: Removing Way Clutch
12. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC

a. Using a screwdriver, remove the hole snap ring.
cardiagn.com
Fig. 236: Removing Hole Snap Ring
b. Remove the flange, cushion plate, 4 discs and 4 plates from the input shaft assy.
cardiagn.com

13. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC

NOTE:  If the lining of the disc is peeled off or discolored, or even if
only a part of the printed numbers is damaged, replace all discs.
minutes.
cardiagn.com
Fig. 238: Inspecting Forward Multiple Disc Clutch Disc
14. REMOVE COAST CLUTCH DISC

a. Using a screwdriver, remove the hole snap ring.
cardiagn.com
Fig. 239: Removing Hole Snap Ring
b. Remove the flange, the 3 discs and the 3 plates from the input shaft assy.
cardiagn.com
15. INSPECT COAST CLUTCH DISC

NOTE:  If the lining of the disc is peeled off or discolored, or even if only a
part of the printed numbers is damaged, replace all discs.
minutes.
cardiagn.com
Fig. 241: Inspecting Coast Clutch Disc
16. REMOVE INPUT SHAFT ASSY

a. Remove the thrust needle roller bearing from the input shaft assy.
cardiagn.com
b. Remove the input shaft assy from the clutch drum assy.
cardiagn.com
Fig. 243: Removing Input Shaft Assy
c. Remove the thrust needle roller bearing and thrust bearing race from the clutch drum assy.
cardiagn.com
Fig. 244: Removing Thrust Needle Roller Bearing And Thrust Bearing Race
17. REMOVE INPUT SHAFT OIL SEAL RING

a. Remove the 4 oil seal rings from the input shaft assy.
cardiagn.com
Fig. 245: Removing Oil Seal Rings
18. REMOVE CLUTCH BALANCER NO.1

a. Place SST on the clutch balancer No.1, and compress the return spring with a press.
SST 09350-30020 (09350-07040)
b. Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)

cardiagn.com
c. Remove the clutch balancer No.1 and the forward clutch return spring from the input shaft assy.
cardiagn.com
Fig. 247: Removing Clutch Balancer
d. Remove the O-ring from the clutch balancer No.1.

cardiagn.com
19. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSY

If the inside diameter is shorter than the minimum free length, replace the clutch return spring sub-assy.
cardiagn.com
20. REMOVE FORWARD CLUTCH PISTON SUB-ASSY

a. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to
the input shaft to remove the forward clutch piston.
cardiagn.com
Fig. 250: Removing Forward Clutch Piston Sub-Assy
b. Remove the coast clutch piston from the forward clutch piston.
cardiagn.com
Fig. 251: Removing Coast Clutch Piston
21. REMOVE REVERSE CLUTCH FLANGE

a. Remove the reverse clutch flange from the clutch drum assy.
cardiagn.com
Fig. 252: Removing Reverse Clutch Flange
22. REMOVE DIRECT CLUTCH DISK

a. Using a screwdriver, remove the 2 hole snap rings from the clutch drum assy.
cardiagn.com
Fig. 253: Removing Hole Snap Rings
b. Remove the reverse clutch flange, the 6 plates and the 5 discs from the clutch drum assy.
cardiagn.com
Fig. 254: Removing Reverse Clutch Flange

23. INSPECT DIRECT CLUTCH DISK

NOTE:  If the lining of the disc is peeled off or discolored, or even if

only a part of the printed numbers is damaged, replace all discs.
minutes.
cardiagn.com
Fig. 255: Inspecting Direct Clutch Disk
24. REMOVE CLUTCH BALANCER NO.3

a. Place SST on the clutch balancer No.3, and compress the return spring with a press.
SST 09387-00070
b. Using SST, remove the snap ring.

SST 09350-30020 (09350-07070)
cardiagn.com
25. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSY

a. Remove the reverse clutch return spring and the O-ring from the reverse clutch piston.
cardiagn.com
Fig. 257: Removing Reverse Clutch Return Spring
26. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSY

cardiagn.com
27. REMOVE REVERSE CLUTCH PISTON SUB-ASSY

a. Remove the reverse clutch piston sub-assy from the clutch drum sub assy.
cardiagn.com
Fig. 259: Removing Reverse Clutch Piston Sub-Assy
b. Remove the O-ring from the reverse clutch piston sub assy.
cardiagn.com
c. Remove the O-ring from the clutch drum sub assy.

cardiagn.com
28. REMOVE DIRECT CLUTCH PISTON SUB-ASSY

a. Place SST on the direct clutch piston, and compress the return spring with a press.
SST 09320-89010, 09350-30020 (09350-07070)

cardiagn.com
Fig. 262: Removing Direct Clutch Piston Sub-Assy
b. Using 2 screw drivers, remove the direct clutch piston sub assy from the clutch drum.
cardiagn.com
Fig. 263: Removing Direct Clutch Piston Sub Assy
c. Remove the clutch balancer No.2 and the direct clutch return spring sub assy from the direct clutch
piston sub assy.
cardiagn.com
Fig. 264: Removing Clutch Balancer
d. Remove the 2 O-rings from the direct clutch piston sub-assy.

cardiagn.com
29. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSY

cardiagn.com
30. INSTALL DIRECT CLUTCH PISTON SUB-ASSY

a. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
cardiagn.com
Fig. 267: Installing Direct Clutch Piston Sub-Assy
b. Install the clutch balancer No.2 and the direct clutch return spring to the direct clutch piston sub
assy.
c. Be careful not to damage the O-rings, Press in the direct clutch piston into the clutch drum by
hands.
cardiagn.com
Fig. 268: Installing Clutch Balancer
d. Place SST on the direct clutch piston, and compress the return spring with a press.
SST 09320-89010, 09350-30020 (09350-07070)
e. Install the snap ring with a snap ring expander.
NOTE:  Be sure the end gap of the snap ring is not aligned with the
 Stop pressing when the spring sheet is lowered to the place 1 to
2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent
the spring sheet from being deformed.
 Do not expand the snap ring excessively.
cardiagn.com

f. Set the end gap of the snap ring in the piston as shown in the illustration.
cardiagn.com
Fig. 270: Setting End Gap Of Snap Ring
31. INSTALL REVERSE CLUTCH PISTON SUB-ASSY

a. Coat a new O-ring with ATF, and install it on the clutch drum sub assy.
cardiagn.com
Fig. 271: Installing Reverse Clutch Piston Sub-Assy
b. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub assy.
cardiagn.com
Fig. 272: Coating New O-Ring
c. Be careful not to damage the O-ring. Press in the clutch drum sub assy into the reverse clutch
piston with both hands.
cardiagn.com
Fig. 273: Pressing Clutch Drum Sub Assy Into Reverse Clutch Piston
32. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSY

a. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub assy.
b. Install the reverse clutch return spring onto the reverse clutch piston sub assy.
cardiagn.com
Fig. 274: Installing Reverse Clutch Return Spring
33. INSTALL CLUTCH BALANCER NO.3

a. Place SST on the clutch balancer No.3, and compress the clutch balancer with a press.
SST 09387-00070
b. Install the snap ring with a snap ring expander.
SST 09350-30020 (09350-07070)
NOTE:  Be sure the end gap of the snap ring is not aligned with the
2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent
cardiagn.com
c. Set the end gap of the snap ring in the piston as shown in the illustration.
cardiagn.com
34. INSTALL DIRECT CLUTCH DISK

a. Install the reverse clutch flange, the 6 plates and the 5 discs on the clutch drum sub assy.
Install in order: P = Plate, D = Disc, F = Flange, F - D - P - D - P - D - P - D - P - D - P - P

cardiagn.com
Fig. 277: Installing Reverse Clutch Flange

b. Using a screwdriver, install the 2 hole snap rings on the clutch drum sub assy.
cardiagn.com
Fig. 278: Installing Hole Snap Rings
35. INSPECT PACK CLEARANCE OF DIRECT CLUTCH

a. Using a dial gauge, measure the moving distance (distance A) of the clutch flange at the both ends
across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the
average.
HINT:
Flange moving distance A = 0.26 to 1.14 mm
Pack Clearance = Flange moving distance A - 0.05 mm
NOTE: Install a selective flange (t = 3.4 mm) when measuring the moving
distance. (shaded area in the illustration.)
b. If the pack clearance is outside the standard, select and install a clutch flange that brings the pack
clearance within the standard.
HINT:
There is 9 type of flanges that can be used to adjust the pack clearance. Select the one with the most
Flange thickness:
FLANGE THICKNESS
0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
4 3.4 mm (0.134 in.) - -
cardiagn.com
cardiagn.com
Fig. 279: Measuring Moving Distance Of Clutch Flange
36. INSTALL REVERSE CLUTCH FLANGE

a. Install the reverse clutch flange to the clutch drum sub assy.
cardiagn.com
Fig. 280: Installing Reverse Clutch Flange
37. INSTALL REVERSE CLUTCH REACTION SLEEVE

a. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5
reverse clutch discs, and the 4 clutch plates to the reverse clutch hub
Install in order: P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate
S-C-F-D-P-D-P-D-P-D-P-D
b. Using a screwdriver, install the hole snap ring.

38. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
a. Using a dial gauge, measure the reverse clutch piston stroke (distance A) and the moving distance
(distance B) of the reverse clutch flange at the both ends across a diameter while blowing air (392
kPa, 4 kgf/cm2 ,57 psi) from the oil hole as shown in the illustration, and calculate the average.
HINT:
Piston stroke A = 1.05 to 2.15 mm
Flange moving distance B = 0.72 to 1.08 mm
Pack Clearance = Piston stroke A - Flange moving distance B - 0.06

cardiagn.com
cardiagn.com
Fig. 281: Measuring Reverse Clutch Piston Stroke And Moving Distance Of Reverse Clutch
Flange
Fig. 282: Installing Selective Flange
cardiagn.com
HINT:
There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the
most appropriate thickness.
Flange Thickness:
FLANGE THICKNESS
0 2.8 mm (0.110 in.) 6 3.4 mm (0.134 in.)
1 2.9 mm (0.114 in.) 7 3.5 mm (0.138 in.)
2 3.0 mm (0.118 in.) 8 3.6 mm (0.142 in.)
3 3.1 mm (0.122 in.) 9 3.7 mm (0.146 in.)
4 3.2 mm (0.126 in.) A 3.8 mm (0.150 in.)
5 3.3 mm (0.130 in.) -
39. REMOVE REVERSE CLUTCH REACTION SLEEVE

a. Using a screwdriver, remove the snap ring from the clutch drum assy.
cardiagn.com
b. Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5
reverse clutch discs, and the 4 clutch plates from the reverse clutch hub sub assy.
cardiagn.com
Fig. 284: Removing Reverse Clutch Reaction Sleeve
40. INSTALL FORWARD CLUTCH PISTON SUB-ASSY

a. Install the coast clutch piston to the forward clutch piston.
b. Install the forward clutch piston sub-assy to the input shaft.
cardiagn.com
Fig. 285: Installing Forward Clutch Piston Sub-Assy
41. INSTALL CLUTCH BALANCER NO.1

a. Coat a new O-ring with ATF and install it on the clutch balancer No.1.
cardiagn.com
b. Install the clutch balancer No.1 and the forward clutch return spring sub assy.
NOTE: Be careful not to damage the O-ring.

cardiagn.com
c. Place SST on the clutch balancer No.1, and compress the return spring with a press.
SST 09350-30020 (09350-07040, 09350-07070)
d. Install the snap ring with a snap ring expander.
NOTE:  Be sure that the end gap of the snap ring is not aligned with the
2 mm (0.039 to 0.078 in.) from the snap ring groove to prevents
cardiagn.com
e. Set the end gap of the snap ring in the piston as shown in the illustration.
cardiagn.com
42. INSTALL COAST CLUTCH DISC

a. Install the flange, the 3 discs and the 3 plates to the forward clutch piston.
cardiagn.com
Fig. 290: Installing Hole Snap Ring
43. INSPECT PACK CLEARANCE OF COAST CLUTCH

average.
HINT:
Flange moving distance A =
0.38 to 1.48 mm (0.01496 to 0.0583 in.)
Pack Clearance =
Flange moving distance A - 0.02 mm (0.0008 in.)
HINT:
Flange thickness
FLANGE THICKNESS
0 3.0 mm (0.118 in.) 5 3.5 mm (0.138 in.)
1 3.1 mm (0.122 in.) 6 3.6 mm (0.142 in.)
2 3.2 mm (0.126 in.) 7 3.7 mm (0.146 in.)
3 3.3 mm (0.130 in.) 8 3.8 mm (0.150 in.)
4 3.4 mm (0.134 in.) 9 3.9 mm (0.154 in.)
cardiagn.com
cardiagn.com
Fig. 291: Measuring Moving Distance Of Clutch Flange At Both Ends Across A Diameter
44. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
a. Install the flange, the 4 discs and the 5 plates to the input shaft assy.
Install in order: P = Plate, D = Disc, F = Flange, F - D - P - D - P - D - P - D - P - P
cardiagn.com
Fig. 292: Installing Flange

cardiagn.com
Fig. 293: Installing Hole Snap Ring
c. Install the thrust needle roller bearing and thrust bearing race.
THRUST NEEDLE ROLLER BEARING AND THRUST BEARING RACE

Inside Outside
cardiagn.com
45. INSTALL INPUT SHAFT OIL SEAL RING

a. Coat the 4 oil seal rings with ATF.
b. Squeeze the ends of the 4 oil seal rings together, and then install them to the starter shaft groove.
NOTE: Do not expand the ring ends excessively.
HINT:
After installing the oil seal rings, check that they rotate smoothly.
cardiagn.com
Fig. 295: Installing Input Shaft Oil Seal Ring
46. INSPECT PACK CLEARANCE OF FORWARD CLUTCH

average.
HINT:
Flange moving distance A = 0.36 to 1.50 mm
Pack Clearance = Flange moving distance A - 0.11 mm
Pack Clearance: 0.56 - 0.86 mm (0.0220 to.0339 in.)
HINT:
Flange thickness
FLANGE THICKNESS
0 3.0 mm (0.118 in.) 6 3.6 mm (0.142 in.)
1 3.1 mm (0.122 in.) 7 3.7 mm (0.146 in.)
2 3.2 mm (0.126 in.) 8 3.8 mm (0.150 in.)
3 3.3 mm (0.130 in.) 9 3.9 mm (0.154 in.)
4 3.4 mm (0.134 in.) A 4.0 mm (0.158 in.)
5 3.5 mm (0.138 in.)
cardiagn.com
cardiagn.com
Fig. 296: Measuring Moving Distance Of Clutch Flange At Both Ends Across A Diameter
47. INSTALL INPUT SHAFT ASSY

a. Install the input shaft assy to the clutch drum.
cardiagn.com
Fig. 297: Installing Input Shaft Assy
b. Install the thrust needle roller bearing to the clutch drum assy.
NEEDLE ROLLER BEARING DIAMETER

Inside Outside
Thrust needle roller bearing 21.3 (0.839) 41.1 (1.618)
cardiagn.com
48. INSTALL COAST CLUTCH HUB SUB-ASSY

a. Install the thrust bearing race No.2 and the input shaft thrust bearing race RR to the multiple disc
clutch hub.

Inside Outside
Input shaft bearing race RR 22.6 mm (0.890 in.) 44.8 mm (1.764 in.)
cardiagn.com
b. Install the multiple disc clutch hub to the clutch drum assy.
cardiagn.com
Fig. 300: Installing Multiple Disc Clutch Hub
49. INSTALL FORWARD CLUTCH HUB SUB-ASSY

a. Install the 2 thrust needle roller bearings to the forward clutch hub sub assy.

Inside Outside
Bearing A 42.5 (1.673) 61.2 (2.409)
Bearing B 35.6 mm (1.402 in.) 56.6 mm (2.228 in.)
cardiagn.com
Fig. 301: Installing Thrust Needle Roller Bearings
b. Install the forward clutch hub sub assy to the clutch drum assy.
cardiagn.com
Fig. 302: Installing Forward Clutch Hub Sub Assy
50. INSTALL REAR CLUTCH DISC

a. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse
clutch hub.
cardiagn.com
Fig. 303: Installing Clutch Cushion Plate
51. INSTALL REVERSE CLUTCH REACTION SLEEVE

a. Install the reverse clutch reaction sleeve to the reverse clutch hub.
cardiagn.com
Fig. 304: Installing Reverse Clutch Reaction Sleeve
52. INSTALL REVERSE CLUTCH HUB SUB-ASSY

a. Install the reverse clutch hub sub assy, the reverse clutch reaction sleeve, the clutch cushion plate,
the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the clutch drum assy.
cardiagn.com
Fig. 305: Installing Reverse Clutch Hub Sub Assy
b. Using a screwdriver, install the snap ring on the clutch drum and the input shaft assy.
cardiagn.com
TRANSMISSION VALVE BODY ASSY (A761E)
COMPONENTS
cardiagn.com
Fig. 307: Identifying Transmission Valve Body Assy (A761E) Components
OVERHAUL
1. REMOVE TRANSMISSION VALVE BODY ASSY

b. Remove the valve body assy.
cardiagn.com
2. REMOVE SHIFT SOLENOID VALVE SL2

a. Remove the bolt, the 2 straight pins and the lock plate.
b. Remove the shift solenoid valve SL2.
cardiagn.com
Fig. 309: Removing The Shift Solenoid Valve
3. REMOVE SHIFT SOLENOID VALVE SLU

a. Remove the shift solenoid valve SLU.
cardiagn.com
Fig. 310: Removing Shift Solenoid Valve SLU
4. REMOVE SHIFT SOLENOID VALVE SLT

a. Remove the bolt, the 2 straight pins and the lock plate.
b. Remove the shift solenoid valve SLT.
cardiagn.com
Fig. 311: Removing Shift Solenoid Valve SLT

a. Remove shift solenoid valve SL1.
cardiagn.com
Fig. 312: Removing Shift Solenoid Valve SL1
6. REMOVE SHIFT SOLENOID VALVE SR

a. Remove the shift solenoid valve SR.
cardiagn.com
Fig. 313: Removing Shift Solenoid Valve SR
7. REMOVE SHIFT SOLENOID VALVE S1

a. Remove the bolt and the shift solenoid valve S1.
cardiagn.com
Fig. 314: Removing Bolt And Shift Solenoid Valve S1

cardiagn.com

a. Remove the shift solenoid valve S2.
cardiagn.com
Fig. 316: Removing Shift Solenoid Valve S2

cardiagn.com
11. INSTALL SHIFT SOLENOID VALVE S3

a. Instal the bolt and the shift solenoid valve S3.

cardiagn.com
Fig. 318: Installing Bolt And Shift Solenoid Valve S3

a. Install the shift solenoid valve S2.
cardiagn.com
Fig. 319: Installing Shift Solenoid Valve S2

a. Install the shift solenoid valve S4 with the bolt.

cardiagn.com
Fig. 320: Installing Shift Solenoid Valve S4 Bolt

a. Install the shift solenoid valve S1 with the bolt.

cardiagn.com
Fig. 321: Installing Shift Solenoid Valve S1 Bolt
15. INSTALL SHIFT SOLENOID VALVE SR

a. Install the shift solenoid valve SR.
cardiagn.com
Fig. 322: Installing Shift Solenoid Valve SR
16. INSTALL SHIFT SOLENOID VALVE SL1

a. Install the shift solenoid valve SL1.
cardiagn.com
Fig. 323: Installing Shift Solenoid Valve SL1
17. INSTALL SHIFT SOLENOID VALVE SLT

a. Install the shift solenoid valve SLT.
b. Install the bolt, the 2 straight pins and the lock plate.

cardiagn.com
Fig. 324: Installing Shift Solenoid Valve SLT
18. REMOVE SHIFT SOLENOID VALVE SLU

a. Install the shift solenoid valve SLU.
cardiagn.com
Fig. 325: Installing Shift Solenoid Valve SLU

a. Install the shift solenoid valve SL2.
b. Install the bolt, the 2 straight pins and the lock plate.

cardiagn.com
Fig. 326: Installing Bolt
20. INSTALL TRANSMISSION VALVE BODY ASSY

a. Align the groove of the manual valve with the pin of the lever.
cardiagn.com
Fig. 327: Aligning Groove Of Manual Valve With Pin Of Lever
HINT:
Each bolt length is indicated below.
Blot length:
Bolt A: 25 mm (0.98 in.)
Bolt B: 36 mm (1.42 in.)
Bolt C: 45 mm (1.77 in.)
Bolt D: 50 mm (1.97 in.)

cardiagn.com
MEMO
MEMO
MEMO

Transmission A761e Overhaul

Uploaded by

Copyright:

Available Formats

Transmission A761e Overhaul

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Transmission A761e Overhaul

Uploaded by

Copyright:

Available Formats

A761E Overhaul - LS430

HOW TO USE THIS AUTOMATIC TRANSMISSION REPAIR INFORMATION;

Torque: 30 N m (310 kgf.cm, 22 ft.lbf)

REPAIR INSTRUCTION FOR AUTOMATIC TRANSMISSION REPAIR MANUAL

When necessary, use a sealer on gaskets to prevent leaks.

c. BOLTS, NUTS AND SCREWS

Fig. 4: Measuring Length Of Torque Wrench cardiagn.com

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

ABBREVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN MANUAL

GLOSSARY OF SAE AND LEXUS TERMS

GLOSSARY OF SAE AND LEXUS TERMS

SST (Special Service Tools)

SPECIAL SERVICE TOOLS

09350- TOYOTA Automatic AUTOMATIC TRANSMISSION

(09350- No.2 Piston Spring CLUTCH DRUM & INPUT

(09350- No.3 Piston Spring AUTOMATIC TRANSMISSION

(09350- Brake Reaction Sleeve AUTOMATIC TRANSMISSION

(09350- Brake No.1 Piston AUTOMATIC TRANSMISSION

(09351- Oil Seal Replacer OIL PUMP ASSY(A761E)

09351- Tool Set, TOYOTA AUTOMATIC TRANSMISSION

(09351- Pipe AUTOMATIC TRANSMISSION

(09351- Spring Compressor AUTOMATIC TRANSMISSION

(09351- Bolt AUTOMATIC TRANSMISSION

(09351- Spring Compressor AUTOMATIC TRANSMISSION

09387- First & Reverse Brake CLUTCH DRUM & INPUT

(09951- Replacer 35 AUTOMATIC TRANSMISSION

(09951- Handle 100 AUTOMATIC TRANSMISSION

SSM (Special Service Materials)

SPECIAL SERVICE MATERIALS

SPECIFIED TORQUE FOR STANDARD BOLTS

SPECIFIED TORQUE FOR STANDARD BOLTS

HOW TO DETERMINE NUT STRENGTH

AUTOMATIC TRANSMISSION / TRANSAXLE; SERVICE DATA

AUTOMATIC TRANSMISSION / TRANSAXLE SERVICE DATA

STATOR SHAFT BUSHING INSIDE DIAMETER REFERENCE

INTERMEDIATE SHAFT DIAMETER

NOTE:  The automatic transmission is composed of highly precision-finished

When disassembling a valve body, be sure to match each valve together

 New replacement discs for brakes and clutches replacement must be

Clean both sealing surfaces with a non-residue solvent.

Parts must be reassembled within 10 minutes of application. Otherwise,

Fig. 10: Function Of Components A/T

AUTOMATIC TRANSMISSION ASSY (A761E)

Fig. 12: Identifying Components Automatic Transmission Assy (A761E) (2 Of 5)

Fig. 13: Identifying Components Automatic Transmission Assy (A761E) (3 Of 5)

Fig. 14: Identifying Components Automatic Transmission Assy (A761E) (4 Of 5)

Fig. 15: Identifying Components Automatic Transmission Assy (A761E) (5 Of 5)

1. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY

3. REMOVE OIL COOLER TUBE UNION

4. REMOVE TRANSMISSION REVOLUTION SENSOR

Fig. 19: Removing Transmission Revolution Sensor

6. REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSY

7. REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSY

c. Remove the oil seal from the flange yoke assy.

8. REMOVE EXTENSION (ATM) HOUSING SUB-ASSY

b. Using a snap ring expander, remove the snap ring.

d. Use a screwdriver to remove the extension housing sub-assy.