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AC60F hilux

The document provides detailed instructions for the removal and disassembly of the AWR6B45 transmission, including safety precautions and preliminary procedures. It outlines steps for disconnecting various components, draining ATF, and removing the transmission from the engine. Additionally, it includes component views and tightening torque specifications for various parts involved in the transmission assembly.

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0% found this document useful (0 votes)

54 views

AC60F hilux

Uploaded by

cozaciucam

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Transmission removal (AWR6B45)

1. Transmission safety information

Caution
Be careful not to cause any damage.
Because damage to the rib especially decreases the case strength, even greater caution is necessary
when handling the rib sections.

Warning
When performing work on heavy items such as the case and gears, take care to prevent injury.

2. Preliminary and post procedures

1. Preliminary procedures

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1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution
After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
The ECM may malfunction if the battery cable is disconnected within 1 minute.
If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Transfer preparation

1. 4WD models

1) Change the transfer mode to 2WD using the 2-4 switch.

Caution
Before removing the transfer from the vehicle, change the transfer mode to 2WD using the 2-4 switch.

4. Engine hood removal

Caution
Two people are required to install or remove the engine hood.

1) Remove the engine hood from the hood hinge.

Note
Mark the hood hinge position before removing the engine hood.
5. Engine cover removal

1) Remove the engine cover from the engine.

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Legend

1. Engine cover

6. Wiper linkage disconnect

Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage removal".

7. Cowl panel removal

1) Remove the cowl panel from vehicle.

8. Transmission preparation

1) Raise the vehicle using a jack.

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Note
Use a suitable stand to support the vehicle.

Caution
The accurate ATF amount cannot be measured if the vehicle is at an angle. Perform work within ±1°
inclination of the vehicle front and rear.

9. ATF drain

When the transmission is disassembled.

1) Remove the drain plug from the oil pan.

2) Drain the ATF.

Note
Keep a record of the amount of fluid that is drained.

Caution
If chips and particles are found on the oil cleaner magnet when examining it, damage on the gear is
suspected.
Examine the chips and particles on the oil cleaner magnet to determine what type of wear has
occurred in the transmission.
3) Temporarily tighten the drain plug to the oil pan.

10. Rear propeller shaft removal

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Refer to "3.Driveline, Axle 3C.Drive Shaft System rear propeller shaft removal".

11. Front propeller shaft removal

1. 4WD models

Refer to "3.Driveline, Axle 3C.Drive Shaft System front propeller shaft removal".

12. Engine harness disconnect

1. 4WD models

1) Disconnect the engine harness from the connectors of the following parts.

Turbine speed sensor connector

Transmission internal harness connector
Output speed sensor connector
Inhibitor switch connector
2-4 switch connector
Neutral switch connector
Actuator connector

Caution
When disconnecting 2-4 switch connector while the battery is connected, do not turn the vehicle
ignition switch to the ON position.
Legend

1. Turbine speed sensor connector

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Legend

1. Output speed sensor connector

2. Transmission internal harness connector
3. Inhibitor switch connector
Legend

1. Neutral switch connector

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2. 2-4 switch connector
3. Actuator connector

2) Disconnect the clips.

2. 2WD models

1) Disconnect the engine harness from the connectors of the following parts.

Turbine speed sensor connector

Transmission internal harness connector
Output speed sensor connector
Inhibitor switch connector
Legend

1. Turbine speed sensor connector

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Legend

1. Output speed sensor connector

2. Transmission internal harness connector
3. Inhibitor switch connector

2) Disconnect the clips.

RZ4E-TC equipped models

4JJ1 equipped models

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13. Transfer removal

1. 4WD models

1) Remove the transfer from the transmission.

14. Starter motor removal

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor removal".

15. ATF cooler pipe disconnect

1. RZ4E-TC equipped models

1) Disconnect the ATF cooler pipe from the transmission.

Note
Disconnect the flare nut.
Legend

1. OUT side

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2. IN side

2. 4JJ1 equipped models

1) Disconnect the ATF cooler pipe from the transmission.

2) Disconenct the flare nut and remove the clip.

Legend

1. OUT side
2. IN side

16. Automatic transmission control cable disconnect

1) Disconnect the automatic transmission control cable from the select lever.

2) Remove the automatic transmission control cable bracket from the transmission.
Legend

1. Automatic transmission control cable bracket

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2. Automatic transmission control cable

17. Torque converter disconnect

1) Remove the lower cover from the transmission.

2) Remove the flexible plate bolt from the torque converter.

Caution
Do not reuse the flexible plate bolts.

18. Transmission crossmember removal

1) Install special tool to the cylinder head.

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) Engine mounting removal".

Refer to "1.Engine 1B.Mechanical(4JJ1 without DPD) Engine mounting removal".

2) Install the wire to the engine hanger and hoist.

Note
Hold up the engine as high as not to be lifted up.

3) Support the transmission using a transmission jack.

4) Remove the brace from the frame and transmission crossmember.

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5) Remove the nut from the transmission crossmember.

6) Remove the transmission crossmember from the frame.

19. Transmission removal

1) Remove the transmission from the engine.

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20. Cushion rubber removal

1) Remove the cushion rubber from the transmission.

4WD models

2WD models
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Transmission disassembly (AWR6B45)

1. Component views

Transmission case

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Part name

1. Torque converter assembly

2. Bolt
3. Bolt
4. converter housing
5. O-ring
6. Elbow
7. Inhibitor switch
8. Lock washer
9. Nut
10. Bolt
11. Breather hose
12. Breather plug
13. O-ring
14. Bolt
15. Output speed sensor
16. O-ring
17. Filler plug
18. O-ring
19. Bolt
20. Turbine Speed Sensor
21. O-ring

Tightening torque

2: 34 N・m { 3.5 kgf・m / 25 lb・ft }

3: 57 N・m { 5.8 kgf・m / 42 lb・ft }

6: 28 N・m { 2.9 kgf・m / 21 lb・ft }

9: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 13 N・m { 1.3 kgf・m / 115 lb・in }

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14: 5 N・m { 0.5 kgf・m / 44 lb・in }

17: 40 N・m { 4.1 kgf・m / 30 lb・ft }

19: 5 N・m { 0.5 kgf・m / 44 lb・in }

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Part name

1. Manual shaft oil seal

2. Manual valve lever shaft
3. Spacer
4. Manual valve lever
5. Manual shaft oil seal
6. Spring pin
7. Snap ring
8. Parking lock pawl shaft
9. Torsion spring
10. Parking lock pawl
11. Parking lock pawl bracket
12. Parking lock rod
13. Bolt

Tightening torque

13: 18 N・m { 1.8 kgf・m / 13 lb・ft }

Transmission case adapter (4WD models)

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Part name

1. Bolt
2. O-ring
3. Thrust bearing race
4. Thrust needle roller bearing
5. Snap ring
6. Snap ring
7. Transmission case adapter bearing
8. Transmission case adapter
9. Transmission case adapter oil seal
10. Bolt
11. O-ring
12. Bolt

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

10: 34 N・m { 3.5 kgf・m / 25 lb・ft }

12: 7 N・m { 0.7 kgf・m / 62 lb・in }

Extension housing (2WD models)

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Part name

1. Bolt
2. O-ring
3. Thrust bearing race
4. Thrust needle roller bearing
5. Snap ring
6. Extension housing
7. Extension housing oil seal
8. Extension housing dust deflector
9. Bolt
10. O-ring
11. Bolt

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

9: 34 N・m { 3.5 kgf・m / 25 lb・ft }

11: 7 N・m { 0.7 kgf・m / 62 lb・in }

Valve body assembly

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Part name

1. Temperature sensor clamp

2. O-ring
3. Bolt
4. Transmission internal harness
5. O-ring
6. Temperature sensor clamp
7. Bolt
8. Oil temperature sensor
9. Bolt
10. Brake drum gasket
11. Transmission case gasket
12. Valve body assembly
13. Detent spring
14. Detent spring cover
15. Bolt
16. O-ring
17. Bolt
18. Oil strainer
19. Bolt
20. Oil pan gasket
21. Oil cleaner magnet
22. Transmission oil pan sub-assembly
23. Bolt
24. Bolt

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25. Gasket
26. Bolt
27. Gasket

Tightening torque

3: 5 N・m { 0.5 kgf・m / 44 lb・in }

7: 10 N・m { 1.0 kgf・m / 89 lb・in }

9: 11 N・m { 1.1 kgf・m / 97 lb・in }

15: 10 N・m { 1.0 kgf・m / 89 lb・in }

17: 11 N・m { 1.1 kgf・m / 97 lb・in }

19: 10 N・m { 1.0 kgf・m / 89 lb・in }

23: 7 N・m { 0.7 kgf・m / 62 lb・in }

24: 20 N・m { 2.0 kgf・m / 15 lb・ft }

26: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Valve body assembly

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Part name

1. Valve body assembly

Gear train
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Part name

1. Bolt
2. Oil pump assembly
3. Thrust needle roller bearing
4. Thrust bearing race
5. Direct clutch assembly and forward clutch assembly
6. Thrust needle roller bearing
7. Thrust bearing race
8. Forward clutch hub
9. Thrust bearing race
10. Thrust needle roller bearing
11. Clutch hub sub-assembly
12. Thrust needle roller bearing with race
13. Thrust bearing race
14. Sun gear input drum
15. Thrust needle roller bearing with race
16. Thrust bearing race
17. Front planetary gear assembly
18. Thrust bearing race
19. Thrust needle roller bearing with race
20. Front planetary ring gear with front planetary ring gear flange sub-assembly
21. Thrust bearing race
22. Snap ring
23. Brake cylinder No. 2 with brake piston No. 2
24. Brake piston return spring sub-assembly No. 2
25. Brake flange No. 2
26. Brake disc No. 2
27. Brake plate No. 2
28. Brake flange No. 2
29. Thrust needle roller bearing with race
30. Middle planetary ring gear flange with middle planetary ring gear
31. Thrust needle roller bearing

Tightening torque

1: 21 N・m { 2.1 kgf・m / 15 lb・ft }

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Part name

1. Thrust bearing race

2. Middle planetary gear assembly
3. Planetary sun gear
4. Snap ring
5. Brake flange No. 1
6. Brake plate No. 1
7. Brake disc No. 1
8. Snap ring
9. Brake piston return spring sub-assembly
10. Brake cylinder No. 1 with brake piston No. 1
11. Snap ring
12. 1 way clutch assembly No. 3 with inner race
13. Rear planetary ring gear flange sub-assembly
14. Thrust bearing race
15. Thrust needle roller bearing
16. Thrust bearing race
17. Intermediate shaft
18. Brake flange No. 4
19. Brake plate No. 4
20. Brake disc No. 4
21. Brake flange No. 4

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Part name

1. Thrust needle roller bearing with race

2. Thrust bearing race
3. Rear planetary gear assembly
4. Thrust needle roller bearing with race
5. Thrust bearing race
6. Thrust needle roller bearing
7. Thrust bearing race
8. Snap ring
9. Snap ring
10. 1st and reverse brake return spring sub-assembly
11. 1st and reverse brake piston
12. Brake reaction sleeve
13. Inner brake piston No. 4
14. Transmission case
15. Brake plate stopper spring

2. Torque converter assembly removal

1) Remove the torque converter assembly from the transmission case.

Caution
Be careful not to damage the oil pump oil seal.
Be careful not to drop the torque converter assembly.

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3. Inhibitor switch removal

1) Using a screwdriver, pry off the lock washer.

2) Remove the nut and the lock washer from the inhibitor switch.

3) Remove the bolt and the inhibitor switch from the transmission case.

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Note
Make sure that the manual valve lever shaft has not been rotated prior to installing the inhibitor
switch, as the detent spring may become detached from the manual valve lever shaft.

Caution
Do not touch the terminals.
Be careful not to damage the inhibitor switch.

4. Turbine speed sensor removal

1) Remove the turbine speed sensor from the transmission case.

Caution
Be careful not to damage the turbine speed sensor.
5. Output speed sensor removal

1) Remove the output speed sensor from the transmission case.

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Caution
Be careful not to damage the output speed sensor.

6. Breather hose removal

1) Remove the breather hose from the transmission case.

2) Remove the breather plug and the O-ring from the transmission case.
7. Test plug removal

1) Remove the 6 test plugs from the transmission case as necessary.

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2) Remove the 6 O-rings from the test plug.

8. Transmission case plug removal

1) Using a torx wrench (T55), remove the transmission case plug from the transmission case as necessary.

2) Remove the O-ring from the transmission case plug.

9. Elbow removal

1) Remove the 2 elbows from the transmission case.

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2) Remove the 2 O-rings from the elbows.

10. Deflector removal

1. 2WD models

1) Using a plastic hammer, remove the extension housing dust deflector from the extension housing.

Caution
Be careful not to damage the extension housing.
11. Extension housing assembly removal

1. 2WD models

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1) Remove the 8 bolts and the extension housing from the transmission case.

Legend

1. M10 x 1.5 x 45 mm {1.77 in} (Seal bolt)

2. M10 x 1.5 x 40 mm {1.57 in} (Seal bolt)

12. Adapter housing removal

1. 4WD models

1) Remove the 10 bolts and the transmission case adapter.

13. Adapter housing bearing removal

1. 4WD models

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1) Using snap ring pliers, remove the snap ring from the transmission case adapter.

Caution
Be careful not to damage the transmission case adapter.

2) Using special tool, remove the transmission case adapter bearing from the transmission case adapter.

Caution
Be careful not to damage the transmission case adapter.
SST: 5-8840-0084-0 - sliding hammer

SST: 5-8840-2963-0 - oil seal remover

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Legend

1. 5-8840-0084-0
2. 5-8840-2963-0

14. Rear oil seal removal

1. 4WD models

1) Using a screwdriver, remove the transmission case adapter oil seal from the transmission case adapter.

Caution
Tape the screwdriver tip before use.
Be careful not to damage the transmission case adapter.
If using a screwdriver, use a wooden block or equivalent to avoid damaging the fitting surface of the
transmission case adapter.
2. 2WD models

1) Using a screwdriver, remove the extension housing oil seal from the extension housing.

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Caution
Tape the screwdriver tip before use.
Be careful not to damage the extension housing.

15. Converter housing removal

1) Remove the 12 bolts and the converter housing from the transmission case.

Note
The number shown in the figure indicates the kind of bolts.
Legend

1. M10 x 1.5 x 35 mm {1.38 in}

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2. M10 x 1.5 x 35 mm {1.38 in} (Seal bolt)
3. M12 x 1.75 x 38 mm {1.50 in} (Seal bolt)

16. Oil pan removal

1) Remove the 10 bolts from the oil pan.

2) Remove the transmission oil pan and the transmission oil pan gasket from the transmission case.

Caution
Be careful not to damage the fitting surfaces of the transmission case and the oil pan.
Be careful not to deform the oil pan.

3) Remove the 4 oil cleaner magnets from the oil pan.

4) Examine the chips and particles in the oil pan and on the oil cleaner magnet to determine what type of wear
has occurred in the transmission.

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Caution
Keep a record of the amount of fluid that is drained.

Types of Chips
Cause
and Particles
Bearing, gear and
Steel (magnetic)
plate wear
Brass (non-
Bushing wear
magnetic)

17. Transmission internal harness removal

1) Remove the 2 bolts and the 2 temperature sensor clamps, and pull out the 2 oil temperature sensors (OT1,
OT2) from the valve body assembly.

2) Disconnect the 8 solenoid connectors.

Legend

1. Temperature sensor (OT1)

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2. M6 x 1.0 x 14 mm {0.55 in}
3. Temperature sensor (OT2)
4. M6 x 1.0 x 36 mm {1.42 in}

3) Remove the bolt and pull out the transmission wire from the transmission case.

Caution
Be careful not to damage the harness.
Be careful not to pull the harness forcibly.

4) Remove the O-ring from the transmission wire connector.

18. Oil strainer removal

1) Remove the 3 bolts and the oil strainer from the valve body assembly.

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2) Remove the O-ring from the oil strainer.
19. Detent spring removal

1) Remove the bolt and the detent spring and detent spring cover.

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20. Valve body assembly removal

1) Remove the 12 bolts and the valve body assembly from the transmission case.
Legend

1. M6 x 1.0 x 25 mm {0.98 in}

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2. M6 x 1.0 x 36 mm {1.42 in}
3. M6 x 1.0 x 50 mm {1.97 in}

21. Brake drum gasket removal

1) Remove the 2 transmission case gaskets from the transmission case.

2) Remove the 2 brake drum gaskets from the transmission case.

22. Parking lock pawl bracket removal

1) Remove the 3 bolts from the transmission case.

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2) Push the parking lock pawl bracket into the rear side.

3) Pull the parking lock rod towards the front side.

Legend

1. Parking lock pawl bracket

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2. Parking lock rod

4) Slide the parking lock pawl bracket inside the transmission while pushing the parking lock pawl, then slide the
parking lock rod to the bolt hole side.

Legend

1. Bolt hole
2. Parking lock pawl bracket
3. Parking lock rod

5) Remove the parking lock pawl bracket from the transmission case.

23. Parking lock rod removal

1) Disconnect the parking lock rod from the manual valve lever.
24. Parking lock pawl shaft removal

1) Remove the torsion spring from the parking lock pawl shaft.

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Caution
Be careful not to apply too much force to the torsion spring.

2) Remove the parking lock pawl shaft and parking lock pawl from the transmission case.

3) Remove the snap ring from the parking lock pawl shaft.

25. Manual valve lever removal

1) Using a screwdriver and hammer, cut off the spacer and remove it from the manual valve lever shaft.

Caution
Be careful not to damage the manual valve lever shaft.
2) Using a pin punch (3 mm {0.118 in}) and hammer, tap out the spring pin.

Note

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Slowly tap out the spring pin so that it does not fall into the transmission case.

3) Pull the manual valve lever shaft out through the transmission case, and remove the manual valve lever.

26. Manual shaft oil seal removal

1) Using a screwdriver, pry out the 2 manual shaft oil seals from the transmission case.

Caution
Be careful not to damage the transmission case.
Tape the screwdriver tip before use.
If using a screwdriver, use a wooden block or equivalent to avoid damaging the fitting surface of the
transmission case.
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Legend

1. Right side
2. Left side

27. Oil pump removal

1) Remove the 10 bolts from the oil pump assembly.

2) Using a remover, pull out the oil pump assembly from the transmission case.
3) Remove the 2 thrust bearing races from the oil pump assembly.

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28. Forward clutch assembly removal

1) Remove the direct clutch assembly and the forward clutch assembly (input shaft) from the transmission case.

2) Remove the 3 thrust needle roller bearings from the direct clutch assembly and the forward clutch assembly
(input shaft).
3) Remove the direct clutch assembly from the forward clutch assembly (input shaft).

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4) Remove the forward clutch hub from the transmission case.

5) Remove the 2 thrust bearing races from the forward clutch hub.
6) Remove the clutch hub sub-assembly from the transmission case.

7) Remove the thrust needle roller bearing with race and the thrust needle roller bearing from the clutch hub sub-

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assembly.

29. Sun gear input drum removal

1) Remove the sun gear input drum from the transmission case.

2) Remove the thrust needle roller bearing with race and the thrust bearing race from the sun gear input drum.
30. Front planetary gear assembly removal

1) Remove the front planetary gear assembly from the transmission case.

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2) Remove the 2 thrust bearing races from the front planetary gear assembly.

31. Front planetary ring gear removal

1) Remove the front planetary ring gear with the front planetary ring gear flange sub-assembly from the
transmission case.

2) Remove the thrust needle roller bearing with race and the thrust bearing race from the front planetary ring gear
with front planetary ring gear flange sub-assembly.
32. Brake piston No.2 removal

1) Place the special tool on brake cylinder No. 2 with brake piston No. 2, and compress the brake piston return

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spring sub-assembly No. 2 with a shop press.

SST: 5-8840-2971-0 - spring compressor

SST: 5-8840-2973-0 - spring compressor kit

Legend

1. 5-8840-2973-0

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2. 5-8840-2971-0

Caution
Be careful not to shorten the return spring too much.

2) Using a screwdriver, remove the snap ring from the transmission case.

Caution
Be careful not to damage the transmission case.

3) Remove brake cylinder No. 2 with brake piston No. 2 and brake piston return spring sub-assembly No. 2 from
the transmission case.

33. Brake disc No.2 removal

1) Remove the 4 plates, 5 discs and 2 flanges from the transmission case.

Note
Check the number and order of flange, discs and plates.

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Legend

1. Plate
2. Flange
3. Disc

34. Middle planetary ring gear removal

1) Remove the middle planetary ring gear flange with the middle planetary ring gear from the transmission case.

2) Remove the 2 thrust needle roller bearings from the middle planetary ring gear flange with middle planetary ring
gear.
35. Middle planetary gear assembly removal

1) Remove the middle planetary gear assembly from the transmission case.

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2) Remove the thrust bearing race from the middle planetary gear assembly.

36. Planetary sun gear removal

1) Remove the planetary sun gear from the transmission case.

37. Brake disc No.1 removal

1) Using a screwdriver, remove the snap ring from the transmission case.

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Caution
Be careful not to damage the transmission case.

2) Remove the flange, 4 discs and 4 plates from the transmission case.

Legend

1. Flange
2. Disc
3. Plate

38. Brake piston No.1 removal

1) Place the special tool on the brake piston return spring sub-assembly, and compress the brake piston return
spring sub-assembly with a shop press.

Note
Place the special tool on the surface with protrusions.

Caution
Be careful not to shorten the return spring too much.

SST: 5-8840-2973-0 - spring compressor kit

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SST: 5-8840-2962-0 - oil seal installer

SST: 5-8840-3199-0 - spring compressor

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Legend

1. 5-8840-2973-0
2. 5-8840-2962-0
3. 5-8840-3199-0

2) Using a screwdriver, remove the snap ring from the transmission case.

Caution
Be careful not to damage the transmission case.

3) Remove the brake piston return spring sub-assembly and brake cylinder No. 1 with brake piston No. 1 from the
transmission case.
39. 1way clutch No.3 removal

1) Using the special tool, remove the snap ring from the transmission case.

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SST: 5-8840-2961-0 - snap ring pliers

Legend

1. 5-8840-2961-0

2) Remove the intermediate shaft with 1 way clutch assembly No. 3 with inner race and rear planetary ring gear
flange with rear planetary ring gear from the transmission case.
3) Remove the 1 way clutch assembly No. 3 with inner race from the rear planetary ring gear flange with rear
planetary ring gear.

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4) Remove the 1 way clutch inner race from the 1 way clutch assembly No. 3.
40. Rear planetary ring gear removal

1) Remove the rear planetary ring gear flange with rear planetary ring gear from the intermediate shaft.

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2) Remove the thrust needle roller bearing and the 2 thrust bearing races from the intermediate shaft.

41. Brake disc No.4 removal

1) Remove the 2 flanges, 7 discs and 6 plates from the transmission case.

Note
Check the number and order of flange, discs and plates.
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Legend

1. Plate
2. Flange
3. Disc

42. Rear planetary gear assembly removal

1) Using snap ring pliers, remove the snap ring from the rear planetary gear assembly.

2) Remove the 2 thrust bearing races and thrust needle roller bearing from the output shaft.
3) Remove the rear planetary gear assembly from the transmission case.

4) Remove the 2 thrust needle roller bearings and 2 thrust bearing races from the rear planetary gear assembly.

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43. 1st and reverse brake piston removal

1) Set the special tool on the 1st and reverse brake return spring sub-assembly, tighten the special tool and
compress the 1st and reverse brake return spring sub-assembly.

Caution
Be careful not to shorten the return spring too much.

SST: 5-8840-2966-0 - spring compressor

2) Using snap ring pliers, remove the snap ring.

Caution
Be careful not to expand the snap ring too much.

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Legend

1. 5-8840-2966-0

3) Remove the 1st and reverse brake return spring sub-assembly from the transmission case.

4) While pushing the 1st and reverse brake piston by hand, apply compressed air into the oil passage of the
transmission case as shown in the figure and remove the 1st and reverse brake piston.

Caution
Be careful not to damage the 1st and reverse brake piston.

300 kPa { 3 kgf/cm2 / 44 psi } Compressed air

5) Remove the O-ring from the 1st and reverse brake piston.

Note

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In some cases, the 1st and reverse brake piston may be removed with the brake reaction sleeve and
inner brake piston No. 4 attached.

44. Brake reaction sleeve removal

1) Using the special tool, remove the brake reaction sleeve from the transmission case.

SST: 5-8840-2967-0 - reaction sleeve puller

Legend

1. 5-8840-2967-0

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2) Remove the 2 O-rings from the brake reaction sleeve.

3) Using the special tool, remove inner brake piston No. 4 from the transmission case.

SST: 5-8840-2968-0 - piston puller

Legend

1. 5-8840-2968-0

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4) Remove the 2 O-rings from the inner brake piston No. 4.

45. Plate stopper spring removal

1) Remove the 2 brake plate stopper springs from the transmission case.
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Transmission inspection (AWR6B45)

1. 1way clutch No.3 inspection

1) Hold 1 way clutch assembly No. 3 in place. Check that the rear planetary ring gear rotates when turned
clockwise and does not rotate when turned counterclockwise.

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Legend

1. Lock
2. Free

2. Brake disc No.1 inspection

1) Check the lining of all discs.

Note
If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace
with a new lining.
When replacing, check the contact surfaces between the flange, plate and disc.
If they are scratched or have changed color, replace with new parts.
Before replacing with new discs, soak them at least 2 hours in ATF.
3. Brake disc No.2 inspection

1) Check the lining of all discs.

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Note
If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace
with a new lining.
When replacing, check the contact surfaces between the flange, plate and disc.
If they are scratched or have changed color, replace with new parts.
Before replacing with new discs, soak them at least 2 hours in ATF.

4. Brake disc No.4 inspection

1) Check the lining of all discs.

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5. Brake piston return spring sub-assembly No.1 inspection

1) Using vernier calipers, measure the free length of brake piston return spring sub-assembly No. 1.

Caution
If the free length is smaller than the minimum, replace brake piston return spring sub-assembly No. 1
with a new one.

Standard: 16.72 mm { 0.6583 in }

6. Brake piston return spring sub-assembly No.2 inspection

1) Using vernier calipers, measure the free length of the brake piston return spring sub-assembly No.2.

Caution
If the free length is smaller than the minimum, replace brake piston return spring sub-assembly No. 2
with a new one.
Standard: 16.68 mm { 0.6567 in }

7. 1st and reverse brake return spring sub-assembly inspection

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1) Using vernier calipers and a surface plate, measure the free length of the 1st and reverse brake return spring
sub-assembly.

Caution
If the free length is smaller than the minimum, replace the 1st and reverse brake return spring sub-
assembly with a new one.

Standard: 11.44 mm { 0.4504 in }

8. Front planetary gear assembly inspection

1) Using a feeler gauge, measure the front planetary gear pinion thrust clearance.

Caution
If the clearance is not as specified, replace the front planetary gear assembly.

Standard: 0.2 to 0.6 mm { 0.01 to 0.02 in }

2) Using a caliper gauge, measure the inside diameter of the front planetary gear assembly bushing.

Caution

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Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the front planetary gear assembly with a new one.
When the front planetary gear assembly is replaced, inspect the surface in contact with the clutch
hub sub-assembly. If the surface is scratched or discolored, replace the clutch hub sub-assembly
with a new one.

Standard: 35.811 to 35.835 mm { 1.4099 to 1.4108 in }

9. Sun gear input drum inspection

1) Using a caliper gauge, measure the inside diameter of the sun gear input drum bushing.

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the sun gear input drum with a new one.
When the sun gear input drum is replaced, inspect the surface in contact with the clutch hub sub-
assembly. If the surface is scratched or discolored, replace the clutch hub sub-assembly with a new
one.

Standard: 35.811 to 35.835 mm { 1.4099 to 1.4108 in }

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10. Middle planetary gear assembly inspection

1) Using a feeler gauge, measure the middle planetary gear pinion thrust clearance.

Caution
If the clearance is not as specified, replace the middle planetary gear assembly.

Standard: 0.12 to 0.68 mm { 0.0047 to 0.0268 in }

11. Rear planetary gear assembly inspection

1) Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.

Caution
If the clearance is not as specified, replace the rear planetary gear assembly.

Standard: 0.2 to 0.6 mm { 0.0079 to 0.0236 in }

2) Using a caliper gauge, measure the inside diameter of the rear planetary gear bushing.

Caution

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Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the rear planetary gear assembly with a new one.
When the rear planetary gear assembly is replaced, inspect the surface in contact with the
intermediate shaft. If the surface is scratched or discolored, replace the intermediate shaft with a new
one.

Standard: 20.000 to 20.025 mm { 0.78740 to 0.78838 in }

12. Engine harness inspection

1. Oil temperature sensor inspection

1) Disconnect the engine harness from the TCM.

2) Measure the resistance between the connector terminal combinations listed in the table using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not damage the terminals.

Oil temperature sensor (OT1,

OT2)
ATF temperature Resistance
-40 ℃ { -40 °F } 161 kΩ MAX
-30 ℃ { -22 °F } 36.3 to 52.1 kΩ
10 ℃ { 50 °F } 5.626 to 7.303 kΩ
25 ℃ { 77 °F } 3.5 kΩ
110 ℃ { 230 °F } 0.224 to 0.271 kΩ
145 ℃ { 293 °F } 0.102 to 0.121 kΩ
150 ℃ { 302 °F } 0.087 kΩ MIN

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Legend

1. OT1+
2. OT1-
3. OT2-
4. OT2+

3) Check for continuity between each connector terminal combinations listed in the table using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

Oil temperature sensor (OT1,

OT2)
Terminal name Continuity
OT1+ and Body
earth
No
OT1- and Body
earth
OT2+ and Body
earth
OT2- and Body
earth

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Legend

1. OT1+
2. OT1-
3. OT2-
4. OT2+

2. Valve body assembly inspection

1) Disconnect the engine harness from the TCM.

2) Measure the resistance between the connector terminal combinations listed in the table using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not damage the terminals.

Terminal name Resistance

SL and Body
11 to 15 Ω
earth
at 20 ℃ {68 °F}
Legend

1. SL

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Linear solenoid (SL1, SL2, SL3,
SL4, SLT, SLU)
Terminal name Resistance
SL1+ and SL1-
SL2+ and SL2-
SL3+ and SL3-
5.0 to 5.6 Ω
SL4+ and SL4-
SLT+ and SLT-
SLU+ and SLU-
at 20 ℃ {68 °F}

Legend

1. SL4-
2. SL3-
3. SL4+
4. SL3+
5. SL2-
6. SL2+
7. SLT-
8. SLT+
9. SLU-
10. SLU+
11. SL-
12. SL+

3) Check for continuity between each connector terminal combinations listed in the table using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

Linear solenoid (SL1, SL2, SL3,

SL4, SLT, SLU)
Terminal name Continuity
SL1+ and Body

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earth
SL1- and Body
earth
SL2+ and Body
earth
SL2- and Body
earth
SL3+ and Body
earth
SL3- and Body
earth
No
SL4+ and Body
earth
SL4- and Body
earth
SLT+ and Body
earth
SLT- and Body
earth
SLU+ and Body
earth
SLU- and Body
earth
Legend

1. SL4-
2. SL3-

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3. SL4+
4. SL3+
5. SL2-
6. SL2+
7. SLT-
8. SLT+
9. SLU-
10. SLU+
11. SL1-
12. SL1+

13. Transmission internal harness inspection

1. Oil temperature sensor inspection

1) Warm up ATF and insert the transmission fluid temperature sensor.

Legend
1. ATF

2) At each ATF temperature, measure the resistance between terminal OT1+ and OT1-, OT2+ and OT2- of the
transmission internal harness connector using a DMM.

Note
Check that the resistance is as specified in the table.

Caution
Do not damage the terminals.

ATF temperature Resistance

-40 ℃ { -40 °F } 161 kΩ MAX
-30 ℃ { -22 °F } 36.3 to 52.1 kΩ
10 ℃ { 50 °F } 5.626 - 7.303 kΩ
25 ℃ { 77 °F } 3.5 kΩ
110 ℃ { 230 °F } 0.224 - 0.271 kΩ
145 ℃ { 293 °F } 0.102 - 0.121 kΩ
150 ℃ { 302 °F } 0.087 kΩ MIN

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Legend

1. OT1+
2. OT1-
3. OT2+
4. OT2-

3) Check for continuity between each connector terminal combinations listed in the table using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

Terminal name Continuity

OT1+ and Body
No
earth
OT1- and Body
earth
OT2+ and Body
earth
OT2- and Body
earth

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Legend

1. OT1+
2. OT1-
3. OT2+
4. OT2-

2. Valve body assembly inspection

1) Measure the resistance between the connector terminal combinations listed in the table using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not damage the terminals.

SL solenoid
Terminal name Resistance
SL and Body
11 to 15 Ω
earth
at 20 ℃ {68 °F}
Legend

1. SL

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Linear solenoid (SL1, SL2, SL3,
SL4, SLT, SLU)
Terminal name Resistance
SL1+ and SL1-
SL2+ and SL2-
SL3+ and SL3-
5.0 to 6.0 Ω
SL4+ and SL4-
SLT+ and SLT-
SLU+ and SLU-
at 20 ℃ {68 °F}

Legend

1. SLU+
2. SLU-
3. SL4+
4. SL4-
5. SL+
6. SL-
7. SL3+
8. SL3-
9. SLT+
10. SLT-
11. SL2+
12. SL2-

2) Check for continuity between each connector terminal combinations listed in the table using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

Linear solenoid (SL1, SL2, SL3,

SL4, SLT, SLU)
Terminal name Continuity
SL1+ and Body

1. SLU+
2. SLU-

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3. SL4+
4. SL4-
5. SL+
6. SL-
7. SL3+
8. SL3-
9. SLT+
10. SLT-
11. SL2+
12. SL2-

14. Valve body assembly inspection

1. SL solenoid inspection

1) Measure the resistance between the SL solenoid terminal and SL solenoid body using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not impact the SL solenoid.
Do not remove the SL solenoid from the valve body assembly.
Do not damage the terminals.

Terminal name Resistance

SL solenoid
terminal and SL 11 to 15 Ω
solenoid body
at 20 ℃ {68 °F}
Legend

1. Terminal

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2) Inspect that the solenoid operates when the battery positive terminal is connected to the SL solenoid terminal
and the battery negative terminal is connected to the solenoid body.

Caution
Do not impact the SL solenoid.
Do not damage the terminals.

3) Connect the battery positive terminal to the SL solenoid terminal and the battery negative terminal to the SL
solenoid body, operate the solenoid, and inspect that the air flow is as shown in the diagram when air is applied.

Caution
Do not impact the SL solenoid.
Do not damage the terminals.
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Legend

1. Terminal
2. ON
3. OFF

2. Clutch control solenoid (SL1, SL2, SL3, SL4) inspection

1) Measure the resistance between terminal 1 and terminal 2 of the clutch control solenoid (SL1, SL2, SL3, SL4)
using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not impact the clutch control solenoid.
Do not damage the terminals.
Do not remove clutch control solenoid (SL1, SL2, SL3, SL4) from the valve body assembly.

Clutch control solenoid (SL1,

SL2, SL3, SL4)
Terminal name Resistance
Terminal 1 and
5.0 to 5.6 Ω
Terminal 2
at 20 ℃ {68 °F}
Legend

1. -
2. +

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2) Inspect that clutch control solenoid (SL1, SL2, SL3, SL4) operates when the battery positive terminal is
connected to clutch control solenoid (SL1, SL2, SL3, SL4) positive terminal via the bulb (12-21W) and the
battery negative terminal is connected to the negative terminal.

Caution
Do not apply impact to the clutch control solenoid (SL1, SL2, SL3, SL4).
Do not damage the terminals.

Legend

1. -
2. +
3. Bulb (12 to 21 W)

3. Line pressure control solenoid (SLT) inspection

1) Measure the resistance between terminal 1 and terminal 2 of the line pressure control solenoid (SLT) using a
DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not impact the line pressure control solenoid (SLT).
Do not damage the terminals.
Do not remove the line pressure control solenoid (SLT) from the valve body assembly.

Line pressure control solenoid

(SLT)
Terminal name Resistance
Terminal 1 and
5.0 to 5.6 Ω
Terminal 2
at 20 ℃ {68 °F}

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Legend

1. -
2. +

2) Inspect that the solenoid operates when the battery positive terminal is connected to the line pressure control
solenoid (SLT) positive terminal via the bulb (12-21W) and the battery negative terminal is connected to the
negative terminal.

Caution
Do not impact the line pressure control solenoid (SLT).
Do not damage the terminals.
Legend

1. -
2. +

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3. Bulb (12 to 21 W)

4. Lock-up control solenoid (SLU) inspection

1) Measure the resistance between terminal 1 and terminal 2 of the Lock-up control solenoid (SLU) using a DMM.

Note
Check that resistances are as specified in the table.

Caution
Do not impact the lock-up control solenoid (SLU).
Do not damage the terminals.
Do not remove the lock-up control solenoid (SLU) from the valve body assembly.

Lock-up control solenoid (SLU)

Terminal name Resistance
Terminal 1 and
5.0 to 5.6 Ω
Terminal 2
at 20 ℃ {68 °F}
Legend

1. -
2. +

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2) Inspect that the solenoid operates when the battery positive terminal is connected to the lock-up control
solenoid (SLU) positive terminal via the bulb (12-21W) and the battery negative terminal is connected to the
negative terminal.

Caution
Do not impact the lock-up control solenoid (SLU).
Do not damage the terminals.

Legend

1. -
2. +
3. Bulb (12 to 21 W)
Transmission reassembly (AWR6B45)

1. Component views

Race and bearing specifications

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Race (Front) Bearing Race (Rear)

Outer Inner Outer Inner Outer Inner
diameter diameter diameter diameter diameter diameter
87.74 mm { 74.2 mm { 85.6 mm { 71.9 mm {
1 - -
3.4543 in } 2.921 in } 3.370 in } 2.831 in }
52.8 mm { 40.0 mm { 52.0 mm { 34.6 mm {
2 - -
2.079 in } 1.575 in } 2.047 in } 1.362 in }
41.1 mm { 21.3 mm { 44.8 mm { 22.6 mm {
3 - -
1.618 in } 0.839 in } 1.764 in } 0.890 in }
56.5 mm { 38.40 mm { 56.6 mm { 33.3 mm {
4 - -
2.224 in } 1.512 in } 2.228 in } 1.311 in }
52.8 mm { 39.6 mm { 52.8 mm { 40.83 mm {
5 - -
2.079 in } 1.559 in } 2.079 in } 1.6075 in }
61.2 mm { 37.1 mm { 62.8 mm { 44.0 mm {
6 - -
2.409 in } 1.461 in } 2.472 in } 1.732 in }
86.3 mm { 65.8 mm { 78.8 mm { 63.3 mm {
7 - -
3.398 in } 2.591 in } 3.102 in } 2.492 in }
78.9 mm { 66.3 mm { 78.8 mm { 63.3 mm {
8 - -
3.106 in } 2.610 in } 3.102 in } 2.492 in }
76.4 mm { 55.7 mm { 74.0 mm { 53.7 mm {
9 - -
3.008 in } 2.193 in } 2.913 in } 2.114 in }
49.0 mm { 33.4 mm { 49.35 mm { 32.1 mm { 49.0 mm { 32.1 mm {
10
1.929 in } 1.315 in } 1.9429 in } 1.264 in } 1.929 in } 1.264 in }
41.5 mm { 21.0 mm { 41.5 mm { 23.13 mm {
11 - -

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1.634 in } 0.827 in } 1.634 in } 0.9106 in }
61.0 mm { 43.55 mm { 67.1 mm { 47.1 mm {
12 - -
2.402 in } 1.7146 in } 2.642 in } 1.854 in }
51.2 mm { 37.0 mm { 52.5 mm { 36.1 mm { 51.0 mm { 36.1 mm {
13
2.016 in } 1.457 in } 2.067 in } 1.421 in } 2.008 in } 1.421 in }

Transmission case
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Part name

1. Torque converter assembly

2: 34 N・m { 3.5 kgf・m / 25 lb・ft }

3: 57 N・m { 5.8 kgf・m / 42 lb・ft }

6: 28 N・m { 2.9 kgf・m / 21 lb・ft }

9: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 13 N・m { 1.3 kgf・m / 115 lb・in }

14: 5 N・m { 0.5 kgf・m / 44 lb・in }

17: 40 N・m { 4.1 kgf・m / 30 lb・ft }

19: 5 N・m { 0.5 kgf・m / 44 lb・in }

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Part name

1. Manual shaft oil seal

Tightening torque

13: 18 N・m { 1.8 kgf・m / 13 lb・ft }

Transmission case adapter (4WD models)

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Part name

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

10: 34 N・m { 3.5 kgf・m / 25 lb・ft }

12: 7 N・m { 0.7 kgf・m / 62 lb・in }

Extension housing (2WD models)

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Part name

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

9: 34 N・m { 3.5 kgf・m / 25 lb・ft }

11: 7 N・m { 0.7 kgf・m / 62 lb・in }

Valve body assembly

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Part name

1. Temperature sensor clamp

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26. Bolt
27. Gasket

Tightening torque

3: 5 N・m { 0.5 kgf・m / 44 lb・in }

7: 10 N・m { 1.0 kgf・m / 89 lb・in }

9: 11 N・m { 1.1 kgf・m / 97 lb・in }

15: 10 N・m { 1.0 kgf・m / 89 lb・in }

17: 11 N・m { 1.1 kgf・m / 97 lb・in }

19: 10 N・m { 1.0 kgf・m / 89 lb・in }

23: 7 N・m { 0.7 kgf・m / 62 lb・in }

24: 20 N・m { 2.0 kgf・m / 15 lb・ft }

26: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Valve body assembly

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Part name

1. Valve body assembly

Gear train
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Part name

Tightening torque

1: 21 N・m { 2.1 kgf・m / 15 lb・ft }

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Part name

1. Thrust bearing race

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Part name

1. Thrust needle roller bearing with race

2. Plate stopper spring installation

1) Coat the bearing on the differential case with ATF.

2) Install the 2 brake plate stopper springs to the transmission case.

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3. Brake reaction sleeve installation

1) Coat the new 2 O-rings and inner brake piston No. 4 with ATF.

Caution
Do not reuse the O-ring.

2) Install them to inner brake piston No. 4.

O-ring
Inner diameter Thickness
67.35 mm { 2.62 mm { 0.1031
2.6516 in } in }
105.55 mm { 2.62 mm { 0.1031
4.1555 in } in }
3) Coat the new 2 O-rings with ATF.

Caution

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Do not reuse the O-ring.

4) Install them to the brake reaction sleeve.

O-ring
Inner diameter Thickness
79.1 mm { 3.1142 2.62 mm { 0.1031
in } in }
112.7 mm { 2.62 mm { 0.1031
4.4370 in } in }

5) Coat the sliding surface of the transmission case and the brake reaction sleeve and inner brake piston No. 4
with ATF.

6) Install inner brake piston No. 4 to the brake reaction sleeve.

Caution
Be careful not to damage the O-rings.

7) With inner brake piston No. 4 underneath (the rear side), install the brake reaction sleeve and brake piston No.

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4 to the transmission case.

Caution
Be careful not to damage the O-rings and the sliding surface of the transmission case.

4. 1st and reverse brake piston installation

1) Coat the new O-ring and the 1st and reverse brake piston with ATF.

Caution
Do not reuse the O-ring.

2) Install it to the 1st and reverse brake piston.

O-ring
Inner diameter Thickness
131.6 mm { 2.62 mm { 0.1031
5.1811 in } in }

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3) Install the 1st and reverse brake piston to the transmission case while making sure that the protrusion of the 1st
and reverse brake piston is positioned as shown in the figure.

Caution
Be careful not to damage the O-ring.

4) Install the 1st and reverse brake piston return spring sub-assembly to the transmission case.

Note
Place the 1st and reverse brake return spring sub-assembly onto the 1st and reverse brake piston.

5) Set the special tool on the 1st and reverse brake piston return spring sub-assembly, tighten the special tool and
compress the 1st and reverse brake piston return spring sub-assembly.

Caution
Be careful not to shorten the return spring too much.
SST: 5-8840-2966-0 - spring compressor

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6) Using snap ring pliers, install the snap ring in the groove.

Caution
Be careful not to expand the snap ring too much.

Legend

1. 5-8840-2966-0

5. Brake disc No.4 adjustment

1) Make sure that the 1st and reverse brake piston is pushed fully into the case.

2) Using vernier calipers, measure as shown in the illustration.

Caution
Measure the circumference of the 1st and reverse brake piston at three places, and make sure that
the average value is within the specified range.
If the average value is outside the specified range, reinstall the 1st and reverse brake piston, brake
reaction sleeve, and inner brake piston.

Standard: 32.07 to 32.81 mm { 1.2626 to 1.2917 in } Length A

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Legend

1. Transmission case
2. 1st and reverse brake piston

Standard value

a: 32.07 to 32.81 mm { 1.2626 to 1.2917 in } Length A

3) Stack the 7 discs and the 6 plates on top of the surface plate as shown in the illustration.

Note
Check the number and order of discs and plates.

4) With the disc pressed against the surface plate, measure as shown in the illustration using vernier calipers.

Check the measurement load.

3.92 to 4.9 N {0.40 to 0.50 kg / 0.88 to 1.10 lb}

Caution
Measure the facing of the disc at three places, and make sure that the average value is within the
specified range.

Standard: 29.94 to 30.96 mm { 1.1787 to 1.2189 in } Length B

Legend

1. Disc (7 pieces)

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2. Plate (6 pieces)
3. Flange
4. Surface plate

Standard value

a: 29.94 to 30.96 mm { 1.1787 to 1.2189 in } Length B

5) Using vernier calipers, measure brake flange No. 4 as shown in the illustration.

Note
Brake flange No. 4 comes in 11 types.

Standard: 0.00 to 1.43 mm { 0.0000 to 0.0563 in } Length C

Standard value

a: 0.00 to 1.43 mm { 0.0000 to 0.0563 in } Length C

6) Calculate the pack clearance from the measured value and the disc distortion compensation value (0.41 mm
{0.0161 in}).

Standard: 0.7 to 1.0 mm { 0.0276 to 0.0394 in } Pack clearance

No. 4 brake pack clearance = Length A - Length B - Length C - 0.41 mm {0.0161 in}

Caution
If the No. 4 brake pack clearance is not as specified, select an appropriate brake flange No. 4.

Brake flange No. 4

Mark Thickness
0 0 mm { 0 in }
1 0.17 mm { 0.0067 in }
3 0.31 mm { 0.0122 in }
4 0.45 mm { 0.0177 in }
5 0.59 mm { 0.0232 in }
7 0.73 mm { 0.0287 in }
8 0.87 mm { 0.0343 in }
10 1.01 mm { 0.0398 in }
11 1.15 mm { 0.0453 in }
12 1.29 mm { 0.0508 in }

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14 1.43 mm { 0.0563 in }

6. Rear planetary gear assembly installation

1) Coat the thrust bearing race with ATF and install it to the transmission case.

2) Coat the 2 thrust needle roller bearings with races and thrust bearing races with ATF and install them to the
rear planetary gear assembly.

3) Install the rear planetary gear assembly to the transmission case.

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Legend

1. Thrust bearing race

2. Thrust needle roller bearing with race
3. Thrust bearing race

4) Coat the thrust needle roller bearing and 2 thrust bearing races with ATF and install them to the rear planetary
gear assembly.

5) Using snap ring pliers, install the snap ring to the rear planetary gear assembly.
7. Rear planetary gear assembly adjustment

1. 2WD models

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1) Using a feeler gauge, measure the clearance between the snap ring and the thrust bearing race.

Caution
If the output shaft end play is not as specified, select an appropriate thrust bearing race.

Standard: 0.02 to 0.12 mm { 0.0008 to 0.0047 in }

Thrust bearing race size

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Dimensions

1. 3.80 mm {0.1496 in}

2. 3.85 mm {0.1516 in}
3. 3.90 mm {0.1535 in}
4. 3.95 mm {0.1555 in}
5. 4.00 mm {0.1575 in}
6. 4.05 mm {0.1594 in}
7. 4.10 mm {0.1614 in}
8. 4.15 mm {0.1634 in}
9. 4.20 mm {0.1654 in}
10. 4.25 mm {0.1673 in}
11. 4.30 mm {0.1693 in}
12. 4.35 mm {0.1713 in}

8. Brake disc No.4 installation

1) Install the 2 flanges, 7 discs and 6 plates to the transmission case as shown in the figure.

Note
Check the number and order of flange, discs and plates.
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Legend

1. Plate
2. Flange
3. Disc

9. Rear planetary ring gear installation

1) Coat the thrust needle roller bearing and thrust bearing race with ATF and install them to the intermediate shaft.

2) Install the intermediate shaft to the transmission case.

3) Coat the thrust bearing race with ATF and install it to the rear planetary ring gear flange with the rear planetary
ring gear.

4) Install the rear planetary ring gear flange with rear planetary ring gear to the transmission case.

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10. 1way clutch No.3 installation

1) Coat the 1 way clutch inner race and the 1 way clutch assembly No. 3 with ATF.

2) Install it to 1 way clutch assembly No. 3.

Note
Rotate the 1 way clutch inner race clockwise to install it.

3) Install 1 way clutch assembly No. 3 with the 1 way clutch inner race to the transmission case.
4) Using the special tool, install the snap ring to the transmission case.

Caution

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Install the snap ring so that the tapered side is facing out.
Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the
figure.

SST: 5-8840-2961-0 - snap ring pliers

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Legend

1. 5-8840-2961-0

11. Brake piston No.1 installation

1) Install brake cylinder No. 1 with brake piston No. 1 to the transmission case while making sure that the 2 claws
of brake cylinder No. 1 with brake piston No. 1 are positioned as shown in the figure.

2) Align the 2 claws of brake piston return spring sub-assembly No. 1 with the 2 claws of brake cylinder No. 1, and
then install the brake piston return spring sub-assembly No. 1 to brake piston No. 1.
3) Place the special tool on brake piston return spring sub-assembly No. 1, and compress the brake piston return
spring sub-assembly No. 1 with a shop press.

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Note
Place the special tool on the surface with protrusions.

Caution
Be careful not to shorten the return spring too much.

SST: 5-8840-2973-0 - spring compressor kit

SST: 5-8840-2962-0 - oil seal installer

SST: 5-8840-3199-0 - spring compressor

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Legend

1. 5-8840-2973-0
2. 5-8840-2962-0
3. 5-8840-3199-0

4) Using a screwdriver, install the snap ring to the transmission case.

Caution
Be careful not to damage the transmission case.
Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the
figure.
12. Brake disc No.1 adjustment

1) Install the snap ring to the transmission case.

2) With the snap ring pulled up on the converter housing side, measure as shown in the illustration using vernier
calipers.

Standard: 26.27 to 26.99 mm { 1.0342 to 1.0626 in } Length A

Caution
Measure the circumference of the transmission case at three places, and make sure that the average
value is within the specified range.
If the average value is outside the specified range, reinstall brake cylinder No. 1 with brake piston No.
1.

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Legend

1. Snap ring
2. Transmission case
3. Brake cylinder No. 1

Standard value

a: 26.27 to 26.99 mm { 1.0342 to 1.0626 in } Length A

3) Stack the flange, the 4 discs, and the 4 plates on top of the surface plate as shown in the illustration.

Note
When not replacing the disc and plate, use the installed flange.
When using a new disc and plate, use a 5.3 mm {0.2087 in} flange.
Check the number and order of flange, discs and plates.

4) With the flange pressed against the surface plate, measure as shown in the illustration using vernier calipers.

Check the measurement load.

3.92 to 4.9 N {0.40 to 0.50 kg / 0.88 to 1.10 lb}

Caution
Measure the circumference of the flange at three places, and make sure that the average value is
within the specified range.

Standard: 22.43 to 23.00 mm { 0.8831 to 0.9055 in } Length B

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Legend

1. Flange (1 piece)
2. Disc (4 pieces)
3. Plate (4 pieces)
4. Surface plate

Standard value

a: 22.43 to 23.00 mm { 0.8831 to 0.9055 in } Length B

5) Calculate the pack clearance from the measured value, the disc distortion compensation value 0.24 mm {0.009
in}, and the snap ring thickness 3.0 mm {0.118 in}.

Standard: 0.40 to 0.70 mm { 0.0157 to 0.0276 in } Pack clearance

No. 1 brake pack clearance = Length A - Length B - 0.24 mm {0.009 in} - 3.0 mm {0.118 in}

Caution
If the No. 1 brake pack clearance is not as specified, select an appropriate brake flange No. 1.

Brake flange No. 1

Mark Thickness
0 4.9 mm { 0.1929 in }
1 5.0 mm { 0.1969 in }
2 5.1 mm { 0.2008 in }
3 5.2 mm { 0.2047 in }
4 5.3 mm { 0.2087 in }
5 5.4 mm { 0.2126 in }
6 5.5 mm { 0.2165 in }
7 5.6 mm { 0.2205 in }
8 5.7 mm { 0.2244 in }
A 5.8 mm { 0.2283 in }

13. Brake disc No.1 installation

1) Install the flange, 4 discs and 4 plates to the transmission case as shown in the figure.

Note
Check the number and order of flange, discs and plates.

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Legend

1. Flange
2. Disc
3. Plate

2) Using a screwdriver, install the snap ring to the transmission case.

Caution
Be careful not to damage the transmission case.
Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the
figure.
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14. Planetary sun gear installation

1) Install the planetary sun gear to the transmission case.

15. Middle planetary gear assembly installation

1) Coat the thrust bearing race with ATF and install it to the middle planetary gear assembly.

2) Install the middle planetary gear assembly to the transmission case.

16. Middle planetary ring gear installation

1) Coat the thrust needle roller bearing and thrust needle roller bearing with race with ATF and install them to the

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middle planetary ring gear flange with middle planetary ring gear.

2) Install the middle planetary ring gear flange with the middle planetary ring gear to the transmission case.

Legend

1. Thrust needle roller bearing

2. Thrust needle roller bearing with race

17. Brake disc No.2 adjustment

1) Install the snap ring to the transmission case.

2) With the snap ring pulled up on the converter housing side, measure as shown in the illustration using vernier
calipers.

Note
Measure 3 locations and use the average value.

Caution
Be careful not to expand the snap ring too much.

Standard: 59.72 to 59.88 mm { 2.3512 to 2.3575 in } Length A

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Legend

1. Snap ring
2. Transmission case

Standard value

a: 59.72 to 59.88 mm { 2.3512 to 2.3575 in } Length A

3) Make sure that brake piston No. 2 is pushed fully into brake cylinder No. 2.

4) Using vernier calipers, measure as shown in the illustration.

Standard: 28.22 to 28.54 mm { 1.1110 to 1.1236 in } Length B

Caution
Measure the circumference of brake cylinder No. 2 with brake piston No. 2 at three places, and make
sure that the average value is within the specified range.
If the average value is outside the specified range, reinstall brake cylinder No. 2 with brake piston No.
2.
Legend

1. Brake cylinder No. 2

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2. Brake piston No. 2

Standard value

a: 28.22 to 28.54 mm { 1.1110 to 1.1236 in } Length B

5) Stack the flange, the 5 discs, and the 5 plates on top of the surface plate as shown in the illustration.

Note
When not replacing the disc and plate, use the installed flange.
When using a new disc and plate, use a 2.4 mm {0.0945 in} flange.
Check the number and order of flange, discs and plates.

6) With the flange pressed against the surface plate, measure as shown in the illustration using vernier calipers.

Check the measurement load.

3.92 to 4.9 N {0.40 to 0.50 kg / 0.88 to 1.10 lb}

Caution
Measure the circumference of the flange at three places, and make sure that the average value is
within the specified range.

Standard: 26.06 to 26.71 mm { 1.0260 to 1.0516 in } Length C

Legend

1. Flange for adjustment (1 piece)

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2. Disc (5 pieces)
3. Plate (4 pieces)
4. Flange (1 piece)
5. Surface plate

Standard value

a: 26.06 to 26.71 mm { 1.0260 to 1.0516 in } Length C

7) Calculate the pack clearance from the measured value, the disc distortion compensation value 0.37 mm
{0.0146 in}, and the snap ring thickness 4.0 mm {0.1575 in}.

Standard: 0.50 to 0.80 mm { 0.0197 to 0.0315 in } Pack clearance

No. 2 brake pack Clearance = Length A - Length B - Length C - 0.37 mm {0.0146 in} - 4.0 mm {0.1575 in}

Caution
If the No. 2 brake pack clearance is not as specified, select an appropriate brake flange No. 2.

Brake flange No. 2

Mark Thickness
0 2.0 mm { 0.0787 in }
1 2.1 mm { 0.0827 in }
2 2.2 mm { 0.0866 in }
3 2.3 mm { 0.0906 in }
4 2.4 mm { 0.0945 in }
5 2.5 mm { 0.0984 in }
6 2.6 mm { 0.1024 in }
7 2.7 mm { 0.1063 in }
8 2.8 mm { 0.1102 in }

18. Brake disc No.2 installation

1) Install the 4 plates, 5 discs and the 2 flanges to the transmission case as shown in the figure.

Note
Check the number and order of flange, discs and plates.

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Legend

1. Plate
2. Flange
3. Disc

19. Brake piston No.2 installation

1) Install brake piston return spring sub-assembly No. 2 to the transmission case while making sure that the claw
of the brake piston return spring sub-assembly is positioned as shown in the figure.
2) Install brake cylinder No. 2 with brake piston No. 2 to the transmission case while making sure that the claw of
brake cylinder No. 2 with brake piston No. 2 is positioned as shown in the figure.

Note
Align the brake piston No. 2 oil hole and the transmission case oil hole.

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Legend

1. Oil hole

3) Place the special tool on brake cylinder No. 2 with brake piston No. 2, and compress the brake piston return
spring sub-assembly with a shop press.

Caution
Be careful not to shorten the return spring too much.
Be careful not to damage brake cylinder No. 2.

SST: 5-8840-2971-0 - spring compressor

SST: 5-8840-2973-0 - spring compressor kit

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Legend

1. 5-8840-2973-0
2. 5-8840-2971-0

4) Using a screwdriver, install the snap ring to the transmission case.

Caution
Be careful not to damage the transmission case.
Be sure to install the snap ring so that the ends of the snap ring are within the area shown in the
figure.
20. Front planetary ring gear installation

1) Coat the thrust needle roller bearing with race and thrust bearing race with ATF and install them to the front
planetary ring gear with front planetary ring gear flange sub-assembly.

2) Install the front planetary ring gear with front planetary ring gear flange sub-assembly to the transmission case.

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Legend

1. Thrust needle roller bearing with race

2. Thrust bearing race

21. Front planetary gear assembly installation

1) Coat the 2 thrust bearing races with ATF and install them to the front planetary gear assembly.

2) Install the front planetary gear assembly to the transmission case.

22. Sun gear input drum installation

1) Coat the thrust needle roller bearing with race and thrust bearing race with ATF and install them to the sun gear
input drum.

2) Install the sun gear input drum to the transmission case.

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Legend

1. Thrust needle roller bearing with race

2. Thrust bearing race

23. Forward clutch assembly installation

1) Coat the 2 thrust needle roller bearings with ATF and install them to the forward clutch hub sub-assembly.

2) Install the clutch hub sub-assembly to the transmission case.

3) Coat the 2 thrust bearing races with ATF and install them to the forward clutch hub.

4) Install the forward clutch hub to the transmission case.

5) Coat the 2 thrust needle roller bearings with races with ATF and install them to the forward clutch assembly
(input shaft).

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6) Install the forward clutch assembly (input shaft) to the transmission case.

7) Coat the thrust needle roller bearing with race with ATF and install it to the direct clutch assembly.

8) Install the direct clutch assembly to the transmission case.

24. Oil pump installation

1) Coat the 2 thrust bearing races with ATF and install them to the oil pump assembly.

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2) Set the oil pump assembly on the C-2 clutch drum sub-assembly, and align the bolt holes of the oil pump
assembly with the transmission case.

Caution
Be careful not to damage the seal rings and transaxle oil seal ring.

3) Temporarily install the oil pump assembly to the transmission case.

4) Install the oil pump assembly with the 10 bolts.

Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft }

25. Manual shaft oil seal installation

1) Coat the lip of the 2 new manual shaft oil seals with grease.

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Caution
Do not reuse the oil seal.

2) Using the special tool and a hammer, install the 2 new manual shaft oil seals to the transmission case.

-0.5 to 0.5 mm { -0.020 to 0.020 in } Press-fitting depth (From the end of the transmission case)

Caution
Be careful not to damage the manual valve lever shaft oil seal.
Be careful not to damage the transmission case.
Be careful not to damage the manual valve lever shaft.

SST: 5-8840-2169-0 - oil seal installer

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Legend

1. 5-8840-2169-0

26. Manual valve lever installation

1) Install a new spacer to the manual valve lever.

Caution
Do not reuse the spacer.

2) Install the manual valve lever shaft to the transmission case through the manual valve lever.
3) Using a pin punch (3 mm {0.118 in}) and hammer, tap in a new spring pin.

Caution

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Do not reuse the spring pin.

4) Align the manual valve lever indentation with the spacer hole, and stake them together with a punch.

5) Make sure that the shaft rotates smoothly.

Legend

1. Spring pin

27. Parking lock pawl shaft installation

1) Install the snap ring to the parking lock pawl shaft.

2) Install the parking lock pawl and the parking lock pawl shaft to the transmission case.

3) Install the torsion spring to the parking lock pawl shaft.

Caution
Be careful not to apply too much force to the spring.

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28. Parking lock rod installation

1) Connect the parking lock rod to the manual valve lever.

29. Parking lock pawl bracket installation

1) Place the parking lock pawl bracket and parking lock pawl onto the transmission case.

2) Install the 3 bolts.

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }

30. Brake drum gasket installation

1) Coat the 2 new brake drum gaskets with ATF.

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Caution
Do not reuse the gasket.

2) Install 2 new brake drum gaskets to the transmission case.

Note
Install the brake drum gasket metal side facing outward.

3) Coat the 2 new transmission case gaskets with ATF.

Caution
Do not reuse the gasket.

4) Install 2 new transmission case gaskets to the transmission case.

31. Valve body assembly installation

1) Insert the manual valve lever into the groove on the end of the manual valve.

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2) Install the valve body assembly with the new 12 bolts to the transmission case.

Caution
Do not reuse the bolt.

Tightening torque: 11 N・m { 1.1 kgf・m / 97 lb・in }

Legend

1. M6 x 1.0 x 25 mm {0.98 in}

2. M6 x 1.0 x 36 mm {1.42 in}
3. M6 x 1.0 x 50 mm {1.97 in}

32. Detent spring installation

1) Install the detent spring and detent spring cover with the bolt to the transmission case.
Caution
Make sure to align the center of the detent spring roller with the center of the manual valve lever.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

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33. Oil strainer installation

1) Coat a new O-ring with ATF, and install it to the oil strainer.

Caution
Do not reuse the O-ring.

O-ring
Inner diameter Thickness
27.73 mm { 2.62 mm { 0.1031
1.0917 in } in }

2) Install the oil strainer with the 3 bolts to the valve body assembly.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

34. Transmission internal harness installation

1) Coat a new O-ring with ATF, and install it to the transmission wire.

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Caution
Do not reuse the O-ring.

O-ring
Inner diameter Thickness
36.8 mm { 1.4488 2.4 mm { 0.0945
in } in }

2) Install the transmission wire to the transmission case with the bolt.

Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }

3) Connect the 8 solenoid connectors.

4) Install the 2 oil temperature sensors (OT1, OT2) and 2 temperature sensor clamps to the valve body assembly
with the 2 bolts.
Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in } M6 x 1.0 x 14 mm {0.55 in}

Tightening torque: 11 N・m { 1.1 kgf・m / 97 lb・in } M6 x 1.0 x 36 mm {1.42 in}

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Legend

1. Temperature sensor (OT1)

2. M6 x 1.0 x 14 mm {0.55 in}
3. Temperature sensor (OT2)
4. M6 x 1.0 x 36 mm {1.42 in}

35. Oil pan installation

1) Clean the transmission oil pan sub-assembly.

2) Install the 4 oil cleaner magnets to the transmission oil pan sub-assembly.

Note
Clean the oil cleaner magnet before installing it.

3) Clean oil off the oil pan gasket fitting surface of the transmission case and the 10 bolt holes.
Note
Completely remove oil with white gasoline or similar.

4) Install a new oil pan gasket and the transmission oil pan sub-assembly to the transmission case.

Caution
Do not reuse the oil pan gasket.
Be careful not to damage the fitting surfaces of the transmission case and the transmission oil pan
sub-assembly.
Be careful not to deform the transmission oil pan sub-assembly.

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Legend

1. Correct
2. Incorrect
3. Protrusion
4. Sleeve

5) Install the 10 bolts to the transmission case.

Caution
Make sure that there is no oil or foreign matter on the oil pan gasket seal surface and transmission oil
pan sub-assembly contact surface.
Install the oil pan gasket so that there is no slack in the oil pan gasket, and that the seal surface's
entire circumference is level.
Make sure that the oil pan gasket drop prevention protrusions are set on the transmission oil pan
sub-assembly.
When tightening the transmission oil pan sub-assembly, make sure that the oil pan gasket is not
pinched between the oil pan gasket tightening area's sleeve and the transmission case seal surface.
Tightening torque: 7 N・m { 0.7 kgf・m / 62 lb・in }

36. Converter housing installation

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1) Clean sealant and oil off the converter housing contact surface of the transmission case and the 12 bolt holes.

Note
Completely remove sealant and oil with white gasoline or similar.

2) Install the converter housing to the transmission case.

Note
Hit all around the contact surface with a plastic hammer during installation.

Caution
Be careful not to damage the fitting surface of the converter housing and the transmission case.

3) Temporarily tighten the 12 bolts by hand as shown in the figure.

Note
The number shown in the figure indicates the kind of bolts.
Legend

1. M10 x 1.5 x 35 mm {1.38 in}

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2. M10 x 1.5 x 35 mm {1.38 in} (Seal bolt)
3. M12 x 1.75 x 38 mm {1.50 in} (Seal bolt)

4) Tighten the 12 bolts in the order shown in the figure.

Caution
Be sure to tighten bolts (M10 x 1.5 x 35 mm {1.38 in}) before tightening bolts (M10 x 1.5 x 35 mm {1.38
in} (Seal bolt) and M12 x 1.75 x 38 mm {1.50 in} (Seal bolt)).
Be sure to tighten bolts (M10 x 1.5 x 35 mm {1.38 in}) evenly and gradually, in a diagonally opposing
sequence.

Tightening torque: 34 N・m { 3.5 kgf・m / 25 lb・ft } M10 bolt

Tightening torque: 57 N・m { 5.8 kgf・m / 42 lb・ft } M12 bolt

37. Adapter housing bearing installation

1. 4WD models
1) Using special tool and a press, install the new transmission case adapter bearing to the transmission case
adapter.

Note
Use driver tool set No. 70.
Face the surface that the balls can be seen towards the case side and install.
Press-fit the adapter housing bearing until it makes contact with the transmission case adapter.

Caution
Do not reuse the adapter housing bearing.
Be careful not to damage the transmission case adapter.

SST: 5-8840-2863-0 - driver tool set

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Legend

1. 5-8840-2863-0

2) Using snap ring pliers, install the snap ring to the transmission case adapter.

Caution
Be careful not to damage the transmission case adapter.
38. Rear oil seal installation

1. 4WD models

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1) Coat the lip of the new transmission case adapter oil seal with grease.

Caution
Do not reuse the oil seal.

2) Using the special tool and a hammer, install the new transmission case adapter oil seal to the transmission
case adapter.

1.5 to 2.5 mm { 0.059 to 0.098 in } Press-fitting depth (From the end of the transmission case adapter)

Caution
Be careful not to damage the transmission case adapter oil seal.
Be careful not to damage the transmission case adapter.

SST: 5-8840-2964-0 - oil seal installer

Legend

1. 5-8840-2964-0

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2. 2WD models

1) Coat the lip of the new extension housing oil seal with grease.

Caution
Do not reuse the oil seal.

2) Using the special tool and a hammer, install the new extension housing oil seal to the extension housing.

5.4 to 5.8 mm { 0.213 to 0.228 in } Press-fitting depth (From the end of the extension housing)

Caution
Be careful not to damage the extension housing oil seal.
Be careful not to damage the extension housing.

SST: 5-8840-2964-0 - oil seal installer

Legend

1. 5-8840-2964-0

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39. Adapter housing installation

1. 4WD models

1) Clean sealant and oil off the transmission case adapter contact surface of the transmission case and the 10
bolt holes.

Note
Completely remove sealant and oil with white gasoline or similar.

2) Apply formed in place gasket to the transmission case adapter as shown in the figure.

Note
Spread formed in place gasket over the contact surface.

3) Install the transmission case adapter with the new 10 bolts to the transmission case.
Caution
Do not reuse the bolt.

Tightening torque: 34 N・m { 3.5 kgf・m / 25 lb・ft }

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40. Extension housing assembly installation

1. 2WD models

1) Clean sealant and oil off the extension housing contact surface of the transmission case and the 8 bolt holes.

Note
Completely remove sealant and oil with white gasoline or similar.

2) Apply formed in place gasket to the extension housing in the figure.

Note
Spread formed in place gasket over the contact surface.

3) Install the extension housing with the new 8 seal bolts to the transmission case.
Caution
Do not reuse the bolt.

Tightening torque: 34 N・m { 3.5 kgf・m / 25 lb・ft }

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Legend

1. M10 x 1.5 x 45 mm {1.77 in} (Seal bolt)

2. M10 x 1.5 x 40 mm {1.57 in} (Seal bolt)

41. Deflector installation

1. 2WD models

1) Using a plastic hammer, install the extension housing dust deflector to the extension housing.

Note
Press-fit the deflector until it makes contact with the extension housing.

Caution
Be careful not to damage the extension housing oil seal.
Be careful not to deform the extension housing.

SST: 5-8840-2965-0 - deflector installer

Legend

1. 5-8840-2965-0

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42. Elbow installation

1) Coat the 2 new O-rings with ATF, and install them to the 2 elbows.

Caution
Do not reuse the O-ring.

O-ring
Inner diameter Thickness
11.68 mm { 1.98 mm { 0.0780
0.4598 in } in }

2) Install the 2 elbows to the transmission case.

Caution
The installation angle of the elbow should be as shown in the diagram.

Tightening torque: 29 N・m { 3.0 kgf・m / 21 lb・ft }

Standard value

a: 18 to 22 °

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b: -2 to 2 °

43. Test plug installation

1) Coat the 6 new O-rings with ATF, and install them to the 6 test plugs.

Caution
Do not reuse the O-ring.

O-rings
Inner diameter Thickness
6.07 mm { 0.2390 1.78 mm { 0.0701
in } in }

2) Install the 6 test plugs to the transmission case.

Tightening torque: 7 N・m { 0.7 kgf・m / 62 lb・in }

44. Transmission case plug installation

1) Coat a new O-ring with ATF, and install it to the transmission case plug.

Caution
Do not reuse the O-ring.

O-ring
Inner diameter Thickness
11.68 mm { 1.98 mm { 0.0780
0.4598 in } in }

2) Using a torx wrench (T55), install the transmission case plug to the transmission case.

Tightening torque: 39 N・m { 4.0 kgf・m / 29 lb・ft }

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45. Breather hose installation

1) Coat a new O-ring with ATF, and install it to the breather plug.

Caution
Do not reuse the O-ring.

O-ring
Inner diameter Thickness
8.2 mm { 0.3228 1.9 mm { 0.0748
in } in }

2) Install the breather hose to the breather plug.

3) Install the breather plug and the breather hose to the transmission case.
46. Output speed sensor installation

1) Install the output speed sensor to the transmission case.

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Caution
Be careful not to damage the output speed sensor.

Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }

47. Turbine speed sensor installation

1) Install the turbine speed sensor to the transmission case.

Caution
Be careful not to damage the turbine speed sensor.

Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }

48. Inhibitor switch installation

1) Install the inhibitor switch onto the manual valve lever shaft and temporarily install the bolt.

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Note
Tighten the bolt after adjusting the inhibitor switch to the N position.

2) Install the new lock washer with the new nut to the inhibitor switch.

Caution
Do not reuse the lock washers and nuts.

Tightening torque: 7 N・m { 0.7 kgf・m / 62 lb・in }

3) Using a screwdriver, stake the lock washer.

4) Adjust the manual valve lever shaft to the N position.

5) Align the groove and neutral basic line.

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6) Hold in position and tighten the bolt.

Tightening torque: 13 N・m { 1.3 kgf・m / 115 lb・in }

Legend

1. Neutral basic line

2. Groove

49. Torque converter assembly installation

1) Using a screwdriver, position the drive gear on the oil pump assembly in the center. Then install the torque
converter assembly on the transmission case.

Caution
Be careful not to damage the oil pump oil seal.
Be careful not to drop the torque converter assembly.

Warning
Be careful not to pinch fingers.

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2) Measure the dimension from the end face of the converter housing to the torque converter assembly as shown
in the figure, and check that the torque converter assembly is installed properly.

Over than

42.5 mm { 1.6732 in }
Transmission installation (AWR6B45)

1. Cushion rubber installation

1. 4WD models

1) Install the cushion rubber to the transmission.

Caution
Mark to be on the rear side of vehicle.

Tightening torque: 97 N・m { 9.9 kgf・m / 72 lb・ft }

4JJ1 equipped models

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Legend

1. Mark

RZ4E-TC equipped models

Legend

1. Mark

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2. 2WD models

1) Install the rear engine mounting bracket to the transmission.

2) Temporarily tighten the mounting bolt of the rear engine mounting bracket.

3) Final tighten the mounting bolt of the rear engine mounting bracket in the order shown in the diagram.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

4) Install the cushion rubber to the rear engine mounting bracket.

Caution
Mark to be on the rear side of vehicle.

Tightening torque: 97 N・m { 9.9 kgf・m / 72 lb・ft }

4JJ1 equipped models

Legend

1. Mark

RZ4E-TC equipped models

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Legend

1. Mark

2. Transmission installation

1) Slowly operate the transmission jack so that the front of transmission aligns with the rear of the engine.

2) Slowly operate the transmission jack so that the transmission becomes parallel to the engine.

3) Install the transmission to the engine.

Note
Tighten the transmission installation nut and bolt.

Tightening torque: 76 N・m { 7.7 kgf・m / 56 lb・ft }

RZ4E-TC equipped models

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Dimensions

a: 50 mm { 1.97 in }

b: 35 mm { 1.38 in }

c: 18 mm { 0.71 in }

d: 15 mm { 0.59 in }

e: 40 mm { 1.57 in }

f: 21 mm { 0.83 in }

g: 30 mm { 1.18 in }

h: 25 mm { 0.98 in }

i: 29 mm { 1.14 in }

j: 19 mm { 0.75 in }

k: 2 mm { 0.08 in }
l: 100 mm { 3.94 in }

m: 44.5 mm { 1.75 in }

n: 24 mm { 0.94 in }

o: 26 mm { 1.02 in }

p: 11.7 mm { 0.46 in }

q: 20 mm { 0.79 in }

r: 17 mm { 0.67 in }

4JJ1 equipped models

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Dimensions

a: 26 mm { 1.02 in }

b: 50 mm { 1.97 in }

c: 14.5 mm { 0.57 in }

d: 18 mm { 0.71 in }
e: 4.5 mm { 0.18 in }

f: 29 mm { 1.14 in }

g: 12.5 mm { 0.49 in }

h: 2 mm { 0.08 in }

i: 60 mm { 2.36 in }

j: 12 mm { 0.47 in }

k: 3.2 mm { 0.13 in }

l: 32 mm { 1.26 in }

m: 15 mm { 0.59 in }

n: 22 mm { 0.87 in }

o: 15.5 mm { 0.61 in }

p: 14 mm { 0.55 in }

q: 19 mm { 0.75 in }

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r: 17.5 mm { 0.69 in }

s: 20 mm { 0.79 in }

t: 27 mm { 1.06 in }

u: 17 mm { 0.67 in }

3. Transmission crossmember installation

1) Install the transmission crossmember to the frame.

Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }

2) Connect the cushion rubber to the transmission crossmember.

Tightening torque: 140 N・m { 14.3 kgf・m / 103 lb・ft }

3) Install the brace to the frame and transmission crossmember.

Tightening torque: 106 N・m { 10.8 kgf・m / 78 lb・ft }

4) Remove the jack from the transmission.

5) Remove the wire from the engine hanger and the hoist.

6) Remove special tool from the cylinder head.

4. Torque converter connect

1) Install the flexible plate bolt to the torque converter in the order shown in the diagram.

Note
Temporarily tighten the 1st bolt of the installation order as shown in the diagram, and then final
tighten the 2nd to 6th bolt of the installation order.
Final tighten the 1st bolt of the installation order as shown in the diagram.

Caution
Do not reuse the flexible plate bolts.

Tightening torque: 54 N・m { 5.5 kgf・m / 40 lb・ft }

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2) Install the lower cover to the transmission in the order shown in the diagram.

Note
The lower cover does not have a back/front direction.

Tightening torque: 9 N・m { 0.9 kgf・m / 80 lb・in }

5. Automatic transmission control cable connect

1) Install the automatic transmission control cable bracket to the transmission.

2) Connect the automatic transmission control cable to the select lever.

6. Automatic transmission control cable adjustment

Caution
Adjust the automatic transmission control cable when replacing the automatic transmission control
cable.

1) Check that the selector lever is in the N position.

2) Check that the transmission is in the N position.

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Legend

1. P
2. R
3. N
4. D

3) Slide the cover in the direction indicated by the arrow.

Legend

1. Cover

4) Use an ordinary screwdriver to move the lock piece from the position indicated by the arrow.
5) Continue to move the lock piece until the adjuster position begins to change.

Legend

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1. Adjuster
2. Lock piece

6) Insert the lock piece to the adjuster.

7) Slide the cover on the adjuster and secure lock piece.

Legend

1. Cover

8) Connect the automatic transmission control cable to the select control lever.

9) Press the select lever knob button 5 times, and then check that the select lever moves smoothly to each of its
positions.

10) Check that the shift position indicated by the selector lever and the actual shift position are the same.
7. ATF cooler pipe connect

1. RZ4E-TC equipped models

1) Connect the ATF cooler pipe to the transmission.

Note
After temporally tightening the flare nut, tighten it to the specified torque.

Tightening torque: 45 N・m { 4.6 kgf・m / 33 lb・ft }

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Legend

1. OUT side
2. IN side

2. 4JJ1 equipped models

1) Connect the ATF cooler pipe to the transmission.

Note
After temporally tightening the flare nut and the bolt of the clip, tighten them to the specified torque.

Tightening torque: 45 N・m { 4.6 kgf・m / 33 lb・ft } Flare nut

Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } Bolt

Legend

1. OUT side

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2. IN side

8. Starter motor installation

Refer to "1.Engine 1J.Electrical(4JJ1 without DPD) starter motor installation".

9. Transfer installation

1. 4WD models

1) When replacing the following parts with new ones, refer to the diagram to press-fit the dowel pin to the transfer.

Transfer
Transfer case

Caution
If the dowel pin is not press-fitted, press-fit the dowel pin to the transfer side.
Legend

a: 9 mm { 0.35 in }

2) Apply BESCO L-2 grease or equivalent to the input shaft spline section.

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3) Install the transfer assembly to the transmission.

Caution
When assembling the transfer to the transmission, check that the dowel pins (2 pcs.) are press-fitted
to the transfer side.

Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

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Dimensions

a: 20 mm { 0.79 in }

b: 9 mm { 0.35 in }

c: 11 mm { 0.43 in }

d: 45 mm { 1.77 in }

e: 25 mm { 0.98 in }

f: 20 mm { 0.79 in }

10. Engine harness connect

1. 4WD models

1) Connect the connectors of the following parts to the engine harness.

Turbine speed sensor connector

Transmission internal harness connector
Output speed sensor connector
Inhibitor switch connector
2-4 switch connector
Neutral switch connector
Actuator connector

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Legend

1. Turbine speed sensor connector

Legend

1. Output speed sensor connector

2. Transmission internal harness connector
3. Inhibitor switch connector
Legend

1. Neutral switch connector

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2. 2-4 switch connector
3. Actuator connector

2) Connect the clips.

2. 2WD models

1) Connect the connectors of the following parts to the engine harness.

Turbine speed sensor connector

Transmission internal harness connector
Output speed sensor connector
Inhibitor switch connector
Legend

1. Turbine speed sensor connector

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Legend

1. Output speed sensor connector and clip

2. Transmission internal harness connector
3. Inhibitor switch connector

2) Connect the clips.

RZ4E-TC equipped models

4JJ1 equipped models

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11. Front propeller shaft installation

1. 4WD models

Refer to "3.Driveline, Axle 3C.Drive Shaft System front propeller shaft installation".

12. Rear propeller shaft installation

Refer to "3.Driveline, Axle 3C.Drive Shaft System rear propeller shaft installation".

13. Cowl panel installation

1) Install the cowl panel to vehicle.

14. Wiper linkage installation

Refer to "9.Body, Cab, Accessories 9B.Wiper, Washer Systems wiper linkage installation".

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15. Engine cover installation

1) Install the engine cover to the engine.

Legend

1. Engine cover

16. Engine hood installation

1) Align the engine hood with the marking position placed during removal, and temporarily secure.

2) Adjust the clearance between the engine hood and the fender to the standard value.
Dimensions

a. Clearance: 4.0 mm {0.16 in}

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b. Height, level difference: -1.5 mm ｛-0.06 in｝

3) Final tighten the hinge bolt to the engine hood.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

17. Engine hood adjustment

1) Turn the hood rest to adjust its height, and adjust the level difference against the engine hood.

Legend

1. Hood rest

18. Preliminary and post procedures

1. Post procedures
1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

19. ATF filling

If the transmission has been disassembled

1) Clean the drain plug.

2) Install a new gasket and the drain plug to the oil pan.

Caution
Do not reuse the gasket.

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Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

3) Remove the filler plug and O-ring from the transmission.

O-ring
Inner diameter Thickness
15.41 mm { 0.61 2.20 mm { 0.09 in
in } }

4WD
2WD

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4) Replenish the transmission with the ATF.

Caution
When Replenishing ATF, always perform the oil level adjustment using the overflow hole.

9.5 L { 2.51 US gal / 2.09 Imp.gal } Oil capacity [reference value]

Note
The volume of oil cooler on the vehicle side is contained.

20. ATF adjustment

1. ATF adjustment

1) Connect a jumper between the terminals No.12 and No.4 (or No.5) of the DLC to short the TCM.

Note
Check whether the check trans warning light flashes when the DLC is short-circuited.
2) Start the engine.

3) Move the select lever through each gear range, pausing for more than 2 seconds in each range to fill the
hydraulic circuit. Repeat the same manner 2 times, and then move the select lever in P range.

Hold 2 sec. on each range (2 times).

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4) Operate the oil level adjustment control in order to switch the illumination temperature of the automatic
transmission fluid warning light.

Note
Move the select lever back and forth between N range and D range within 1.5 seconds. Repeat it for at
least 6 seconds until the automatic transmission fluid warning light turns ON in N range.

5) When the oil level adjustment control is activated, the automatic transmission fluid warning light will be
illuminated for 2 seconds in N range. Keep the select lever in N range.

After activating the oil level adjustment control, the automatic transmission fluid warning light will operate
according to the ATF temperature condition.

Operating temperature of the

automatic transmission fluid
warning light at activating the oil
level adjustment control
OFF 40 ℃ { 104 °F } or less
41 to 50 ℃ { 106 to 122
Illuminated
°F }
Flashing 51 ℃ { 124 °F } or more

Caution
If the automatic transmission fluid warning light flashes, the ATF temperature exceeds the oil level
adjustment temperature. After the ATF is cooled, perform the procedure again from the beginning.
Also, the level cannot be adjusted with the stable oil level if it continues to illuminate after
illuminating for 2 seconds. Therefore, perform the procedures from the beginning after the ATF is
cooled.

6) Perform the temperature up until the automatic transmission fluid warning light turns ON so that the ATF

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temperature reaches the oil level adjustment temperature.

Note
Change to D range to raise the temperature up to the oil level adjustment temperature, depress the
accelerator, and keep at 1000 rpm for 5 seconds. Then immediately return to idling, change to the N
range, and check the automatic transmission fluid warning light.

7) Retain idling in the N range after the automatic transmission fluid warning light illuminates, and check that it
continues to illuminate for 1 minute or more.

Standard: 750 rpm Idling speed (RZ4E-TC equipped models)

Standard: 700 rpm Idling speed (4JJ1 equipped models)

Note
If the automatic transmission fluid warning light does not illuminate or if it turns OFF within 1 minute,
temperature rise is insufficient, so repeat the temperature raising operation.

Caution
Operating the select lever with the overflow plug removed changes the oil level and the ATF may drip,
so perform with the overflow plug tightened.

8) Remove the overflow plug and verify that the ATF overflow through the overflow hole.
Note
If the ATF drips, wait until the ATF falls in drops with the automatic transmission fluid warning light
illuminated.

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Note
If the ATF does not drip, add ATF into the filler hole until the ATF drips with the automatic
transmission fluid warning light illuminated, and wait until the ATF falls in drops.

Caution
The engine speed should be stable at idle speed when checking.

9) Tighten the overflow plug to the specified torque.

Caution
Do not reuse the gasket.
Be sure to install the gasket in the correct direction as shown in the figure.
After tightening the overflow plug, thoroughly wipe the dribbled ATF with a clean rag.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

10) Tighten the filler plug to the specified torque.

Note

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Coat a new O-ring with ATF, and install it to the filler plug.

Caution
Do not reuse the O-ring.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

4WD

2WD
11) Shift to the P range, and stop the engine.

12) Remove the short circuit in the DLC and restart the engine.

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13) Check that the automatic transmission fluid warning light and check trans warning light turn OFF, and stop the
engine.

21. TCM reset

Caution
After replacing the following parts, it is necessary to clear the TCM self-learning data.

Transmission
Valve body assembly
Clutch No. 1 and No. 2 components
Brake No. 1, No. 2, and No. 4 components

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select Diagnostics.

4) Select Transmission.

5) Select AT.

6) Select Programming.

7) Select Clear Learning Value and Diag Information.

Note
Clear the self-learning date following the instructions on the screen.
ATF cooler pipe removal (AWR6B45)

1. ATF cooler pipe removal

1. RZ4E-TC equipped models

1) Disconnect the ATF cooler pipe from the ATF hose.

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2) Remove the ATF cooler pipe from the transmission.

Note
Disconnect the flare nut.

Legend
1. OUT side
2. IN side

2. 4JJ1 equipped models

1) Disconnect the ATF cooler pipe from the ATF hose.

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2) Disconnect the ATF cooler pipe from the transmission.

Note
Disconenct the flare nut and remove the clip.

Legend

1. OUT side
2. IN side

2. ATF hose removal

1) Remove the 2 ATF hoses from the oil pipe.

ATF cooler pipe inspection (AWR6B45)

1. ATF cooler pipe inspection

1) Inspect it whether there is abnormal pipe bending in the ATF cooler pipe R part, pipe deformation and small
cross-section area of pipeline.

Note
Apply compressed air from ATF cooler pipe inlet side, inspect whether there is no ATF cooler pipe
choke by confirming that the airflow is smooth.

200 kPa { 2.0 kgf/cm2 / 29 psi } Compressed air

Note
Bending and choke of ATF cooler pipe can cause the following problem.

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A little flow quantity to oil cooler, increasing of oil temperature and blowing oil from breather.
Return of TCC lock-up off pressure shall be closed, and engine will stop at idle condition because of
keeping lock-up operation.

Caution
Replace failure parts.
Remove foreign particles and clean the inside of pipeline.
ATF cooler pipe installation (AWR6B45)

1. ATF cooler pipe cleaning

1) Clean the ATF Cooler and pipes using a cleaning agent and compressed air.

200 kPa { 2.0 kgf/cm2 / 29 psi } Compressed air

Note
After air-drying the cleaning agent in the ATF Cooler and pipe, clean them with transmission fluid.

2. ATF hose installation

1) Install the 2 ATF hoses to the oil pipe.

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Note
Shove the ATF hoses securely.

Legend

1. Shove the ATF hose completely over the hose fitting end.
2. Shove the ATF hose completely over the corner end of the hose fitting.

3. ATF cooler pipe installation

1. RZ4E-TC equipped models

1) Temporarily install the ATF cooler pipe, and determine the assembly direction of the ATF cooler pipe.

2) Tighten the ATF cooler pipe at the specified torque.

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft }

Legend

1. OUT side

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2. IN side

3) Connect the ATF cooler pipe to the ATF hoses and fix it with the clip.

2. 4JJ1 equipped models

1) Temporarily install the ATF cooler pipe and clips, and determine the assembly direction of the ATF cooler pipe.

2) Tighten the ATF cooler pipe and clip at the specified torque

Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } Bolt

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Flare nut

Legend

1. OUT side

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2. IN side

3) Connect the ATF cooler pipe to the ATF hoses and fix it with the clip.

4. ATF filling

1) Park the vehicle on a level place, move the select lever in P range and apply the parking brake firmly.

2) Put blocks at the front and rear of the tire.

3) Remove the filler plug and O-ring from the transmission.

O-ring
Inner diameter Thickness
15.41 mm { 0.61 2.21 mm { 0.09 in
in } }

4WD
2WD

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4) Replenish the ATF.

0.5 L { 0.13 US gal / 0.11 Imp.gal }

Caution
When replacing the transmission and changing the ATF, fill new ATF that is same amount of the
recovered ATF.
When overhauling the transmission, fill the specified amount of fluid listed below.

9.5 L { 2.51 US gal / 2.09 Imp.gal } Oil capacity [reference value]

Note
The volume of oil cooler on the vehicle side is contained.

5) Install the O-ring to the filler plug, and temporarily tighten the filler plug to the transmission.

Caution
After refilling the ATF, always perform the ATF adjustment using the overflow hole.
5. ATF adjustment

1. ATF adjustment

1) Connect a jumper between the terminals No.12 and No.4 (or No.5) of the DLC to short the TCM.

Note
Check whether the check trans warning light flashes when the DLC is short-circuited.

2) Start the engine.

Hold 2 sec. on each range (2 times).

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4) Operate the oil level adjustment control in order to switch the illumination temperature of the automatic
transmission fluid warning light.

Note
Move the select lever back and forth between N range and D range within 1.5 seconds. Repeat it for at
least 6 seconds until the automatic transmission fluid warning light turns ON in N range.

5) When the oil level adjustment control is activated, the automatic transmission fluid warning light will be
illuminated for 2 seconds in N range. Keep the select lever in N range.
After activating the oil level adjustment control, the automatic transmission fluid warning light will operate
according to the ATF temperature condition.

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Caution
Perform the temperature up from low temperature condition to assure the steady oil temperature and
oil level in the transmission.
Verify that the automatic transmission fluid warning light turns OFF.

Operating temperature of the

6) Perform the temperature up until the automatic transmission fluid warning light turns ON so that the ATF
temperature reaches the oil level adjustment temperature.

7) Retain idling in the N range after the automatic transmission fluid warning light illuminates, and check that it
continues to illuminate for 1 minute or more.

Standard: 750 rpm Idling speed (RZ4E-TC equipped models)

Standard: 700 rpm Idling speed (4JJ1 equipped models)

Note
If the automatic transmission fluid warning light does not illuminate or if it turns OFF within 1 minute,
temperature rise is insufficient, so repeat the temperature raising operation.

Caution
Operating the select lever with the overflow plug removed changes the oil level and the ATF may drip,
so perform with the overflow plug tightened.

8) Remove the overflow plug and verify that the ATF overflow through the overflow hole.

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Note
If the ATF drips, wait until the ATF falls in drops with the automatic transmission fluid warning light
illuminated.

Note
If the ATF does not drip, add ATF into the filler hole until the ATF drips with the automatic
transmission fluid warning light illuminated, and wait until the ATF falls in drops.

Caution
The engine speed should be stable at idle speed when checking.
9) Tighten the overflow plug to the specified torque.

Caution
Do not reuse the gasket.
Be sure to install the gasket in the correct direction as shown in the figure.
After tightening the overflow plug, thoroughly wipe the dribbled ATF with a clean rag.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

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10) Tighten the filler plug to the specified torque.

Note
Coat a new O-ring with ATF, and install it to the filler plug.

Caution
Do not reuse the O-ring.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

4WD

2WD
11) Shift to the P range, and stop the engine.

12) Remove the short circuit in the DLC and restart the engine.

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13) Check that the automatic transmission fluid warning light and check trans warning light turn OFF, and stop the
engine.
ATF inspection (AWR6B45)

1. ATF inspection

1) Inspect the ATF for contamination with foreign material.

Caution
If there is excessive mixing of metal particles and lining particles, it may be due to internal AT wear.

2) Inspect the ATF for discoloration.

Caution
Especially when there is white colored contamination, the cause may be water intrusion. Inspect the
cooling system.

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ATF replacement (AWR6B45)

1. ATF safety information

1. Regarding ATF level

If ATF is insufficient

Caution
The oil pump absorbs air and the line pressure is decreased, and this causes malfunctions such as
clutch slipping and burnout.

If ATF is excessive

Caution
Gears in the A/T stir the ATF, and cause oil foaming and deterioration, which leads to a malfunction.

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The ATF level increases when the vehicle is running, and the ATF leaks out from the breather.

2. Regarding ATF refill and adjustment

Caution
When filling the ATF, be sure to use only specified ATF.

Specified oil
ISUZU ATF WSI

Caution
The illumination check needs to be performed in the N range, because the automatic transmission
fluid warning light turns OFF when the range is shifted to a range other than N, even if the oil level
adjustment control is operated.
When warming up the ATF in D range, so that the ATF temperature does not go over the oil level
adjustment temperature due to rapid heating, do not raise the engine speed over 1,000 rpm. Also do
not perform this operation for more than 5 seconds continuously.
Perform oil level adjustment at idle speed in the N range because the ATF temperature and oil level
should be stable when adjusting the oil level.

Standard: 750 rpm Idling speed (RZ4E-TC equipped models)

Standard: 700 rpm Idling speed (4JJ1 equipped models)

Note
The oil level is not stable at engine stopping or high engine speed.

Caution
If the adjustment is performed at an ATF temperature lower than the oil level adjustment temperature,
the ATF will exceed the proper oil amount, and then the ATF will gush out.
Also, if the adjustment is performed at an ATF temperature higher than the oil level adjustment
temperature, the ATF becomes less than the proper oil amount, then abnormal noise such as
continuous beep, acceleration or shifting malfunction occurs.
Always apply the parking brake so that the vehicle does not begin to move unexpectedly.
2. ATF drain

1. ATF draining (1st time)

1) Keep the vehicle horizontal and jack up.

Caution
The correct replacement or adjustment cannot be performed if the vehicle is at an angle. Perform
work within ±1° inclination of the vehicle front and rear.

2) Remove the drain plug and gasket from the oil pan, and drain the ATF.

3) Temporarily tighten the drain plug to the oil pan.

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4) Remove the filler plug and O-ring from the transmission.

4WD

2WD
5) Remove the overflow plug and gasket from the transmission.

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6) Add ATF through the filler hole until ATF comes out of the overflow hole.

Caution
Use ISUZU ATF WSI for the ATF to be added.
Add ATF slowly. If added fast, the oil hits the internal parts and splashes back, which may result in
spilling out of the filler hole.

4WD
Legend

1. Filler hole

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2WD

Legend

1. Filler hole

7) Wait until the ATF flow stops and falls in drops.

8) Temporarily tighten the overflow plug to the oil pan.

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2. ATF refill (for draining)

1) Add ATF to the specified amount through the filler hole.

1.0 L { 0.26 US gal / 0.22 Imp.gal } [Reference value]

Note
If all the ATF does not go in when adding the specified amount of ATF, perform the ATF circulation (for
draining) procedure.

4WD
Legend

1. Filler hole

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2WD

Legend

1. Filler hole

2) Temporarily tighten the filler plug to the transmission.

3. ATF circulation (for draining)

1) Lower the vehicle.

2) Depress and hold the brake pedal.

3) Start the engine.

Caution
Turn OFF the electrical parts such as A/C, audio, and lighting device.
4) Move the select lever through each gear range, pausing for more than 2 seconds in each range to fill the
hydraulic circuit. Repeat the same manner 2 times, and then move the select lever in P range.

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5) Warm up while idling for 30 seconds.

6) Turn OFF the ignition switch.

Note
If the specified amount of ATF did not all go in when refilling the ATF (for draining), add the remaining
ATF, and then perform the ATF circulation (for draining) procedure again.

4. ATF draining (2nd time)

1) Repeat the procedures from ATF draining (1st time) to ATF circulation (for draining).

5. ATF draining (3rd time)

1) Keep the vehicle horizontal and jack up.

Caution
The correct replacement or adjustment cannot be performed if the vehicle is at an angle. Perform
work within ±1° inclination of the vehicle front and rear.

2) Remove the drain plug and gasket from the oil pan, and drain the ATF.

3) Install the drain plug and gasket to the oil pan.

Caution
Do not reuse the gasket.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

3. ATF filling

1) Remove the filler plug and O-ring from the transmission.

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4WD

2WD
2) Remove the overflow plug and gasket from the transmission.

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3) Add ATF through the filler hole until ATF comes out of the overflow hole.

Caution
Use ISUZU ATF WSI for the ATF to be added.
Add ATF slowly. If added fast, the oil hits the internal parts and splashes back, which may result in
spilling out of the filler hole.

4WD
Legend

1. Filler hole

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2WD

Legend

1. Filler hole

4) Wait until the ATF flow stops and falls in drops.

5) Temporarily tighten the overflow plug to the oil pan.

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6) Add ATF to the specified amount through the filler hole.

1.0 L { 0.26 US gal / 0.22 Imp.gal } [Reference value]

Note
If all the ATF does not go in when adding the specified amount of ATF, perform the ATF circulation (for
refilling) procedure.

4WD
Legend

1. Filler hole

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2WD

Legend

1. Filler hole

7) Temporarily tighten the filler plug to the transmission.

1. ATF circulation (for refilling)

1) Lower the vehicle.

2) Depress and hold the brake pedal.

3) Start the engine.

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5) Warm up while idling for 30 seconds.

6) Turn OFF the ignition switch.

Note
Add the remaining ATF.

4. ATF adjustment

1. ATF adjustment

1) Connect a jumper between the terminals No.12 and No.4 (or No.5) of the DLC to short the TCM.

Note
Check whether the check trans warning light flashes when the DLC is short-circuited.

2) Start the engine.

Hold 2 sec. on each range (2 times).

4) Operate the oil level adjustment control in order to switch the illumination temperature of the automatic
transmission fluid warning light.

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Note
Move the select lever back and forth between N range and D range within 1.5 seconds. Repeat it for at
least 6 seconds until the automatic transmission fluid warning light turns ON in N range.

5) When the oil level adjustment control is activated, the automatic transmission fluid warning light will be
illuminated for 2 seconds in N range. Keep the select lever in N range.

After activating the oil level adjustment control, the automatic transmission fluid warning light will operate
according to the ATF temperature condition.

Caution
Perform the temperature up from low temperature condition to assure the steady oil temperature and
oil level in the transmission.
Verify that the automatic transmission fluid warning light turns OFF.
Operating temperature of the
automatic transmission fluid
warning light at activating the oil
level adjustment control
OFF 40 ℃ { 104 °F } or less
41 to 50 ℃ { 106 to 122
Illuminated
°F }
Flashing 51 ℃ { 124 °F } or more

6) Perform the temperature up until the automatic transmission fluid warning light turns ON so that the ATF
temperature reaches the oil level adjustment temperature.

Note

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Change to D range to raise the temperature up to the oil level adjustment temperature, depress the
accelerator, and keep at 1000 rpm for 5 seconds. Then immediately return to idling, change to the N
range, and check the automatic transmission fluid warning light.

7) Retain idling in the N range after the automatic transmission fluid warning light illuminates, and check that it
continues to illuminate for 1 minute or more.

Standard: 750 rpm Idling speed (RZ4E-TC equipped models)

Standard: 700 rpm Idling speed (4JJ1 equipped models)

Note
If the automatic transmission fluid warning light does not illuminate or if it turns OFF within 1 minute,
temperature rise is insufficient, so repeat the temperature raising operation.

Caution
Operating the select lever with the overflow plug removed changes the oil level and the ATF may drip,
so perform with the overflow plug tightened.

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Note
If the ATF does not drip, add ATF into the filler hole until the ATF drips with the automatic
transmission fluid warning light illuminated, and wait until the ATF falls in drops.

Caution
The engine speed should be stable at idle speed when checking.

9) Tighten the overflow plug to the specified torque.

Caution
Do not reuse the gasket.
Be sure to install the gasket in the correct direction as shown in the figure.
After tightening the overflow plug, thoroughly wipe the dribbled ATF with a clean rag.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

10) Tighten the filler plug to the specified torque.

Note

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Coat a new O-ring with ATF, and install it to the filler plug.

Caution
Do not reuse the O-ring.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

4WD

2WD
11) Shift to the P range, and stop the engine.

12) Remove the short circuit in the DLC and restart the engine.

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13) Check that the automatic transmission fluid warning light and check trans warning light turn OFF, and stop the
engine.
Automatic transmission control cable removal (AWR6B45)

1. Component views

Automatic transmission control cable (RZ4E-TC equipped models)

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Part name

1. Selector lever
2. Shift cable retaining pawl
3. Select control lever
4. Adjuster
5. Bracket (lower)
6. Clip (LH side)
7. Automatic transmission control cable
8. Bracket (upper)
9. Clip (upper)
10. Shift lever plate sub-assembly

Automatic transmission control cable (4JJ1 equipped models)

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Part name

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Console box removal

Refer to "9.Body, Cab, Accessories 9L.Exterior, Interior Trim console box removal".

4. Automatic transmission control cable removal

1) Disconnect the automatic transmission control cable from the shift lever plate sub assembly.

Note

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Press the cap part of the automatic transmission control cable.

2) Disconnect the automatic transmission control cable from the select control lever.

3) Disconnect the automatic transmission control cable from the bracket.

Legend

1. Bracket

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2. Automatic transmission control cable

4) Remove the clip from the bracket.

Note
Remove the clip of LH side and disconnect the automatic transmission control cable.
Remove the clip of upper side and disconnect the automatic transmission control cable.

5) Pull the automatic transmission control cable free from the bottom of the vehicle.
Automatic transmission control cable installation (AWR6B45)

1. Component views

Automatic transmission control cable (RZ4E-TC equipped models)

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Part name

Automatic transmission control cable (4JJ1 equipped models)

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Part name

2. Automatic transmission control cable installation

1) Install the automatic transmission control cable toward the inside of the cabin from the bottom of the vehicle.

2) Connect the automatic transmission control cable to the shift lever plate sub assembly.
Note
Push the automatic transmission control cable into the shift lever plate sub assembly.

3) Install the clip to the bracket.

Note
Install the clip of upper side on the marking of the automatic transmission control cable.
Install the clip of LH side on the marking of the automatic transmission control cable.
Install the clip to connect the automatic transmission control cable.

3. Automatic transmission control cable adjustment

Caution
Adjust the automatic transmission control cable when replacing the automatic transmission control
cable.

1) Check that the selector lever is in the N position.

2) Check that the transmission is in the N position.

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Legend

1. P
2. R
3. N
4. D

3) Slide the cover in the direction indicated by the arrow.

Legend

1. Cover

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4) Use an ordinary screwdriver to move the lock piece from the position indicated by the arrow.

5) Continue to move the lock piece until the adjuster position begins to change.

Legend

1. Adjuster
2. Lock piece

6) Insert the lock piece to the adjuster.

7) Slide the cover on the adjuster and secure lock piece.

Legend

1. Cover

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8) Connect the automatic transmission control cable to the select control lever.

9) Press the select lever knob button 5 times, and then check that the select lever moves smoothly to each of its
positions.

10) Check that the shift position indicated by the selector lever and the actual shift position are the same.

4. Console box installation

Refer to "9.Body, Cab, Accessories 9L.Exterior, Interior Trim console box installation".

5. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

Brake piston No.1 disassembly (AWR6B45)

1. Component views

Brake disc No. 1, No. 2

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Part name

1. Snap ring
2. Brake cylinder No.2
3. O-ring
4. Brake piston No. 2
5. Brake piston return spring sub-assembly No. 2
6. Brake flange No. 2
7. Brake disc No. 2
8. Brake plate No. 2
9. Brake flange No. 2
10. Snap ring
11. Brake flange No. 1
12. Brake disc No. 1
13. Brake plate No. 1
14. Snap ring
15. Brake piston return spring sub-assembly No. 1
16. O-ring
17. Brake piston No. 1
18. Brake cylinder No. 1

2. Brake piston No.1 disassembly

1) While holding brake piston No. 1 by hand, apply compressed air into the oil passage of brake cylinder No. 1 as
shown in the figure and remove brake piston No. 1.

Caution
Be careful not to damage brake piston No. 1.

300 kPa { 3 kgf/cm2 / 44 psi } Compressed air

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2) Remove the 2 O-rings from the brake piston No.1.
Brake piston No.1 reassembly (AWR6B45)

1. Component views

Brake disc No. 1, No. 2

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Part name

2. Brake piston No.1 reassembly

1) Coat the new 2 O-rings and brake piston No. 1 with ATF.

Caution
Do not reuse the O-ring.

2) Install them to brake piston No. 1.

O-rings
Inner diameter Thickness

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119.6 mm { 2.62 mm { 0.10 in
4.7087 in } }
148.9 mm { 5.86 2.62 mm { 0.10 in
in } }

3) With brake piston return spring sub-assembly No. 1 installed to brake piston No. 1, align the 2 claws of brake
piston return spring sub-assembly No. 1 with the 2 claws of brake cylinder No. 1, and then install brake piston
No. 1 to brake cylinder No. 1.
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Brake piston No.2 disassembly (AWR6B45)

1. Component views

Brake disc No. 1, No. 2

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Part name

2. Brake piston No.2 disassembly

1) While holding brake piston No. 2 by hand, apply compressed air into the oil passage of the brake cylinder No. 2
as shown in the figure and remove brake piston No. 2.

Caution
Be careful not to damage brake piston No. 2.

300 kPa { 3 kgf/cm2 / 44 psi } Compressed air

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2) Remove the 2 O-rings from the brake piston No.2.
Brake piston No.2 reassembly (AWR6B45)

1. Component views

Brake disc No. 1, No. 2

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Part name

2. Brake piston No.2 reassembly

1) Coat the new 2 O-rings and brake piston No. 2 with ATF.

Caution
Do not reuse the O-ring.

2) Install them to brake piston No. 2.

O-rings
Inner diameter Thickness

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147.0 mm { 2.62 mm { 0.1031
5.7874 in } in }
170.2 mm { 2.62 mm { 0.1031
6.7008 in } in }

3) With brake piston return spring sub-assembly No. 2 installed to brake piston No. 2, align the claw of brake
piston return spring sub-assembly No. 2 with the claw of the brake cylinder No. 2, and then install brake piston
No. 2 to brake cylinder No. 2.
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Forward clutch assembly disassembly (AWR6B45)

1. Component views

Clutch disc No. 1 and Clutch disc No. 2 assembly

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Part name

1. No. 2 clutch drum sub-assembly

2. O-ring
3. Direct clutch piston
4. Direct clutch return spring sub-assembly
5. O-ring
6. Clutch balancer No. 2
7. Snap ring
8. Clutch plate No. 2
9. Clutch disc No. 2
10. Clutch flange No. 2
11. Snap ring
12. Seal ring
13. Forward clutch drum sub-assembly
14. O-ring
15. Forward clutch piston
16. Forward clutch return spring sub-assembly
17. O-ring
18. Clutch balancer No. 1
19. Snap ring
20. Clutch plate No. 1
21. Clutch disc No.1
22. Clutch flange No. 1
23. Snap ring
24. Forward clutch hub
25. Clutch hub sub-assembly

2. Seal ring removal

1) Remove the 3 seal rings from the forward clutch drum sub-assembly.

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3. Clutch disc No.1 removal

1) Using a screwdriver, remove the snap ring from the forward clutch drum sub-assembly.
2) Remove the flange, 5 discs and the 5 plates from the forward clutch drum sub-assembly.

Note

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Check the number of discs and plates.

Legend

1. Plate
2. Flange
3. Disc

4. Forward clutch return spring sub-assembly removal

1) Place the special tool on clutch balancer No. 1, and compress the forward clutch return spring sub-assembly
with a shop press.

Caution
Be careful not to shorten the return spring too much.
SST: 5-8840-2970-0 - spring compressor

2) Using snap ring pliers, remove the snap ring from the forward clutch drum sub-assembly.

Caution
Be careful not to expand the snap ring too much.

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Legend

1. 5-8840-2970-0

3) Remove clutch balancer No. 1 and the forward clutch return spring sub-assembly from the forward clutch drum
sub-assembly.
4) Remove the O-rings from clutch balancer No. 1.

5. Forward clutch piston removal

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1) While pushing the forward clutch piston by hand, apply compressed air into the oil passage as shown in the
figure and remove the forward clutch piston from the forward clutch drum sub-assembly.

392 kPa { 4 kgf/cm2 / 57 psi } Compressed air

2) Remove the O-ring from the forward clutch piston.

3) Remove the O-ring from the forward clutch drum sub-assembly.

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6. Clutch disc No.2 removal

1) Using a screwdriver, remove the snap ring from the No. 2 clutch drum sub-assembly.
2) Remove the flange, 5 discs and the 5 plates from the No. 2 clutch drum sub-assembly.

Note

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Check the number of discs and plates.

Legend

1. Plate
2. Flange
3. Disc

7. Direct clutch return spring sub-assembly removal

1) Place the special tool on clutch balancer No. 2, and compress the direct clutch return spring sub-assembly with
a shop press.

Caution
Be careful not to shorten the return spring too much.

2) Using the special tool, remove the snap ring from the No. 2 clutch drum sub-assembly.
Caution
Be careful not to expand the snap ring too much.

SST: 5-8840-2972-0 - spring compressor

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Legend

1. 5-8840-2972-0

3) Remove clutch balancer No. 2 and the direct clutch return spring sub-assembly from the No. 2 clutch drum sub-
assembly.

4) Remove the O-ring from clutch balancer No. 2.

8. Direct clutch piston removal

1) Place the oil pump assembly onto the torque converter assembly, and then place the No. 2 clutch drum sub-

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assembly onto the oil pump assembly.

2) While pushing the direct clutch piston by hand, apply compressed air into the oil passage as shown in the figure
and remove the direct clutch piston from the No. 2 clutch drum sub-assembly.

392 kPa { 4 kgf/cm2 / 57 psi } Compressed air

3) Remove the 2 O-rings from the direct clutch piston.

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Forward clutch assembly inspection (AWR6B45)

1. Clutch disc No.1 inspection

1) Check the lining of all discs.

Note
If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace
with a new lining. When replacing, check the contact surfaces between the flange and plate and the
disc. If they are scratched or have changed color, replace with new parts.
Before replacing with new discs, soak them at least 2 hours in ATF.

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2. Clutch disc No.2 inspection

1) Check the lining of all discs.

Note
If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace
with a new lining. When replacing, check the contact surfaces between the flange and plate and the
disc. If they are scratched or have changed color, replace with new parts.
Before replacing with new discs, soak them at least 2 hours in ATF.
3. Forward clutch return spring sub-assembly inspection

1) Using vernier calipers, measure the free length of the forward clutch return spring sub-assembly.

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Caution
If the free length is smaller than the minimum, replace the forward clutch return spring sub-assembly
with a new one.

Standard: 26.74 mm { 1.0528 in }

4. Direct clutch return spring sub-assembly inspection

1) Using vernier calipers, measure the free length of the direct clutch return spring sub-assembly.

Caution
If the free length is smaller than the minimum, replace the direct clutch return spring sub-assembly
with a new one.

Standard: 22.14 mm { 0.8717 in }

5. Forward clutch assembly inspection

1. Forward clutch drum sub-assembly bushing inspection

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1) Using a dial indicator, measure the inside diameter of the forward clutch drum sub-assembly bushing.

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the forward clutch drum sub-assembly with a new one.
When the forward clutch drum sub-assembly is replaced, inspect the surface in contact with the
intermediate shaft. If the surface is scratched or discolored, replace the intermediate shaft with a new
one.

Standard: 20.000 to 20.025 mm { 0.7874 to 0.7884 in }

2. No. 2 clutch drum sub-assembly bushing inspection

1) Using a dial indicator, measure the inside diameter of the No. 2 clutch drum sub-assembly bushing.

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the No. 2 clutch drum sub-assembly with a new one.
When the No. 2 clutch drum sub-assembly is replaced, inspect the surface in contact with the oil
pump assembly (stator shaft). If the surface is scratched or discolored, replace the oil pump
assembly (stator shaft) with a new one.

Standard: 59.515 to 59.540 mm { 2.3431 to 2.3441 in }

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3. Clutch hub sub-assembly bushing inspection

1) Using a caliper gauge, measure the inside diameter of the clutch hub sub-assembly bushing.

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the clutch hub sub-assembly with a new one.
When the clutch hub sub-assembly is replaced, inspect the surface in contact with the intermediate
shaft. If the surface is scratched or discolored, replace the intermediate shaft with a new one.

Standard: 26.037 to 26.062 mm { 1.0251 to 1.0261 in }

Standard value
a: 26.037 to 26.062 mm { 1.0251 to 1.0261 in } Rear

b: 26.037 to 26.062 mm { 1.0251 to 1.0261 in } Front

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Forward clutch assembly reassembly (AWR6B45)

1. Component views

Clutch disc No. 1 and Clutch disc No. 2 assembly

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Part name

1. No. 2 clutch drum sub-assembly

2. Direct clutch piston installation

1) Coat the 2 new O-rings with ATF.

Caution

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Do not reuse the O-ring.

2) Install them to the direct clutch piston.

O-rings
Inner diameter Thickness
74.7 mm { 2.9409 2.62 mm { 0.1031
in } in }
121.0 mm { 3.1 mm { 0.1220
4.7638 in } in }

3) Coat the sliding surface of the No. 2 clutch drum sub-assembly with ATF.

4) Install the direct clutch piston to the No. 2 clutch drum sub-assembly.

Caution
Be careful not to damage the O-rings and the No. 2 clutch drum sub-assembly and direct clutch
piston.

3. Direct clutch return spring sub-assembly installation

1) Coat a new O-ring with ATF.

Caution
Do not reuse the O-ring.

2) Install it to clutch balancer No. 2.

O-ring
Inner diameter Thickness
127.0 mm { 2.62 mm { 0.1031
5.0000 in } in }

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3) Install the direct clutch return spring and clutch balancer No. 2 to the No. 2 clutch drum sub-assembly.

Note
Refer to the diagram, and install the direct clutch return spring by aligning it with the clutch balancer
No. 2 arrow positions.

Caution
Be careful not to damage the O-ring on clutch balancer No. 2.
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4) Place the special tool on clutch balancer No. 2, and compress the direct clutch return spring sub-assembly with
a shop press.

Caution
Be careful not to shorten the return spring too much.

5) Using the special tool, install the snap ring in the groove.

Caution
Be careful not to expand the snap ring too much.

SST: 5-8840-2972-0 - spring compressor

Legend

1. 5-8840-2972-0

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4. Clutch disc No.2 installation

1) Install the 5 plates, 5 discs and the flange to the No. 2 clutch drum sub-assembly as shown in the figure.

5 Disc Type (F-D-P-D-P-D-P-D-P-

D-P)
Clutch Flange Disc Plate
C2 1 5 5

Caution
Check the number and order of flange, discs and plates.

Note
Install the plates, discs and the flange following the order shown in the figure.
When measuring the No.2 clutch pack clearance, use a flange of 3.5 mm {0.1378 in} thickness.
Legend

1. Plate
2. Flange
3. Disc

5. Clutch disc No.2 measurement

1) Using a screwdriver, install the snap ring in the groove.

Caution
When installing the snap ring, set the end gap of the snap ring as shown in the figure.

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2) Place the oil pump assembly onto the torque converter assembly, and then place the No. 2 clutch drum sub-
assembly onto the oil pump assembly.

Note
As shown in the following diagram, prepare a board with a hole that matches the nozzle as necessary.

Legend
1. Hole
2. Board

3) Using a dial indicator, apply compressed air as shown in the figure.

196 kPa { 2 kgf/cm2 / 28 psi } Compressed air

Note
When not replacing the disc and plate, use the installed flange.
When using a new disc and plate, use a 3.5 mm {0.1378 in} flange.

Caution
Measure the circumference of the flange at three places, and make sure that the average value is
within the specified range.
If the average value is outside the specified range, check the installation condition.

4) Measure the pack clearance, and adjust to align with the standard value.

Standard: 0.5 to 0.8 mm { 0.0197 to 0.0315 in } No. 2 clutch pack clearance

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Caution
If the No. 2 clutch pack clearance is not as specified, select an appropriate clutch flange No. 2.

Clutch flange No. 2

Thickness
3.0 mm { 0.1181
Flange thickness in }
3.1 mm { 0.1220
in }
3.2 mm { 0.1260
in }
3.3 mm { 0.1299
in }
3.4 mm { 0.1339
in }
3.5 mm { 0.1378
in }
3.6 mm { 0.1417
in }
3.7 mm { 0.1457
in }
3.8 mm { 0.1496
in }

6. Forward clutch piston installation

1) Coat a new O-ring with ATF.

Caution

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Do not reuse the O-ring.

2) Install it to the forward clutch drum sub-assembly.

O-ring
Inner diameter Thickness
33.67 mm { 2.62 mm { 0.1031
1.3256 in } in }

3) Coat a new O-ring with ATF.

Caution
Do not reuse the O-ring.

4) Install it to the forward clutch piston.

O-ring
Inner diameter Thickness
108.06 mm { 3.1 mm { 0.1220
4.2543 in } in }

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5) Install the forward clutch piston to the forward clutch drum sub-assembly.

Caution
Be careful not to damage the O-rings on the forward clutch drum sub-assembly and forward clutch
piston.

7. Forward clutch return spring sub-assembly installation

1) Coat a new O-ring with ATF.

Caution
Do not reuse the O-ring.

2) Install it to clutch balancer No. 1.

O-ring
Inner diameter Thickness
107.4 mm { 2.62 mm { 0.1031
4.2283 in } in }

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3) Install the forward clutch return spring sub-assembly and the clutch balancer No. 1 to the forward clutch drum
sub-assembly.

Caution
Be careful not to damage the O-rings on the clutch balancer No. 1.

4) Place the special tool on clutch balancer No. 1, and compress the forward clutch return spring sub-assembly
with a shop press.

Caution
Be careful not to shorten the return spring too much.

5) Using the special tool, install the snap ring in the groove.

Caution
Be careful not to expand the snap ring too much.

SST: 5-8840-2970-0 - spring compressor

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Legend

1. 5-8840-2970-0

8. Clutch disc No.1 installation

1) Install the 5 plates, 5 discs and the flange to the forward clutch drum sub-assembly as shown in the figure.

5 Disc Type (F-D-P-D-P-D-P-D-P-

D-P)
Clutch Flange Disc Plate
C1 1 5 5

Caution
Check the number and order of flange, discs and plates.

Note
Install the plates, discs and the flange following the order shown in the figure.
Legend

1. Plate

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2. Flange
3. Disc

9. Clutch disc No.1 measurement

1) Using a screwdriver, install the snap ring in the groove.

Caution
When installing the snap ring, set the end gap of the snap ring as shown in the figure.

2) Using a dial indicator, apply compressed air as shown in the figure.

196 kPa { 2 kgf/cm2 / 28 psi } Compressed air

Note
When not replacing the disc and plate, use the installed flange.
When using a new disc and plate, use a 3.5 mm {0.1378 in} flange.
Caution
Measure the circumference of the flange at three places, and make sure that the average value is
within the specified range.
If the average value is outside the specified range, check the installation condition.

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3) Measure the pack clearance, and adjust to align with the standard value.

No. 1 clutch pack clearance

Standard: 0.75 to 1.05 mm { 0.0295 to 0.0413 in } No. 1 clutch pack clearance

Caution
If the No. 1 clutch pack clearance is not as specified, select an appropriate clutch flange No. 1.

Clutch flange No. 1

Thickness
3.0 mm { 0.1181
in }
3.1 mm { 0.1220
in }
3.2 mm { 0.1260
Flange Thickness in }
3.3 mm { 0.1299
in }
3.4 mm { 0.1339
in }
3.5 mm { 0.1378
in }
3.6 mm { 0.1417
in }
3.7 mm { 0.1457
in }
3.8 mm { 0.1496
in }
3.9 mm { 0.1535
in }
4.0 mm { 0.1575
in }
4.1 mm { 0.1614
in }
4.2 mm { 0.1654
in }

10. Seal ring installation

1) Coat the new 3 seal rings with ATF.

Caution

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Do not reuse the seal rings.

2) Install them to the forward clutch drum sub-assembly.

Seal ring
Outer diameter Thickness
31.97 mm { 2.3 mm { 0.0906
1.2587 in } in }

Caution
Be careful not to expand the seal rings too much.
When shortening the seal rings, make sure to wrap them in the axial direction.

Standard value

a: 0 to 5 mm { 0.0000 to 0.1969 in }

3) Check that seal rings rotate smoothly after installing them.

Front planetary ring gear disassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

2. Thrust bearing race
3. Sun gear input drum
4. Thrust needle roller bearing with race
5. Thrust bearing race
6. Front planetary gear assembly
7. Thrust bearing race
8. Thrust needle roller bearing with race
9. Front planetary ring gear
10. Snap ring
11. Front planetary ring gear flange sub-assembly
12. Thrust bearing race
13. Thrust needle roller bearing with race
14. Snap ring
15. Middle planetary ring gear flange
16. Middle planetary ring gear
17. Thrust needle roller bearing
18. Thrust bearing race
19. Middle planetary gear assembly
20. Planetary sun gear
21. Snap ring
22. Rear planetary ring gear flange
23. Rear planetary ring gear
24. Thrust bearing race
25. Thrust needle roller bearing

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Front planetary ring gear flange removal

1) Using needle-nose pliers, remove the snap ring and front planetary ring gear flange sub-assembly from the
front planetary ring gear.
Front planetary ring gear inspection (AWR6B45)

1. Front planetary ring gear flange inspection

1) Using a caliper gauge, measure the inside diameter of the front planetary ring gear flange sub-assembly
bushing.

Standard: 54.038 to 54.063 mm { 2.1275 to 2.1285 in }

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the front planetary ring gear flange sub-assembly with
a new one.
When the front planetary ring gear flange sub-assembly is replaced, inspect the surface in contact
with the front planetary gear assembly. If the surface is scratched or discolored, replace the front

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planetary gear assembly with a new one.
Front planetary ring gear reassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Front planetary ring gear flange installation

1) Set the snap ring onto the front planetary ring gear flange sub-assembly. Using needle-nose pliers, insert the
snap ring into the front planetary ring gear while squeezing it, and then expand the snap ring to install it.
Inhibitor switch removal (AWR6B45)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

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If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

2. Engine harness disconnect

1) Disconnect the engine harness from the inhibitor switch.

3. Inhibitor switch removal

1) Using a screwdriver, pry off the lock washer.

2) Remove the nut and the lock washer from the inhibitor switch.

3) Remove the bolt and the inhibitor switch from the transmission case.
Note
Make sure that the manual valve lever shaft has not been rotated prior to installing the inhibitor
switch, as the detent spring may become detached from the manual valve lever shaft.

Caution
Do not touch the terminals.
Be careful not to damage the inhibitor switch.

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Inhibitor switch inspection (AWR6B45)

1. Engine harness vehicle inspection

1) Disconnect the engine harness from the ECM.

2) Measure the continuity between the terminals using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

Inhibitor switch

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Shift
P - IG R - IG N - IG D - IG
position
P
Continuity No No No
range
R
No Continuity No No
range
N
No No Continuity No
range
D
No No No Continuity
range

Legend

1. P
2. R
3. N
4. D
5. IG
2. Inhibitor switch vehicle inspection

1) Disconnect the harness from the connector.

2) Check for continuity between each connector terminal combinations listed in the table using a DMM.

Note
Check that continuity is as specified in the table.

Caution
Do not damage the terminals.

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3. Automatic transmission control cable vehicle inspection

1) Inspect that the shift lever can be shifted smoothly and accurately when shifting the shift lever from N to
another range.

2) Inspect that indicating light can be turned on correctly.

Caution
If a problem is found, adjust the shift cable again so that there is no looseness in the cable.
P0707 and P0708 may be set by improper automatic transmission control cable adjustments.

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Inhibitor switch installation (AWR6B45)

1. Inhibitor switch installation

1) Install the inhibitor switch onto the manual valve lever shaft and temporarily install the bolt.

Note
Tighten the bolt after adjusting the inhibitor switch to the N position.

2) Install the new lock washer with the new nut to the inhibitor switch.

Caution
Do not reuse the lock washers and nuts.

Tightening torque: 7 N・m { 0.7 kgf・m / 62 lb・in }

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3) Using a screwdriver, stake the lock washer.
2. Engine harness connect

1) Connect the engine harness to the inhibitor switch.

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3. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

4. Inhibitor switch adjustment

1) Inspect that the engine can be started with the shift lever at N or P only, but not in other range.

2) Set the select lever assembly in N range and remove the automatic transmission control cable.

3) Make sure the neutral basic line align with the groove.

Note
If a problem is found, adjust the inhibitor switch.

4) Loosen the inhibitor switch bolt.

5) Adjust the manual valve lever shaft to the N position.

6) Align the groove and neutral basic line.

7) Hold in position and tighten the bolt.

Tightening torque: 13 N・m { 1.3 kgf・m / 115 lb・in }

Legend

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1. Neutral basic line
2. Groove
Middle planetary ring gear disassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Middle planetary ring gear flange removal

1) Using a screwdriver, remove the snap ring from the middle planetary ring gear flange with middle planetary ring
gear.

2) Remove the middle planetary ring gear from the middle planetary ring gear flange.
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Middle planetary ring gear reassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Middle planetary ring gear flange installation

1) Install the middle planetary ring gear flange to the middle planetary ring gear.

2) Using a screwdriver, install the snap ring to the middle planetary ring gear flange with middle planetary ring
gear.
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Oil pump disassembly (AWR6B45)

1. Component views

Oil pump

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Part name

1. Oil pump oil seal

2. Transaxle oil seal
3. Oil pump assembly
4. Seal ring

2. Oil pump disassembly

1) Remove the transaxle oil seal ring from the oil pump assembly.
2) Remove the 2 seal rings from the oil pump assembly.

3) Using a screwdriver, remove the oil pump oil seal from the oil pump body.

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Caution
Be careful not to damage the oil pump body bush and oil pump body.
Oil pump inspection (AWR6B45)

1. Oil pump inspection

1. Stator shaft bushing inspection

1) Using a caliper gauge, measure the inside diameter of the stator shaft bushing.

Standard: 22.201 to 22.227 mm { 0.8741 to 0.8751 in }

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the oil pump assembly with a new one.
When the oil pump assembly is replaced, inspect the surface in contact with the forward clutch drum
sub-assembly (input shaft). If the surface is scratched or discolored, replace the forward clutch drum

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sub-assembly with a new one.

2. Oil pump body bushing inspection

1) Using a caliper gauge, measure the inside diameter of the oil pump body bushing.

Standard: 38.118 to 38.138 mm { 1.5007 to 1.5015 in }

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the oil pump assembly with a new one.
When the oil pump assembly is replaced, inspect the surface in contact with the torque converter
assembly. If the surface is scratched or discolored, replace the torque converter assembly with a new
one.
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Oil pump reassembly (AWR6B45)

1. Component views

Oil pump

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Part name

1. Oil pump oil seal

2. Transaxle oil seal
3. Oil pump assembly
4. Seal ring

2. Oil pump reassembly

1) Coat 2 new seal rings and the sliding surface of the stator shaft with ATF.

Caution
Do not reuse the seal rings.

2) Compress the 2 seal rings as shown in the figure. Then install the 2 seal rings to the oil pump assembly.

Seal ring
Outer diameter Thickness
67.46 mm { 2.32 mm { 0.0913
2.6559 in } in }

Caution
Be careful not to expand the seal rings too much.
When shortening the seal rings, make sure to wrap them in the axial direction.

Note
Check that seal rings rotate smoothly after installing them.
Standard value

a: 0 to 5 mm { 0.0000 to 0.1969 in }

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3) Coat a new transaxle oil seal ring with ATF.

Caution
Do not reuse the seal rings.

4) Install it to the oil pump assembly.

Transaxle oil seal ring

Inner diameter Thickness
218.4 mm { 3.5 mm { 0.1378
8.5984 in } in }

Caution
Be careful not to damage the transaxle oil seal ring.
Make sure that the painted part of the transaxle oil seal ring is on the outer circumference.
Install the transaxle oil seal ring so that it touches the oil pump assembly, being careful not to twist it.
Legend

1. Paint

5) Coat the lip of the new oil pump oil seal with grease.

Caution
Do not reuse the oil seal.

6) Using the special tool and a hammer, install a new oil pump oil seal to the oil pump assembly.

Standard: -0.3 to 0.3 mm { -0.0118 to 0.0118 in } From the end of the pump body

Caution
Be careful not to damage the oil pump oil seal.
Be careful not to damage the oil pump assembly.

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SST: 5-8840-2962-0 - oil seal installer

Legend

1. 5-8840-2962-0
Rear planetary ring gear disassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Rear planetary ring gear flange removal

1) Remove the rear planetary ring gear flange with rear planetary ring gear and the thrust bearing race from the
intermediate shaft.

2) Remove the thrust needle roller bearing and the thrust bearing race from the intermediate shaft.
3) Using a screwdriver, remove the snap ring from the rear planetary ring gear flange with rear planetary ring gear.

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4) Remove the rear planetary ring gear from the rear planetary ring gear flange.
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Rear planetary ring gear inspection (AWR6B45)

1. Rear planetary ring gear flange inspection

1) Using a caliper gauge, measure the inside diameter of the rear planetary ring gear flange bushing.

Standard: 32.176 to 32.201 mm { 1.2668 to 1.2678 in }

Caution
Measure the inside diameter at several places (More than 3 places) and take an average. If the
average is greater than the maximum, replace the rear planetary ring gear flange with a new one.
When the rear planetary ring gear flange is replaced, inspect the surface in contact with the
intermediate shaft. If the surface is scratched or discolored, replace the intermediate shaft with a new
one.

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2. Intermediate shaft inspection

1) Using a dial indicator, check the intermediate shaft runout.

Standard: 0.03 mm { 0.0012 in }

Caution
If the runout is not as specified, replace the intermediate shaft with a new one.
2) Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the figure.

Caution

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If the outer diameter is not as specified, replace the intermediate shaft with a new one.

Outer
Standard value
diameter
32.062 to 32.075 mm {
A
1.2623 to 1.2628 in }
25.962 to 25.975 mm {
B
1.0221 to 1.0226 in }
19.963 to 19.976 mm {
C
0.7859 to 0.7865 in }

Legend

1. Outer diameter A
2. Outer diameter B
3. Outer diameter C
Rear planetary ring gear reassembly (AWR6B45)

1. Component views

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

2. Rear planetary ring gear flange installation

1) Install the rear planetary ring gear flange to the rear planetary ring gear.

2) Using a screwdriver, install the snap ring to the rear planetary ring gear flange with rear planetary ring gear.
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Selector lever removal (AWR6B45)

1. Component views

Selector lever

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Part name

1. Selector lever knob

2. Screw
3. Knob cover
4. Position indicator upper cover
5. Position indicator lower cover
6. Slide cover A
7. Slide cover B
8. Slide cover C
9. Light assembly
10. Shift lock release button
11. Spring
12. Detent cushion (base side)
13. Shift lock solenoid assembly
14. Detent cushion (lever side)
15. Plate spring
16. Bolt
17. Shift lever plate sub-assembly
18. Inter lock controller assembly
19. Seal

Tightening torque

2: 2 N・m { 0.2 kgf・m / 18 lb・in }

15: 2 N・m { 0.2 kgf・m / 18 lb・in }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

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2) Disconnect the battery cable from the battery negative terminal.

Steering angle sensor setting

Setting for front door power window switch with AUTO UP/AUTO DOWN function

3. Console box removal

Refer to "9.Body, Cab, Accessories 9L.Exterior, Interior Trim console box removal".

4. Selector lever removal

1) Disconnect the harness connector from the inter lock controller assembly.
2) Disconnect the harness connector from the light assembly.

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3) Disconnect the automatic transmission control cable from the selector lever assembly.

Note
Press the cap part of the automatic transmission control cable.
4) Remove the selector lever assembly from the floor panel.

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Selector lever disassembly (AWR6B45)

1. Component views

Selector lever

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Part name

1. Selector lever knob

Tightening torque

2: 2 N・m { 0.2 kgf・m / 18 lb・in }

15: 2 N・m { 0.2 kgf・m / 18 lb・in }

2. Selector lever disassembly

1) Remove the selector lever knob from the shift lever plate sub assembly.

2) Remove the knob cover from the selector lever knob.

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3) Remove the position indicator upper cover from the shift lever plate sub assembly.

4) Remove the light assembly from the position indicator lower cover.

5) Remove the position indicator lower cover from the shift lever plate sub assembly.

6) Remove the slide cover A from the shift lever plate sub assembly.

7) Remove the slide cover B from the slide cover A.

8) Remove the slide cover C from the slide cover B.

9) Remove the shift lock release button from the shift lever plate sub assembly.

10) Remove the spring from the shift lever plate sub assembly.

11) Disconnect the harness connector from the inter lock controller assembly.

12) Remove the shift lock solenoid assembly from the shift lever plate sub assembly.

13) Remove the inter lock controller assembly from the shift lever plate sub assembly.

14) Remove the detent cushion from the shift lever plate sub assembly.

Note
Remove the detent cushion of base side.
Remove the detent cushion of lever side.

15) Remove the plate spring from the shift lever plate sub assembly.

16) Remove the seal from the shift lever plate sub assembly.
Selector lever reassembly (AWR6B45)

1. Component views

Selector lever

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Part name

1. Selector lever knob

Tightening torque

2: 2 N・m { 0.2 kgf・m / 18 lb・in }

15: 2 N・m { 0.2 kgf・m / 18 lb・in }

2. Selector lever reassembly

1) Install the seal to the shift lever plate sub assembly.

2) Move the select lever to the N position.

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Legend

1. N position
2. P position

3) Insert the detent pin into the base plate detent groove until it touches the front wall.

4) Stack the plate spring and tighten the screws to the specified torque.

Tightening torque: 2 N・m { 0.2 kgf・m / 18 lb・in }

5) Temporarily install the selector lever knob, and check that the detent pin moves smoothly in the detent groove.

6) Install the detent cushion to the shift lever plate sub assembly.

Note
Install the detent cushion of the lever side.
Install the detent cushion of the base side.

7) Install the inter lock controller assembly to the shift lever plate sub assembly.

8) Install the shift lock solenoid assembly to the shift lever plate sub assembly.

9) Connect the harness connector to the inter lock controller assembly.

10) Install the spring to the shift lever plate sub assembly.

11) Install the shift lock release button to the shift lever plate sub assembly.

12) Install the slide cover C to the slide cover B.

13) Install the slide cover B to the slide cover A.

14) Install the slide cover A to the shift lever plate sub assembly.

15) Install the position indicator lower cover to the shift lever plate sub assembly.

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16) Install the light assembly to the position indicator lower cover.

17) Install the position indicator upper cover to the shift lever plate sub assembly.

18) Install the knob cover to the selector lever knob.

19) Install the selector lever knob to the shift lever plate sub assembly.

Tightening torque: 2 N・m { 0.2 kgf・m / 18 lb・in }

Selector lever installation (AWR6B45)

1. Component views

Selector lever

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Part name

1. Selector lever knob

Tightening torque

2: 2 N・m { 0.2 kgf・m / 18 lb・in }

15: 2 N・m { 0.2 kgf・m / 18 lb・in }

2. Selector lever installation

1) Install the selector lever assembly to the floor panel.

Tightening torque: 7 N・m { 0.7 kgf・m / 62 lb・in }

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2) Connect the automatic transmission control cable to the selector lever assembly.

3) Connect the harness connector to the light assembly.

4) Connect the harness connector to the inter lock controller assembly.

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3. Automatic transmission control cable adjustment

Caution
Adjust the automatic transmission control cable when replacing the automatic transmission control
cable.

1) Check that the selector lever is in the N position.

2) Check that the transmission is in the N position.

Legend

1. P

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2. R
3. N
4. D

3) Slide the cover in the direction indicated by the arrow.

Legend

1. Cover

4) Use an ordinary screwdriver to move the lock piece from the position indicated by the arrow.

5) Continue to move the lock piece until the adjuster position begins to change.
Legend

1. Adjuster

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2. Lock piece

6) Insert the lock piece to the adjuster.

7) Slide the cover on the adjuster and secure lock piece.

Legend

1. Cover

8) Connect the automatic transmission control cable to the select control lever.

9) Press the select lever knob button 5 times, and then check that the select lever moves smoothly to each of its
positions.

10) Check that the shift position indicated by the selector lever and the actual shift position are the same.

4. Console box installation

Refer to "9.Body, Cab, Accessories 9L.Exterior, Interior Trim console box installation".

5. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

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Supplementary Information (AWR6B45)

1. Component views

Race and bearing specifications

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Race (Front) Bearing Race (Rear)

Transmission case
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Part name

1. Torque converter assembly

2: 34 N・m { 3.5 kgf・m / 25 lb・ft }

3: 57 N・m { 5.8 kgf・m / 42 lb・ft }

6: 28 N・m { 2.9 kgf・m / 21 lb・ft }

9: 7 N・m { 0.7 kgf・m / 62 lb・in }

10: 13 N・m { 1.3 kgf・m / 115 lb・in }

14: 5 N・m { 0.5 kgf・m / 44 lb・in }

17: 40 N・m { 4.1 kgf・m / 30 lb・ft }

19: 5 N・m { 0.5 kgf・m / 44 lb・in }

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Part name

1. Manual shaft oil seal

Tightening torque

13: 18 N・m { 1.8 kgf・m / 13 lb・ft }

Transmission case adapter (4WD models)

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Part name

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

10: 34 N・m { 3.5 kgf・m / 25 lb・ft }

12: 7 N・m { 0.7 kgf・m / 62 lb・in }

Extension housing (2WD models)

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Part name

Tightening torque

1: 40 N・m { 4.1 kgf・m / 30 lb・ft }

9: 34 N・m { 3.5 kgf・m / 25 lb・ft }

11: 7 N・m { 0.7 kgf・m / 62 lb・in }

Valve body assembly

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Part name

1. Temperature sensor clamp

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26. Bolt
27. Gasket

Tightening torque

3: 5 N・m { 0.5 kgf・m / 44 lb・in }

7: 10 N・m { 1.0 kgf・m / 89 lb・in }

9: 11 N・m { 1.1 kgf・m / 97 lb・in }

15: 10 N・m { 1.0 kgf・m / 89 lb・in }

17: 11 N・m { 1.1 kgf・m / 97 lb・in }

19: 10 N・m { 1.0 kgf・m / 89 lb・in }

23: 7 N・m { 0.7 kgf・m / 62 lb・in }

24: 20 N・m { 2.0 kgf・m / 15 lb・ft }

26: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Valve body assembly

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Part name

1. Valve body assembly

Gear train
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Part name

Tightening torque

1: 21 N・m { 2.1 kgf・m / 15 lb・ft }

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Part name

1. Thrust bearing race

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Part name

1. Thrust needle roller bearing with race

Clutch disc No. 1 and Clutch disc No. 2 assembly

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Part name

1. No. 2 clutch drum sub-assembly

Brake disc No. 1, No. 2

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Part name

Brake disc No.4 and 1 way clutch assembly No. 3

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Part name

1. Snap ring
2. 1 way clutch inner race
3. 1way clutch assembly No.3
4. Brake flange No. 4
5. Brake disc No. 4
6. Brake plate No. 4
7. Brake flange No. 4
8. Snap ring
9. 1st and reverse brake return spring sub-assembly
10. 1st and reverse brake piston
11. O-ring
12. Brake reaction sleeve
13. O-ring
14. Inner brake piston No. 4
15. O-ring
16. Transmission case
17. Brake plate stopper spring

Gear and shaft

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Part name

1. Thrust needle roller bearing with race

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26. Thrust bearing race
27. Intermediate shaft
28. Thrust needle roller bearing with race
29. Thrust bearing race
30. Rear planetary gear assembly

Oil pump

Part name

1. Oil pump oil seal

2. Transaxle oil seal
3. Oil pump assembly
4. Seal ring

Selector lever
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Part name

1. Selector lever knob

Tightening torque
2: 2 N・m { 0.2 kgf・m / 18 lb・in }

15: 2 N・m { 0.2 kgf・m / 18 lb・in }

Automatic transmission control cable (RZ4E-TC equipped models)

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Part name

Automatic transmission control cable (4JJ1 equipped models)

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Part name

JK6 12 TON ELAM
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