Part 1
AA80E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY
1. BEARING POSITION
Bearing Position:
2. INSTALL REAR OUTPUT SHAFT RADIAL BALL BEARING
(a) Using SST, fully tap the bearing into the transmission case.
SST : 09316-60011
09316-00011
09316-00021
(b) Using needle-nose pliers, install the snap ring.
3. INSTALL REAR AUTOMATIC TRANSMISSION OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.
(b) Using SST and a hammer, tap the oil seal into the transmission case.
SST : 09214-76011
Standard oil seal depth:
3.3 to 3.7 mm (0.130 to 0.146 in.)
4. INSTALL BRAKE PLATE STOPPER SPRING
(a) Install the 2 brake plate stopper springs.
5. INSTALL NO. 2 BRAKE PISTON
(a) Coat 3 new O-rings with ATF, and install them to the No. 2 brake piston.
(b) Install the No. 2 brake piston to the transmission case.
HINT
Make sure that the parking hole of the No. 2 brake piston is on the bottom side by engaging the 2 brake piston protrusions to the transmission case spline grooves. (One groove is 3 places clockwise from the top, and the other is 2 places clockwise from the bottom as shown in the illustration).
(c) Install the No. 2 brake piston return spring to the transmission case.
(d) Set SST on the No. 2 brake piston return spring, tighten SST and compress the return spring.
SST : 09380-50010
(e) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
6. SELECT NO. 2 BRAKE FLANGE
(a) Measure length A (from the tip of the No. 2 brake piston to the step in the transmission case) in the illustration.*1
Standard length:
14.77 to 15.37 mm (0.581 to 0.605 in.)
(b) Assemble the 4 No. 2 brake discs, 3 No. 2 brake plates, and No. 2 brake flange as shown in the illustration. Then, with a weight of 500 g (17.64 oz ) or less placed on the flange, measure length B.*2
Standard:
14.11 to 14.69 mm (0.556 to 0.578 in.)
(c) Choose a No. 2 brake flange from the table so that the value of measured length A minus length B (from steps *1 and *2) will be 0.52 to 0.82 mm (0.0205 to 0.0323 in.).
Flange Thickness:
7. INSTALL DIRECT CLUTCH PISTON
(a) Coat a new O-ring with ATF, and install it to the direct clutch drum sub-assembly.
(b) Coat a new O-ring with ATF, and install it to the direct clutch piston.
(c) Install the direct clutch piston to the direct clutch drum sub-assembly.
(d) Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.
(e) Install the direct clutch piston return spring sub-assembly and No. 2 clutch balancer to the direct clutch drum sub-assembly.
(f) Place SST on the No. 2 clutch balancer and compress the return spring with a press.
SST : 09387-00020
(g) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
8. INSTALL NO. 2 CLUTCH DISC SET
(a) Install the 6 plates, 6 discs and flange to the direct clutch drum.
Install in order:
P - D - P - D - P - D - P - D - P - D - P - D - F
HINT
P = Plate
D = Disc
F = Flange
NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.
(c) Using a dial indicator, measure the distance (distance A) the clutch flange moves at both ends while blowing compressed air (196 kPa, 2.0 kgf*cm2, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value will be within the standard range.
Standard:
0.90 to 1.20 mm (0.0354 to 0.0472 in.)
Flange Thickness:
(d) Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.
9. CONNECT DIRECT CLUTCH ASSEMBLY
(a) Coat 2 new oil seal rings with ATF, and install them to the direct clutch drum sub-assembly.
NOTICE:
Do not expand the ring ends excessively.
(b) Coat 3 new oil seal rings with ATF, and install them to the output shaft.
NOTICE:
Do not expand the ring ends excessively.
(c) Install the thrust needle roller bearing and thrust bearing race.
Standard Bearing and Race Diameter:
NOTICE:
Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
(d) Install the direct clutch assembly to the output shaft.
10. INSTALL REAR PLANETARY RING GEAR
(a) Install the snap ring to the groove of the output shaft.
(b) Using needle-nose pliers, attach the snap ring to install the ring gear to the output shaft.
11. INSTALL DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY
(a) Install the 2 thrust needle bearings, 2 thrust bearing races, direct clutch with rear planetary ring gear and output shaft to the transmission case.
Standard Bearing and Race Diameter:
NOTICE:
Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
12. INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY
(a) Using SST, install a new oil seal to the automatic transmission flange yoke.
SST : 09950-60010
09951-00410
SST : 09950-70010
09951-07100
Standard depth:
0 to 0.3 mm (0 to 0.0118 in.)
(b) Install the rear cover sleeve and 2 output shaft rear bearing No. 1 spacers.
(c) Install the automatic transmission flange yoke.
(d) Set SST.
SST : 09330-00021
SST : 09950-30012
09955-03040
(e) Using SST and a 30 mm socket wrench, temporarily install and tighten a new nut.
Torque : 135 Nm (1376 kgf-cm, 99 ft-lbf)
13. SELECT REAR COVER SLEEVE
(a) Using a dial indicator, measure the output shaft end play. Then, choose from the 15 sleeve thicknesses in the table so that the measured value will be within the standard range.
Standard end play:
0.21 to 0.36 mm (0.00827 to 0.0142 in.)
Sleeve Thickness:
(b) Temporarily remove the lock nut, flange yoke, 2 spacers and sleeve, attach the selected sleeve and restore the flange yoke.
(c) Using a chisel and hammer, securely stake the nut.
14. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the thrust bearing race, rear planetary gear assembly and thrust needle roller bearing to the transmission case.
Standard Bearing and Race Diameter:
NOTICE:
* Before installing the rear planetary gear, apply ATF to its bushing. After the installation, check that the rear planetary gear rotates smoothly.
* Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
15. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Install the thrust bearing race and rear planetary sun gear to the transmission case.
Standard Bearing Race Diameter:
NOTICE:
* Before installing the sun gear, apply ATF to the contact surfaces inside the sun gear. After the installation, check that the sun gear rotates smoothly.
* Use a small amount of MP grease to secure the thrust bearing race in place.
16. INSTALL NO. 2 BRAKE DISC SET
(a) Install the selected flange, 4 discs, 3 No. 2 plates and No. 1 plate.
Install in order:
F - D - No. 2 P - D - No. 2 P - D - No. 2 P - D - No. 1 P
HINT
F = Flange
D = Disc
P = Plate
HINT
Assemble the transmission case, flanges and plates by aligning their grooves as shown in the following illustration.
NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.
17. INSTALL NO. 1 ONE-WAY CLUTCH
(a) Install the No. 1 one-way clutch to the one-way clutch outer race with the 2 snap rings.
NOTICE:
Make sure to install the one-way clutch in the correct direction.
18. INSPECT NO. 1 ONE-WAY CLUTCH Transmission Unit
19. INSTALL ONE-WAY CLUTCH OUTER RACE WITH NO. 1 ONE-WAY CLUTCH
(a) Install the one-way clutch outer race with No. 1 one-way clutch to the transmission case.
(b) Using SST, install the snap ring to the transmission case.
SST : 09350-30020
09350-07060
NOTICE:
* Install the snap ring so that its tapered face will be facing the front side of the transmission case.
* Install the snap ring so that its end gap will be within the range shown in the illustration.
20. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY
(a) Install the thrust bearing race, thrust needle roller bearing and sun gear input drum.
Standard Bearing and Race Diameter:
NOTICE:
* Before installing the sun gear input drum, apply ATF to the contact surfaces inside the sun gear input drum. After the installation, check that the sun gear input drum rotates smoothly.
* Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
21. INSTALL FORWARD CLUTCH PISTON
(a) Coat 2 new O-rings with ATF, and install them to the forward clutch piston.
(b) Install the forward clutch piston to the forward clutch drum.
(c) Coat a new O-ring with ATF, and install it to the No. 1 clutch balancer.
(d) Install the forward clutch return spring sub-assembly and No. 1 clutch balancer to the forward clutch drum.
(e) Place SST on the No. 1 clutch balancer, and compress the clutch balancer with a press.
SST : 09380-50010
(f) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
NOTICE:
* Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
* Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent spring seat deformation.
* Do not expand the snap ring excessively.
22. INSTALL FORWARD MULTIPLE CLUTCH DISC SET
(a) Install the cushion plate, 6 plates, 6 discs and flange to the forward clutch drum.
Install in order:
C - P - D - P - D - P - D - P - D - P - D - P - D - F
HINT
C = Cushion plate
P = Plate
D = Disc
F = Flange
NOTICE:
* Assemble the cushion plate by facing its marked side towards the plates.
* Before assembling new discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.
(c) Temporarily assemble the front planetary gear assembly to the forward clutch assembly.
(d) Using a dial indicator, measure the distance (distance A) the clutch flange moves at both ends while blowing compressed air (196 kPa, 2.0 kgf*cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value will be within the standard range.
Standard:
0.90 to 1.20 mm (0.0354 to 0.0472 in.)
Flange Thickness:
(e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.
(f) Remove the front planetary gear assembly.
23. INSTALL FRONT PLANETARY RING GEAR
(a) Install the snap ring to the forward clutch drum groove.
(b) Using needle-nose pliers, attach the snap ring to install the front planetary ring gear to the forward multiple clutch disc.
NOTICE:
Check that the snap ring is securely fit into the groove by looking through the ring gear slots on both sides.
24. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the thrust needle roller bearing, thrust bearing race and multiple disc clutch hub to the forward clutch assembly.
Standard Bearing and Race Diameter:
NOTICE:
Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
25. INSTALL FORWARD CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR AND MULTIPLE DISC CLUTCH HUB
(a) Install the thrust bearing race, thrust needle roller bearing and forward clutch assembly with front planetary ring gear and multiple disc clutch hub to the transmission case.
Standard Bearing and Race Diameter:
NOTICE:
* Before installing the sun gear input drum, apply ATF to the contact surfaces inside the sun gear input drum. After the installation, check that the sun gear input drum rotates smoothly.
* Use a small amount of MP grease to secure the thrust bearing and thrust bearing race in place.
26. INSTALL OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the overdrive direct clutch drum sub-assembly.
(b) Coat a new O-ring with ATF, and install it to the overdrive direct clutch piston sub-assembly.
(c) Install the overdrive direct clutch piston to the overdrive direct clutch drum.
(d) Coat a new O-ring with ATF, and install it to the No. 3 clutch balancer.
(e) Install the overdrive clutch return spring and No. 3 clutch balancer to the overdrive direct clutch piston.
(f) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.
SST : 09380-50010
(g) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
NOTICE:
* Be sure not to align the snap ring end gap with the spring retainer claw.
* Stop pressing when the balancer is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent spring seat deformation.
* Do not expand the snap ring excessively.