Part 2

A960E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY - Continued

31. INSTALL NO. 3 BRAKE SNAP RING

(a) Using a screwdriver, install the snap ring.





SST : 09350-30020

09350-07060

32. INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY

(a) Install the No. 2 one-way clutch assembly and clutch drum thrust washer to the clutch drum and input shaft.





33. INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY Transmission Unit

34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

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





(b) Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.

(c) Install the No. 2 clutch balancer and the direct clutch return spring to the direct clutch piston sub-assembly.





(d) Press the direct clutch piston into the reverse clutch drum sub-assembly by hands.

NOTICE:
Do not damage the O-rings.

(e) Place SST on the direct clutch piston, and compress the return spring with a press.





SST : 09320-89010

SST : 09350-30020

09350-07070

(f) Install the snap ring with a snap ring expander.

NOTICE:
* Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
* Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.

(g) Set the end gap of the snap ring in the piston as shown in the illustration.





Text in Illustration





35. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

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





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





(c) Press the clutch drum sub-assembly into the reverse clutch piston with both hands.





NOTICE:
Do not damage the O-ring.

36. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

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

(b) Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.





37. INSTALL NO. 3 CLUTCH BALANCER

(a) Install the No. 3 clutch balancer to the reverse clutch return spring.

(b) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.





SST : 09387-00070

(c) Install the snap ring with a snap ring expander.

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 spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.

(d) Set the end gap of the snap ring in the piston as shown in the illustration.





Text in Illustration





38. INSTALL NO. 2 DIRECT CLUTCH DISC

(a) Install the direct clutch flange, the 5 plates and the 5 discs on the reverse clutch drum sub-assembly.





Installation order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P - D - P - D - P

(b) Using a screwdriver, install the 2 hole snap rings on the reverse clutch drum sub-assembly.





39. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transmission Unit

40. INSTALL REVERSE CLUTCH FLANGE

(a) Install the reverse clutch flange to the reverse clutch drum sub-assembly.





41. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates to the reverse clutch hub.





Installation order:

P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate

S - C - F - D - P - D - P - D - P - D

(b) Using a screwdriver, install the hole snap ring.

42. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Transmission Unit

43. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.





(b) Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates from the reverse clutch hub sub-assembly.





44. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Install the coast clutch piston to the input shaft.





(b) Coat a new O-ring with ATF.

(c) Install the new O-ring to the forward clutch.

(d) Install the forward clutch piston sub-assembly

45. INSTALL NO. 1 CLUTCH BALANCER

(a) Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.





(b) Install the No. 1 clutch balancer and the forward clutch return spring sub-assembly.





NOTICE:
Do not damage the D-ring.

(c) Place SST on the No. 1 clutch balancer, and compress the return spring with a press.





SST : 09350-30020

09350-07040

SST : 09316-20011

(d) 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 spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.

(e) Set the end gap of the snap ring in the piston as shown in the illustration.





Text in Illustration





46. INSTALL COAST CLUTCH DISC

(a) Install the flange, the 4 discs and the 4 plates to the forward clutch piston.





(b) Using a screwdriver, install the hole snap ring.

47. INSPECT PACK CLEARANCE OF COAST CLUTCH Transmission Unit

48. INSTALL NO. 1 CLUTCH DISC

(a) Install the flange, the 4 discs, 4 plates and clutch cushion plate to the input shaft assembly.





Installation order:

P = Plate, D = Disc, F = Flange, C = Cushion Plate

F - D - P - D - P - D - P - D - P - C

(b) Using a screwdriver, install the hole snap ring.





Text in Illustration





(c) Install the thrust needle roller bearing and the thrust bearing race.









Text in Illustration





49. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat 4 new oil seal rings with ATF.





(b) Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.

NOTICE:
Do not expand the ring ends excessively.

HINT
After installing the oil seal rings, check that they rotate smoothly.

50. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transmission Unit

51. INSTALL INPUT SHAFT

(a) Install the input shaft to the reverse clutch drum sub-assembly.





(b) Install the thrust needle roller bearing and the thrust bearing race to the reverse clutch drum sub-assembly.





Thrust Needle Roller Bearing and Race Diameter





Text in Illustration





52. INSTALL NO. 4 ONE-WAY CLUTCH ASSEMBLY

(a) Install the clutch hub thrust washer and the No. 4 one-way clutch assembly to the coast clutch hub.





53. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

(a) Install the coast clutch hub sub-assembly to the reverse clutch drum sub-assembly.





54. INSTALL CLUTCH HUB SUB-ASSEMBLY

(a) Install the 2 thrust needle roller bearings and No. 2 thrust bearing race to the clutch hub sub-assembly.





Bearing and Race Diameter





Text in Illustration





(b) Install the clutch hub thrust washer and forward clutch hub sub-assembly to the reverse clutch drum sub-assembly.





55. INSTALL NO. 3 CLUTCH DISC

(a) Install the clutch cushion plate, the reverse clutch flange, the 3 plates and the 4 discs to the reverse clutch hub.





Text in Illustration





56. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve to the reverse clutch hub.





57. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 No. 3 clutch discs, and the 3 No. 3 clutch plates to the reverse clutch drum sub-assembly.





(b) Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly and the input shaft assembly.





58. INSTALL CLUTCH DRUM AND INPUT SHAFT

(a) Install the thrust needle roller bearing and thrust washer.





Text in Illustration





(b) Coat the washer with petroleum jelly and install them onto the clutch drum and input shaft.

Thrust Needle Roller Bearing Diameter





(c) Install the clutch drum and input shaft into the transmission case.





59. INSTALL OIL PUMP ASSEMBLY

(a) Install the No. 1 thrust bearing race to the oil pump.









Text in Illustration





(b) Coat a new O-ring with ATF, and install it around the oil pump assembly.

(c) Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.

(d) Hold the input shaft, and lightly press the oil pump to slide the oil seal rings into the overdrive direct clutch drum.

(e) Install the 9 bolts.





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)