Part 3

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

60. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST and a hammer, drive in 2 new oil seals.

SST : 09350-30020

09350-07110

(b) Coat the oil seal lips with MP grease.

61. INSPECT INDIVIDUAL PISTON OPERATION Transmission Unit

62. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

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

Text in Illustration

(b) Install the manual valve lever shaft to the transmission case through the manual valve lever.

(c) Using a hammer, drive in a new spring pin.

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

(e) Make sure that the shaft rotates smoothly.

63. INSTALL PARKING LOCK PAWL SHAFT

(a) Install a new E-ring to the shaft.

(b) Install a new parking lock pawl, the shaft and the spring.

Text in Illustration

64. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

(a) Connect the parking lock rod to the manual valve lever.

65. INSTALL PARKING LOCK PAWL BRACKET

(a) Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.

Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)

(b) Shift the manual valve lever to the P position, and confirm that the planetary gear is correctly locked up by the lock pawl.

Text in Illustration

66. INSTALL B-1 ACCUMULATOR VALVE

(a) Install the spring and the accumulator valve to the hole.

B-1 Accumulator Spring

67. INSTALL C-3 ACCUMULATOR PISTON

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

(b) Install the 2 springs and the accumulator piston to the hole.

C-3 Accumulator Spring (Inner Spring)

C-3 Accumulator Spring (Outer Spring)

Text in Illustration

68. INSTALL B-3 ACCUMULATOR PISTON

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

(b) Install the spring and the accumulator piston to the hole.

B-3 Accumulator Spring

Text in Illustration

69. INSTALL C-2 ACCUMULATOR PISTON

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

(b) Install the spring and the accumulator piston to the hole.

C-2 Accumulator Spring

Text in Illustration

70. INSTALL CHECK BALL BODY

(a) Install the check ball body and the spring.

Text in Illustration

71. INSTALL BRAKE DRUM GASKET

(a) Install 3 new brake drum gaskets.

72. INSTALL TRANSAXLE CASE GASKET

(a) Install 3 new transaxle case gaskets.

Text in Illustration

73. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve lever with the pin of the manual valve.

Text in Illustration

(b) Install the 19 bolts.

Torque : 11 Nm (110 kgf-cm, 8 ft-lbf)

HINT
Each bolt length is indicated below.

Bolt length:

Bolt A
25 mm (0.984 in.)

Bolt B
36 mm (1.42 in.)

Bolt C
45 mm (1.77 in.)

Bolt D
50 mm (1.97 in.)

(c) Install the detent spring and the detent spring cover with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

74. INSTALL TRANSMISSION WIRE

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

Text in Illustration

(b) Install the O-ring to the transmission wire.

(c) Install the transmission wire harness.

(d) Install the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(e) Connect the 9 solenoid connectors.

(f) Install the ATF temperature sensor and temperature sensor clamp with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(g) Install the clamp and the 2 bolts.

Bolt A - Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)

Bolt B - Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

75. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

(a) Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.

Text in Illustration

(b) Install the oil strainer with the 4 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

76. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

(a) Install the 3 transmission oil cleaner magnets.

Text in Illustration

(b) Install a new gasket on the oil pan.

(c) Install and tighten the 20 bolts.

Torque : 4.4 Nm (45 kgf-cm, 39 in-lbf)

(d) Install a new gasket and the drain plug.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

(e) Install a new gasket and the overflow plug.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

77. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Coat the lip of a new oil seal with MP grease.

(b) Using SST and a hammer, install the oil seal until it fits with the extension housing.

SST : 09325-40010

Oil seal drive in depth:

5.4 to 5.8 mm (0.213 to 0.228 in.)

78. INSTALL EXTENSION HOUSING DUST DEFLECTOR

(a) Using SST and a press, install a new extension housing dust deflector.

SST : 09950-60020

09951-01030

79. INSTALL EXTENSION (ATM) HOUSING SUB-ASSEMBLY

(a) Install the transmission case adapter radial ball bearing to the extension (ATM) housing.

(b) Using a snap ring plier, install the snap ring.

(c) Install the thrust needle roller bearing and the 2 bearing races.

(d) Using a snap ring expander, install the snap ring.

(e) Using a feeler gauge, measure the clearance between the snap ring and the race.

Clearance:

0.02 to 0.12 mm (0.000787 to 0.00472 in.)

If the clearance is outside the specified range, select another race that brings the clearance within the specified range.

HINT
There are 12 different thicknesses for the race.

Flange Thickness

(f) Clean the threads of the bolts and the case with non-residue solvent.

(g) Apply FIPG to the extension (ATM) housing as shown in the illustration.

FIPG:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Text in Illustration

(h) Install the extension (ATM) housing with 6 new bolts.

Torque : 34 Nm (345 kgf-cm, 25 ft-lbf)

NOTICE:
Assemble the extension (ATM) housing within 10 minutes after the FIPG application.

HINT
Each bolt length is indicated below.

Bolt length:

Bolt A
45 mm (1.772 in.)

Bolt B
35 mm (1.378 in.)

80. INSTALL AUTOMATIC TRANSMISSION HOUSING

(a) Clean the threads of the bolts and the case with white gasoline.

(b) Install the transmission housing with the 10 bolts.

A {14 mm (0.551 in.) bolt} - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

B {17 mm (0.669 in.) bolt} - Torque : 57 Nm (581 kgf-cm, 42 ft-lbf)

81. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

(a) Install the breather tube.

(b) Install the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

82. INSTALL TRANSMISSION REVOLUTION SENSOR

(a) Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.

(b) Install the 2 transmission revolution sensors.

(c) Install the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

83. INSTALL TRANSMISSION OIL COOLER

(a) Coat 2 new O-rings with ATF, and install them to the transmission oil cooler.

Text in Illustration

(b) Install the transmission oil cooler with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

84. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.

HINT
Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch as the detent spring may become detached from the manual valve lever shaft.

(b) Install a new lock washer and the nut.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

(c) Using the control shaft lever, turn the manual lever shaft back all the way and then forward 2 notches. It is now in neutral.

(d) Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

Text in Illustration

(e) Using a screwdriver, bend the tabs of the lock washer.

HINT
Bend at least 2 of the lock washer tabs.

85. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH

(a) Install the control shaft lever RH, washer and the nut.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

86. INSTALL TRANSMISSION CASE COVER

(a) Install the transmission case cover with the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)