Part 2

A760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY - Continued

30. INSTALL NO. 3 BRAKE SNAP RING

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





31. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

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





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





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

NOTICE:
Do not damage the 2 O-rings.

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





SST : 09320-89010

SST : 09350-30020

09350-07070

(e) 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 (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.

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





Text in Illustration





32. 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 reverse clutch drum sub-assembly into the reverse clutch piston with both hands.





NOTICE:
Do not damage the O-rings.

33. 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.





34. 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 (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.

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





Text in Illustration





35. INSTALL NO. 2 DIRECT CLUTCH DISC

(a) Install the reverse clutch flange, 6 No. 2 clutch plates and 5 No. 2 clutch discs on the reverse clutch drum sub-assembly.





Installation order:

*3 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *2 - *1 - *1

Text in Illustration





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





36. INSPECT PACK CLEARANCE OF NO. 2 DIRECT CLUTCH Transmission Unit

37. INSTALL REVERSE CLUTCH FLANGE

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





38. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 No. 3 clutch discs and 4 No. 3 clutch plates to the reverse clutch hub.





Installation order:

*1 - *2 - *3 - *4 - *5 - *4 - *5 - *4 - *5 - *4 - *5 - *4

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

Text in Illustration





39. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH Transmission Unit

40. 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, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the reverse clutch hub sub-assembly.





41. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Install the coast clutch piston to the forward clutch piston sub-assembly.





(b) Coat a new O-ring with ATF, and install it on the input shaft.

(c) Install the forward clutch piston sub-assembly to the input shaft.

42. 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 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

09350-07070





(d) 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 (0.0394 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





43. INSTALL COAST CLUTCH DISC

(a) Install the flange, 3 coast clutch discs and 3 coast clutch plates to the forward clutch piston sub-assembly.





Installation order:

*1 - *3 - *2 - *3 - *2 - *3 - *2

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

Text in Illustration





44. INSPECT PACK CLEARANCE OF COAST CLUTCH Transmission Unit

45. INSTALL NO. 1 CLUTCH DISC

(a) Install the flange, 4 No. 1 clutch discs, 4 No. 1 clutch plates and clutch cushion plate to the input shaft assembly.





Installation order:

*1 - *4 - *2 - *4 - *2 - *4 - *2 - *4 - *2 - *3

Text in Illustration





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





Text in Illustration





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





Thrust Needle Roller Bearing and Race Diameter:





Text in Illustration





46. 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 starter shaft groove.

NOTICE:
Do not expand the ring ends excessively.

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

47. INSPECT PACK CLEARANCE OF NO. 1 CLUTCH Transmission Unit

48. INSTALL INPUT SHAFT

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





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





Thrust Needle Roller Bearing Diameter:





49. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

(a) Install the underdrive one-way clutch, clutch hub thrust washer and input shaft rear thrust bearing race to the coast clutch hub.





Bearing and Race Diameter:





Text in Illustration





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





50. INSTALL CLUTCH HUB SUB-ASSEMBLY

(a) Install the 2 thrust needle roller bearings 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.





51. INSTALL NO. 3 CLUTCH DISC

(a) Install the clutch cushion plate, reverse clutch flange, 4 No. 3 clutch plates and 5 No. 3 clutch discs to the reverse clutch hub.





Installation order:

*1 - *2 - *4 - *3 - *4 - *3 - *4 - *3 - *4 - *3 - *4

Text in Illustration





52. INSTALL REVERSE CLUTCH REACTION SLEEVE

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





53. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Install the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 No. 3 clutch discs and 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 input shaft assembly.





54. INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY

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





55. INSTALL CLUTCH DRUM AND INPUT SHAFT

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





Text in Illustration





(b) Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.

Thrust Needle Roller Bearing and Race Diameter:





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





56. INSTALL OIL PUMP ASSEMBLY

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





Thrust Bearing Race Diameter:





(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 10 bolts.





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

57. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

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





Text in Illustration





SST : 09350-30020

09350-07110

Oil seal drive in depth:

-0.3 to 0.3 mm (-0.0118 to 0.0118 in.)

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

58. INSPECT INDIVIDUAL PISTON OPERATION Transmission Unit

59. 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.