Part 2

AA80E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY (Continued)

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.

27. INSTALL REVERSE CLUTCH DRUM SUB-ASSEMBLY

(a) Coat 3 new O-rings with ATF, and install them to the reverse clutch drum.

(b) Install the reverse clutch drum to the overdrive direct clutch drum sub-assembly.

28. INSTALL REVERSE CLUTCH PISTON

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

(b) Install the reverse clutch piston to the reverse clutch drum.

(c) Install the reverse clutch return spring and reverse clutch balancer to the reverse clutch drum.

(d) Place SST on the reverse clutch balancer, and compress the clutch balancer with a press.

SST : 09380-50010

(e) 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.

29. INSTALL REVERSE CLUTCH DISC SET

(a) Install the cushion plate, 5 plates, 5 discs and flange to the No. 2 reverse clutch drum.

Install in order:

C - 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) Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft onto the oil pump.

(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/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:

0.75 to 1.05 mm (0.0295 to 0.0413 in.)

Flange Thickness:

(e) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.

30. INSTALL OVERDRIVE CLUTCH DISC SET

(a) Install the 4 plates, 4 discs and flange to the overdrive direct clutch drum.

Install in order:

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:

0.6 to 0.9 mm (0.0236 to 0.0354 in.)

Flange Thickness:

(d) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring.

31. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary sun gear to the front planetary gear.

(b) Coat 2 new oil seal rings with ATF, and install them to the planetary gear.

NOTICE:
Do not expand the ring ends excessively.

(c) Coat 3 new oil seal rings with ATF, and install them to the planetary gear.

NOTICE:
Do not expand the ring ends excessively.

(d) Install the clutch drum thrust washer to the planetary gear.

NOTICE:
Use a small amount of MP grease to secure the thrust washer in place.

(e) Assemble the front planetary gear assembly with the front planetary sun gear to the overdrive and reverse clutch disc assembly.

32. SELECT NO. 1 BRAKE FLANGE

(a) Measure length A (from the step of the oil pump installation surface of the transmission case to the step of the No. 1 brake flange installation surface) in the illustration.*1

Standard:

59.77 to 60.03 mm (2.35 to 2.36 in.)

(b) Measure length B (from the flange face of the oil pump assembly to the tip of the stator shaft piston) in the illustration.*2

Standard:

34.636 to 34.964 mm (1.36 to 1.38 in.)

(c) Assemble the 5 brake plates, 5 brake discs, and brake flange, and measure length C in the illustration.*3

Standard:

23.84 to 24.36 mm (0.939 to 0.959 in.)

(d) Choose a No. 1 brake flange from the table so that the value of measured length A minus lengths B and C (from steps *1, *2, *3) will be 0.75 to 1.05 mm (0.0295 to 0.0413 in.).

Flange Thickness:

33. INSTALL OVERDRIVE AND REVERSE CLUTCH DISC WITH FRONT PLANETARY GEAR ASSEMBLY

(a) Install the thrust bearing race, thrust needle roller bearing, overdrive and reverse multiple disc clutch assembly with front planetary gear assembly to the transmission case.

Standard Bearing and Race Diameter:

Install in order:

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

HINT
F = Flange

D = Disc

P = Plate

NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.

35. INSTALL OIL PUMP ASSEMBLY

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

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

(c) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the No. 3 clutch drum.

(d) Install the 11 bolts.

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

NOTICE:
* Make sure to apply seal packing to the flanges of the bolts.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or equivalent

* Do not allow seal packing to contact the bolt threads.
* During installation, do not allow oil to contact the bolts or the surface of the oil pump body.

36. INSPECT INDIVIDUAL PISTON OPERATION

(a) Check for operating sounds while applying compressed air into the oil holes indicated in the illustration.

HINT
C1 = Forward multiple clutch

C2 = No. 2 clutch

C3 = No. 3 clutch

C4 = Reverse clutch

B1 = No. 1 brake

B2 = No. 2 brake

37. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal.

SST : 09350-30020

09350-07110

Standard depth:

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

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

38. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

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

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

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

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

(e) Make sure that the shaft rotates smoothly.

39. INSTALL PARKING LOCK PAWL SHAFT

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

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

40. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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