Part 1
AA80F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY
1. BEARING POSITION
Bearing Position:
2. 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.
Text in Illustration
HINT
Make sure that the parking hole of the No. 2 brake piston is on the bottom side by engaging the brake piston's 2 protrusions with the transmission case's spline grooves (one groove is 3 places clockwise from the top, and the other is 2 places clockwise from the bottom).
(c) Install the No. 2 brake piston return spring sub-assembly to the transmission case.
(d) Set SST against the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.
SST : 09380-50010
Text in Illustration
(e) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
3. INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING
(a) Using SST, tap in a new output shaft rear radial ball bearing to the transmission case.
SST : 09316-60011
09316-00011
09316-00021
(b) Using needle-nose pliers, install the snap ring.
4. INSTALL TRANSFER CASE ADAPTER REAR OIL SEAL
(a) Coat the lip of a new transfer case adapter rear oil seal with MP grease.
(b) Using SST and a hammer, tap the transfer case adapter rear oil seal into the transmission case.
SST : 09502-12010
SST : 09513-36040
Standard oil seal depth:
3.3 to 3.7 mm (0.13 to 0.15 in.)
5. 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:
14.77 to 15.37 mm (0.5815 to 0.6051 in.)
(b) Assemble the 4 No. 2 brakes 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 (0.5555 to 0.5783 in.)
Text in Illustration
(c) Choose a No. 2 brake flange so that the value of measured length A minus length B (from steps *1 and *2) is 0.52 to 0.82 mm (0.0204 to 0.0323 in.).
Flange Thickness:
6. 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 return spring and No. 2 clutch balancer to the direct clutch drum.
(f) Place SST on the No. 2 clutch balancer and compress the direct clutch return spring with a press.
SST : 09387-00020
(g) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
7. INSTALL NO. 2 CLUTCH DISC SET
(a) Install the 6 No. 2 clutch plates, 6 No. 2 clutch discs and direct clutch flange to the direct clutch drum sub-assembly.
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 No. 2 clutch discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.
(c) Using a dial indicator, measure the moving distance (distance A) of the direct clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.
Standard:
0.90 to 1.20 mm (0.0354 to 0.0472 in.)
Flange Thickness:
Text in Illustration
(d) Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.
8. CONNECT DIRECT CLUTCH ASSEMBLY
(a) Coat 2 new oil seal rings with ATF and install them to the direct clutch drum.
Text in Illustration
NOTICE:
Do not excessively widen the rings.
(b) Coat 3 new oil seal rings with ATF and install them to the output shaft.
Text in Illustration
NOTICE:
Do not excessively widen the rings.
(c) Install the thrust needle roller bearing and thrust bearing race.
Standard bearing and race diameter:
Text in Illustration
NOTICE:
Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.
(d) Connect the direct clutch drum sub-assembly to the output shaft sub-assembly.
9. INSTALL REAR PLANETARY RING GEAR
(a) Install the snap ring to the groove of the output shaft sub-assembly.
(b) Using needle-nose pliers, attach the snap ring to install the rear planetary ring gear to the output shaft sub-assembly.
10. INSTALL DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY
(a) Install the 2 thrust needle roller bearings, the 2 thrust bearing races and the direct clutch drum sub-assembly with rear planetary ring gear and output shaft sub-assembly to the transmission case.
Standard bearing and race diameter:
Text in Illustration
NOTICE:
Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.
11. 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:
Text in Illustration
NOTICE:
* Before installing the rear planetary gear, apply ATF to the sliding surfaces of the rear planetary gear bush. After installation, check that the rear planetary gear rotates smoothly.
* Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.
12. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Install the thrust bearing race and rear planetary sun gear assembly to the transmission case.
Standard bearing race diameter:
NOTICE:
* Before installing the rear planetary sun gear, apply ATF to the sliding surfaces of the sun gear bush. After installation, check that the rear planetary sun gear assembly rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing race stay securely in place.
13. INSTALL NO. 2 BRAKE DISC SET
(a) Install the selected No. 2 brake flange, 4 No. 2 brake discs, 3 No. 2 brake plates and brake plate.
Install in order:
F - D - P - D - P - D - P - D - B
HINT
F = No. 2 Brake Flange
D = No. 2 Brake Disc
P = No. 2 Brake Plate
B = Brake Plate
HINT
Assemble the transmission case, No. 2 brake flanges and No. 2 brake plates by aligning their grooves as shown in the illustration.
Text in Illustration
NOTICE:
Before assembling new No. 2 brake discs, soak them in ATF for at least 2 hours.
14. INSTALL NO. 1 1-WAY CLUTCH
(a) Install the No. 1 1-way clutch to the 1-way clutch outer race with the 2 snap rings.
NOTICE:
Make sure that the No. 1 1-way clutch is facing in the correct direction.
15. INSPECT NO. 1 1-WAY CLUTCH Automatic Transmission Unit
16. INSTALL 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH
(a) Install the 1-way clutch outer race with No. 1 1-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 is facing the front side of the transmission case.
* Install the snap ring so that its gap is within the range shown in the illustration.
Text in Illustration
17. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY
(a) Install the thrust bearing race, thrust needle roller bearing and sun gear input drum sub-assembly.
Standard bearing and race diameter:
Text in Illustration
NOTICE:
* Before installing the sun gear input drum sub-assembly, apply ATF to the sliding surfaces of the sun gear input drum bush. After installation, check that the sun gear input drum sub-assembly rotates smoothly.
* Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.
18. INSTALL FORWARD CLUTCH PISTON
(a) Coat 2 new O-rings with ATF and install them to the front clutch piston.
(b) Install the forward clutch piston to the forward clutch drum sub-assembly.
(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 sub-assembly.
(e) Place SST on the No. 1 clutch balancer and compress the No. 1 clutch balancer with a press.
SST : 09380-50010
(f) Using SST, install the snap ring.
SST : 09350-30020
09350-07070
NOTICE:
* Make 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 a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
* Do not expand the snap ring excessively.
19. INSTALL FORWARD MULTIPLE CLUTCH CLUTCH DISC SET
(a) Install the clutch cushion plate, 6 forward multiple disc clutch clutch plates, 6 forward multiple disc clutch clutch discs and forward clutch flange to the forward clutch drum sub-assembly.
Install in order:
C - P - D - P - D - P - D - P - D - P - D - P - D - F
HINT
C = Clutch Cushion Plate
P = Forward Multiple Disc Clutch Clutch Plate
D = Forward Multiple Disc Clutch Clutch Disc
F = Forward Clutch Flange
NOTICE:
* Install the clutch cushion plate with its marked side facing towards the plates.
* Before assembling new forward multiple disc clutch clutch discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.
(c) Temporarily install the front planetary ring gear to the forward clutch drum assembly.
(d) Using a dial indicator, measure the moving distance (distance A) of the forward clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm, 28 psi) into the oil hole as shown in the illustration. Then choose from the 9 flange thicknesses in the table so that the measured value is within the standard range.
Text in Illustration
Standard:
0.90 to 1.20 mm (0.0354 to 0.0472 in.)
Flange Thickness:
(e) Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.
(f) Remove the front planetary gear assembly.