Part 2
AA80F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY
20. INSTALL FRONT PLANETARY RING GEAR
(a) Install the snap ring to the groove of the forward clutch drum sub-assembly.
(b) Using needle-nose pliers, attach the snap ring to install the forward planetary ring gear to the forward disc clutch drum sub-assembly.
NOTICE:
Check that the snap ring is securely inserted into the groove by looking through the ring gear slots on both sides.
21. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust needle roller bearing, thrust bearing race and multiple disc clutch clutch hub to the forward clutch drum sub-assembly.
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.
22. INSTALL FORWARD CLUTCH DRUM SUB-ASSEMBLY WITH FRONT PLANETARY RING GEAR AND MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race, the thrust needle roller bearing and the forward clutch drum sub-assembly with front planetary ring gear and multiple disc clutch clutch hub to the transmission case.
Standard bearing and race diameter:
Text in Illustration
NOTICE:
* Before installing the forward clutch drum, apply ATF to the sliding surfaces of the forward clutch drum bush. After installation, check that the forward clutch drum rotates smoothly.
* Use a small amount of MP grease to make the thrust needle roller bearing and thrust bearing race stay securely in place.
23. 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 sub-assembly to the overdrive direct clutch drum sub-assembly.
(d) Coat a new O-ring with ATF and install it to the No. 3 clutch balancer.
(e) Install the overdrive clutch return spring sub-assembly and No. 3 clutch balancer to the overdrive direct clutch drum sub-assembly.
(f) Place SST on the No. 3 clutch balancer and compress the No. 3 clutch balancer with a press.
SST : 09380-50010
(g) 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.
24. INSTALL REVERSE CLUTCH DRUM SUB-ASSEMBLY
(a) Coat 3 new O-rings with ATF and install them to the reverse clutch drum sub-assembly.
(b) Install the reverse clutch drum sub-assembly to the overdrive direct clutch drum sub-assembly.
25. 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, reverse clutch return spring sub-assembly and reverse clutch balancer.
(c) Place SST on the reverse clutch balancer and compress the reverse clutch balancer with a press.
SST : 09380-50010
(d) 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.
26. INSTALL REVERSE CLUTCH DISC SET
(a) Install the cushion plate, 5 reverse clutch plates, 5 reverse clutch discs and reverse clutch flange to the reverse clutch drum sub-assembly.
Install in order:
C - P - D - P - D - P - D - P - D - P - D - F
HINT
C = Cushion Plate
P = Reverse Clutch Plate
D = Reverse Clutch Disc
F = Reverse Clutch Flange
NOTICE:
* Install the cushion plate with its marked side facing 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 assembly onto the torque converter, and then place the overdrive direct clutch drum sub-assembly and front planetary gear assembly onto the oil pump assembly.
Text in Illustration
(d) Using a dial indicator, measure the moving distance (distance A) of the 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:
0.75 to 1.05 mm (0.0295 to 0.0354 in.)
Flange Thickness:
(e) Temporarily remove the snap ring, install the selected flange and reinstall the snap ring.
27. INSTALL OVERDRIVE CLUTCH DISC SET
(a) Install the 4 overdrive brake clutch plates, 4 overdrive clutch discs and overdrive clutch flange to the overdrive direct clutch drum sub-assembly.
Install in order:
P - D - P - D - P - D - P - D - F
HINT
P = Overdrive Brake Clutch Plate
D = Overdrive Clutch Disc
F = Overdrive Clutch Flange
NOTICE:
Before assembling new overdrive 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 overdrive 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 7 flange thicknesses in the table so that the measured value is within the standard range.
Standard:
0.6 to 0.9 mm (0.0236 to 0.0354 in.)
Flange Thickness:
Text in Illustration
(d) Temporarily remove the snap ring, install the selected overdrive clutch flange and reinstall the snap ring.
28. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the planetary sun gear.
(b) Coat 2 new clutch drum oil seal rings with ATF and install them to the front planetary gear assembly.
NOTICE:
Do not excessively widen the rings.
(c) Coat 3 new clutch drum oil seal rings with ATF and install them to the front planetary gear assembly.
NOTICE:
Do not excessively widen the rings.
(d) Install the planetary carrier thrust washer to the front planetary gear assembly.
NOTICE:
Use a small amount of MP grease to make the thrust washer stay securely in place.
(e) Install the front planetary gear assembly together with the front planetary sun gear to the overdrive direct clutch drum sub-assembly.
29. 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) shown in the illustration. *1
Standard:
59.77 to 60.03 mm (2.3531 to 2.3634 in.)
(b) Measure length B (from the flange face of the oil pump assembly to the tip of the stator shaft piston) shown in the illustration. *2
Standard:
34.636 to 34.964 mm (1.3636 to 1.3765 in.)
(c) Assemble the 5 No. 1 brake plates, 5 No. 1 brake discs, and No. 1 brake flange, and measure length C shown in the illustration. *3
Standard:
23.84 to 24.36 mm (0.9386 to 0.9591 in.)
Text in Illustration
(d) Choose a No. 1 brake flange so that the value of measured length A minus lengths B and C (from steps *1, *2 and *3) is 0.75 to 1.05 mm (0.0295 to 0.0413 in.).
Flange thickness:
30. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY WITH FRONT PLANETARY GEAR ASSEMBLY
(a) Install the thrust bearing race, the thrust needle roller bearing and the overdrive clutch drum sub-assembly with front planetary gear assembly to the transmission case.
Standard bearing and race diameter:
Text in Illustration
NOTICE:
* Before installing the overdrive and reverse clutch, apply ATF to the sliding surfaces of the overdrive direct clutch drum bush. After installation, check that the overdrive direct clutch drum rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
31. INSTALL NO. 1 BRAKE DISC SET
(a) Install the selected No. 1 brake flange, 5 No. 1 brake discs and 5 No. 1 brake plates to the transmission case.
Install in order:
F - D - P - D - P - D - P - D - P - D - P
HINT
F = No. 1 Brake Flange
D = No. 1 Brake Disc
P = No. 1 Brake Plate
NOTICE:
Before assembling new No. 1 brake discs, soak them in ATF for at least 2 hours.
32. INSTALL OIL PUMP ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the oil pump assembly.
(b) Place the oil pump assembly over the input shaft and align the bolt holes of the oil pump assembly with the transmission case.
(c) Hold the input shaft and lightly press the oil pump assembly to slide the oil seal rings into the overdrive direct clutch drum sub-assembly.
(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 threads of the bolts.
* During installation, do not allow oil to contact the bolts or the surface of the oil pump body.
33. INSPECT INDIVIDUAL PISTON OPERATION
(a) Check the operating sound while blowing compressed air into the oil holes indicated in the illustration.
HINT
C1 = Forward multiple clutch clutch disc
C2 = No. 2 clutch
C3 = Overdrive direct clutch
C4 = Reverse clutch
B1 = No. 1 brake
B2 = No. 2 brake
Text in Illustration
34. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using SST and a hammer, tap in a new manual valve lever shaft oil seal.
SST : 09350-30020
09350-07110
Standard depth:
0 +/-0.3 mm (0 +/-0.012 in.)
(b) Coat the lip of the manual valve lever shaft oil seal with MP grease.
35. 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, tap in a new spring pin.
(d) Align the indentation of the manual valve lever with the spacer hole and stake them together with a punch.
(e) Make sure that the shaft rotates smoothly.
36. INSTALL PARKING LOCK PAWL SHAFT
(a) Install the E-ring to the parking lock pawl shaft.
Text in Illustration
(b) Install the parking lock pawl, parking lock pawl shaft and spring.
37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Connect the parking lock rod sub-assembly to the manual valve lever sub-assembly.
38. INSTALL PARKING LOCK PAWL BRACKET
(a) Place the parking lock pawl bracket onto the transmission case. Loosely install the 3 bolts, and then tighten them in the order shown in the illustration.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Shift the manual valve lever sub-assembly to the P position and confirm that the output shaft is correctly locked by the parking lock pawl.
39. INSTALL AUTOMATIC TRANSMISSION CASE PLUG
(a) Coat a new O-ring with ATF and install it to the automatic transmission case plug.
(b) Install the automatic transmission case plug to the transmission case.
Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)
40. INSTALL SPEED SENSOR
(a) Coat the O-ring with ATF and install it to speed sensor NT.
(b) Using a T30 ''TORX'' wrench, install speed sensor NT with the bolt.
Torque : 6.8 Nm (69 kgf-cm, 60 in-lbf)
(c) Install speed sensors SP2 and NC3 with the 2 bolts.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
41. INSTALL TRANSMISSION WIRE
(a) Coat the O-ring of the transmission wire connector with ATF.
(b) Install the transmission wire.
(c) Install the bolt.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
(d) Connect the 3 speed sensor connectors.
42. INSTALL CHECK BALL BODY
(a) Install the spring and check ball body.
43. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Align the groove of the manual valve lever sub-assembly with the pin of the manual valve and install the pin.
(b) Install the 17 bolts.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT
Each bolt length is indicated below.
Bolt length:
21 mm (0.83 in.) for bolt A
31 mm (1.22 in.) for bolt B
64 mm (2.52 in.) for bolt C
(c) Install the detent spring and detent spring cover with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Text in Illustration
NOTICE:
Make sure that the roller at the end of the detent spring is perpendicular to the manual valve lever, and that the manual valve lever sub-assembly is positioned at the center of the roller.
(d) Connect the 9 connectors to the solenoid valves.
(e) Connect the oil pressure switch connector.
(f) Coat the O-ring of the ATF temperature sensor with ATF.
(g) Install the ATF temperature sensor and lock plate with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
44. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the valve body oil strainer assembly.
NOTICE:
Ensure that the O-ring is not twisted or pinched.
(b) Install the valve body oil strainer assembly to the transmission valve body assembly with the 4 bolts.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
45. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
(a) Install the 3 magnets to the automatic transmission oil pan.
(b) Install a new gasket and the automatic transmission oil pan to the transmission case with the 9 bolts.
Torque : 7.3 Nm (74 kgf-cm, 64 in-lbf)
Text in Illustration
NOTICE:
* Make sure that there is no oil or foreign matter on the gasket seal surface or automatic transmission oil pan contact surface.
* Install the gasket so that there is no slack in the gasket, and that the entire circumference of the seal surface is level.
* Make sure that the 9 gasket drop prevention protrusions are set in place on the oil pan.
* When tightening the bolts of the oil pan, make sure that the gasket is not pinched between the sleeve and the seal surface of the transmission.
46. INSTALL NO. 1 BREATHER PLUG
47. INSTALL OIL COOLER TUBE ELBOW
(a) Coat 2 new O-rings with ATF and install them to the oil cooler tube elbows.
(b) Install the oil cooler tube elbows as shown in the illustration.
Text in Illustration
Torque : 29 Nm (300 kgf-cm, 22 ft-lbf)
48. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Install the park/neutral position switch assembly to the manual valve lever shaft sub-assembly and temporarily install the bolt.
(b) Install a new lock washer with the nut.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
(c) Temporarily install the transmission control shaft lever RH.
(d) Turn the transmission control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position.
(e) Remove the transmission control shaft lever RH.
(f) Align the groove with the neutral basic line.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
Text in Illustration
(g) Hold the switch in position and tighten the bolt.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
(h) Using a screwdriver, bend the tabs of the lock washer.
HINT
Bend at least 2 washer tabs.
49. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH
(a) Install the transmission control shaft lever RH with the nut and spring washer.
Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)