Part 1

AA80E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

1. BEARING POSITION

Bearing Position:

2. INSTALL OUTPUT SHAFT REAR RADIAL BALL BEARING

(a) Using SST, tap in the bearing to the transmission case.

SST : 09316-60011

09316-00011

09316-00021

(b) Using needle-nose pliers, install the snap ring.

3. INSTALL AUTOMATIC TRANSMISSION REAR OIL SEAL

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

(b) Using SST and a hammer, tap in the oil seal until it fits with the transmission case.

SST : 09214-76011

Standard oil seal depth:

3.5 +/-0.2 mm (0.138 +/-0.008 in.)

4. INSTALL NO. 2 BRAKE PISTON

(a) Coat 3 new O-rings with ATF, and install them to the brake piston.

(b) Install the brake piston to the transmission case.

HINT
Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston's 2 protrusions to 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 brake return spring to the transmission case.

(d) Set SST on the brake piston return spring, tighten SST and compress the return spring.

SST : 09380-50010

(e) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

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 fixture 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.)

(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 rear clutch drum sub-assembly.

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

(c) Install the clutch piston to the rear 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 piston return spring sub-assembly and balancer to the rear clutch drum sub-assembly.

(f) Place SST on the clutch balancer and compress the 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 plates, 6 discs and flange to the rear clutch drum.

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 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 clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2cm, 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 is within the standard value.

Standard:

0.90 to 1.20 mm (0.0354 to 0.0472 in.)

Flange thickness:

(d) Temporarily remove the snap ring, attach the selected flange and restore 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 sub-assembly.

NOTICE:
Do not expand the ring ends excessively.

(b) Coat 3 new oil seal rings with ATF, and install them to the output shaft.

NOTICE:
Do not expand the ring ends excessively.

Standard bearing and race diameter:

NOTICE:
Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.

(d) Connect the direct clutch assembly to the output shaft.

9. INSTALL REAR PLANETARY RING GEAR

(a) Install the snap ring to the groove of the output shaft.

(b) Using needle-nose pliers, attach the snap ring to install the ring gear to the output shaft.

10. INSTALL DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY

(a) Install the 2 thrust needle bearings, 2 thrust bearing races, direct clutch with rear planetary ring gear and output shaft to the transmission case.

Standard bearing and race diameter:

NOTICE:
Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.

11. INSTALL AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY

(a) Using SST, install a new oil seal to the automatic transmission flange yoke.

SST : 09950-60010

09951-00410

SST : 09950-70010

09951-07100

(b) Install the rear cover sleeve and 2 output shaft rear bearing No. 1 spacers.

(c) Install the automatic transmission flange yoke.

(d) Set SST.

SST : 09330-00021

SST : 09950-30012

09955-03040

(e) Using SST and a 30 mm socket wrench, temporarily install and tighten a new nut.

Torque : 126 Nm (1,285 kgf-cm, 93 ft-lbf)

12. SELECT REAR COVER SLEEVE

(a) Using a dial indicator, measure the output shaft end play. Then choose from the 15 sleeve thicknesses in the table so that the measured value is within the standard value.

Standard end play:

0.21 to 0.36 mm (0.0083 to 0.0142 in.)

Sleeve thickness:

(b) Temporarily remove the lock nut, flange yoke, 2 spacers and sleeve, attach the selected sleeve and restore the flange yoke.

(c) Using a chisel and hammer, securely stake the nut.

13. 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:

NOTICE:
* Before installing the rear planetary gear, apply ATF to rear planetary gear bush's sliding surfaces. After the installation, check that the rear planetary gear rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.

14. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY

(a) Install the thrust bearing race and sun gear to the transmission case.

Standard bearing race diameter:

NOTICE:
* Before installing the sun gear, apply ATF to sun gear bush's sliding surfaces. After the installation, check that the sun gear rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing race stay securely in place.

15. INSTALL NO. 2 BRAKE DISC SET

(a) Install the selected flange, 4 discs, 3 No. 2 plates and No. 1 plate.

Install in order:

F - D - No. 2 P - D - No. 2 P - D - No. 2 P - D - No. 1 P

HINT
F = Flange

D = Disc

P = Plate

HINT
Assemble the transmission case, flanges and plates by aligning their grooves as shown in the illustration.

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

16. INSTALL NO. 1 1-WAY CLUTCH

(a) Install the 1-way clutch to the outer race with the 2 snap rings.

NOTICE:
Do not mistake the direction of the 1-way clutch.

17. INSPECT NO. 1 1-WAY CLUTCH Transmission Unit

18. INSTALL 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH

(a) Install the 1-way clutch outer race with 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 end is within the range shown in the illustration.

19. INSTALL SUN GEAR INPUT DRUM SUB-ASSEMBLY

(a) Install the thrust bearing race, thrust needle roller bearing and sun gear input drum.

Standard bearing and race diameter:

NOTICE:
* Before installing the sun gear input drum, apply ATF to the sun gear input drum bush's sliding surfaces. After the installation, check that the sun gear input drum rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.

20. INSTALL FORWARD CLUTCH PISTON

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

(b) Install the 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 clutch balancer to the forward clutch drum.

(e) Place SST on the 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 (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
* Do not expand the snap ring excessively.

21. INSTALL FORWARD MULTIPLE CLUTCH DISC SET

(a) Install the cushion plate, 4 plates, 4 discs and flange to the forward clutch drum.

Install in order:

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

HINT
C = Cushion

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 moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2cm, 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 is within the standard value.

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.

22. INSTALL FRONT PLANETARY RING GEAR

(a) Install the snap ring to the groove of forward clutch drum.

(b) Using needle-nose pliers, attach the snap ring to install the ring gear to the forward multiple disc clutch assembly.

NOTICE:
Check that the snap ring is securely fit into the groove by looking through the ring gear slots on both sides.