Part 2

AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY - Continued

35. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

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

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

NOTICE:
* Be careful not to damage the O-ring.
* Make sure to align the holes of the reverse clutch piston and clutch drum as shown in the illustration.
* Make sure to align the protrusions of the reverse clutch piston and the cutout of the clutch drum.

36. INSTALL NO. 3 CLUTCH BALANCER

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

(b) Install the reverse clutch return spring and balancer onto the reverse clutch piston.

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

SST : 09380-60010

09381-06020

09381-06030

09381-06040

09381-06050

09381-06070

09381-06080

NOTICE:
Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

(d) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

NOTICE:
Do not expand the snap ring excessively.

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

NOTICE:
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

37. INSTALL DIRECT CLUTCH DISC

(a) Place the oil pump onto the torque converter clutch, and then place the clutch drum onto the oil pump.

(b) Install the 5 plates, 5 discs and reverse clutch flange to the clutch drum.

Install in order:

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.

(c) Using a screwdriver, install the snap ring to the clutch drum.

(d) Using a dial indicator, measure the moving distance (A) of the clutch flange at both ends across the diameter while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 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 value.

Standard moving distance (A):

0.58 to 0.88 mm (0.0228 to 0.0346 in.)

Flange Thickness:

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

38. SELECT REVERSE CLUTCH FLANGE

(a) Using a screwdriver, install the snap ring to the clutch drum.

NOTICE:
Make sure to install the direct clutch and reverse clutch snap rings so that their openings face opposite directions.

(b) Install the flange, 5 discs, 4 plates, selected flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P - D - S/F - C

HINT
F = Flange

D = Disc

P = Plate

S/F = Selected flange

C = Cushion plate

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

(d) Using a dial indicator, measure the moving distance (A minus B) of the tip of the reverse clutch piston (A) and cushion plate at both ends across the diameter (B) while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 psi) into the oil hole as shown in the illustration. Then choose from the 12 flange thicknesses in the table so that the measured value is within the standard value.

Standard moving distance (A minus B):

0.59 to 0.89 mm (0.0232 to 0.0350 in.)

Flange Thickness:

(e) Remove the snap ring, reverse clutch reaction sleeve and rear clutch disc set from the clutch drum.

39. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY AND COAST CLUTCH PISTON

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

(b) Install the forward clutch piston and coast clutch piston to the input shaft.

(d) Install the forward clutch return spring and No. 1 clutch balancer to the input shaft.

NOTICE:
Be careful not to damage the O-rings.

(e) Place SST on the No. 1 clutch balancer, and compress the return spring with a press.

SST : 09350-30020

09350-07040

NOTICE:
Stop pressing when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.

(f) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

NOTICE:
Do not expand the snap ring excessively.

(g) Set the end gap of the snap ring in the balancer as shown in the illustration.

NOTICE:
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

40. INSTALL COAST CLUTCH DISC SET

(a) Install the 4 plates, 4 discs and flange.

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 moving 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 11 flange thicknesses in the table so that the measured value is within the standard value.

Standard moving distance (A):

0.41 to 0.71 mm (0.0161 to 0.0280 in.)

Flange Thickness:

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

41. INSTALL NO. 4 1-WAY CLUTCH ASSEMBLY

(a) Install the No. 2 clutch hub thrust washer to the coast clutch hub.

HINT
Use a small amount of MP grease to make the thrust washer stay securely in place.

(b) Install the 1-way clutch to the coast clutch hub.

42. INSPECT NO. 4 1-WAY CLUTCH ASSEMBLY Transmission Unit

43. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY WITH NO. 4 1-WAY CLUTCH ASSEMBLY

(a) Install the 2 thrust needle roller bearings, thrust bearing race and coast clutch hub with the No. 4 1-way clutch to the input shaft.

HINT
Use a small amount of MP grease to make the thrust needle roller bearings and race stay securely in place.

Bearing and Race Diameter:

44. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC SET

(a) Install the cushion plate, 6 plates, 6 discs and flange to the input shaft.

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:
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 (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 12 flange thicknesses in the table so that the measured value is within the standard value.

Standard moving distance (A):

0.85 to 1.15 mm (0.0335 to 0.0453 in.)

Flange Thickness:

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

45. INSTALL INPUT SHAFT OIL SEAL RING

(a) Overlap the seal ring edges in the axial direction.

NOTICE:
* Overlapping the seal ring edges in the axial direction prevents damage to the seal ring.
* Do not overlap the seal ring edges in the radial direction, as this may damage the seal ring.

(b) Coat 4 new oil seal rings with ATF.

(c) Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.

NOTICE:
Do not excessively widen the rings.

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

46. INSTALL INPUT SHAFT ASSEMBLY

(a) Install the input shaft to the clutch drum.

47. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

(a) Install the No. 3 clutch hub thrust washer, forward clutch hub and thrust needle roller bearing to the clutch drum.

NOTICE:
Before installing the forward clutch hub, apply ATF to the forward clutch hub bush sliding surfaces. After the installation, check that the forward clutch hub rotates smoothly.

HINT
Use a small amount of MP grease to make the thrust needle roller bearing and thrust washer stay securely in place.

Bearing Diameter:

48. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Install the reverse clutch hub to the clutch drum.

NOTICE:
Before installing the reverse clutch hub, apply ATF to the reverse clutch hub bush sliding surfaces. After the installation, check that the reverse clutch rotates smoothly.

49. INSTALL REAR CLUTCH DISC SET

(a) Install the flange, 5 discs, 4 plates, selected flange, cushion plate and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P - D - S/F - C

HINT
F = Flange

D = Disc

P = Plate

S/F = Selected flange

C = Cushion plate

(b) Using a screwdriver, install the snap ring to the clutch drum.

50. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY

(a) Install the clutch drum thrust washer to the clutch drum.

HINT
Use a small amount of MP grease to make the thrust washer stay securely in place.

(b) Install the 1-way clutch to the clutch drum.

51. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY Transmission Unit

52. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

(a) Install the 2 thrust needle roller bearings.

HINT
Use a small amount of MP grease to make the thrust needle roller bearings stay securely in place.

Bearing Diameter:

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

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

53. INSTALL OIL PUMP ASSEMBLY

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

(b) Install the 2 thrust bearing races to the front oil pump.

Thrust Bearing Race Diameter:

(c) Pass the input shaft through the center hole of the oil pump, 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 body to slide the oil seal rings into the overdrive direct clutch drum.

(e) Apply seal packing to the flanges of the bolts.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

NOTICE:
Do not allow seal packing to contact the bolt threads.

(f) Install the 10 bolts.

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

NOTICE:
During installation, do not allow oil to contact the bolts or the surface of the oil pump body.

54. INSPECT INDIVIDUAL PISTON OPERATION Transmission Unit

55. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST, tap in 2 new oil seals.

SST : 09350-30020

09350-07110

(b) Coat the lips of the oil seals with MP grease.

56. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

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

(b) Push the manual valve lever shaft through the transmission case, and install the manual valve lever to the shaft.

(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 the punch.

(e) Check that the shaft rotates smoothly.

57. INSTALL PARKING LOCK PAWL

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

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

58. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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

59. INSTALL PARKING LOCK PAWL BRACKET

(a) Place the parking lock pawl bracket onto the transmission case and install the 3 bolts.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

(b) Move the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked by the lock pawl.