Part 3

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


20. SELECT NO. 1 BRAKE FLANGE





(a) Measure distance A (from the step in the transmission case to the tip of the No. 1 brake piston) in the illustration.*1
HINT:
Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)





(b) Assemble the 4 plates and 4 discs and measure distance B in the illustration.*2
HINT:
Standard distance B: 16.72 to 17.19 mm (0.658 to 0.677 in.)

(c) Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the flange indicated by the graph point.





HINT:
Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 0.56 to 0.86 mm (0.0220 to 0.0339 in.).

Flange Thickness:






21. INSTALL CENTER PLANETARY RING GEAR





(a) Install the front planetary ring gear flange to the center planetary ring gear.






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






22. INSTALL FRONT PLANETARY RING GEAR
(a) Install the front planetary ring gear to the center planetary ring gear.






23. INSTALL FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY AND CENTER PLANETARY RING GEAR
(a) Install the thrust bearing race and thrust needle roller bearing.
HINT: Use a small amount of MP grease to make the thrust needle roller bearing and race stay securely in place.

Bearing and Race Diameter:






(b) Install the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear to the transmission case.
24. INSTALL FRONT PLANETARY GEAR ASSEMBLY





(a) Install the No. 2 planetary carrier thrust washer to the front planetary gear.
HINT: Use a small amount of MP grease to make the thrust washer stay securely in place.





(b) Install the thrust needle roller bearing, thrust bearing race, front planetary sun gear and front planetary gear.
HINT: Use a small amount of MP grease to make the thrust needle roller bearing and race stay securely in place.

Bearing Diameter:










25. INSTALL 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY
(a) Apply the No. 1 planetary carrier thrust washer to the 1-way clutch inner race, and then install them to the 1-way clutch.
HINT: Use a small amount of MP grease to make the thrust washer stay securely in place.

26. INSPECT 1-WAY CLUTCH ASSEMBLY Transmission Unit







27. INSTALL 1-WAY CLUTCH ASSEMBLY WITH 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY
(a) Install the 1-way clutch with the 1-way clutch inner race to the transmission case.






28. INSTALL NO. 1 BRAKE 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.

29. INSTALL NO. 3 BRAKE PISTON





(a) Coat 2 new O-rings with ATF, and install them to the brake piston.
(b) Press the brake piston into the brake cylinder with both hands.
NOTICE:
Be careful not to damage the O-rings.





(c) Using SST and a press, compress the return spring and install the snap ring with a screwdriver.
SST: 09380-60010
09381-06020
09381-06040
09381-06060
09381-06100
09381-06110
NOTICE:
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

30. INSTALL NO. 3 BRAKE CYLINDER WITH NO. 3 BRAKE PISTON AND NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





(a) Install the No. 3 brake cylinder with the No. 3 brake piston and No. 3 brake piston return spring to the transmission case.
NOTICE:
- Align the oil holes of the No. 3 brake cylinder and transmission case as shown in the illustration.





- Make sure the No. 3 brake piston and cylinder are securely inserted into the transmission case.





31. INSTALL NO. 3 BRAKE PISTON HOLE SNAP RING
(a) Using SST, install the snap ring.
SST: 09350-30020
09350-07060






32. INSTALL NO. 3 BRAKE DISC SET
(a) Install the "O" mark flange, 4 discs, 3 plates and "A" mark flange to the transmission case.
Install in order:
OF - D - P - D - P - D - P - D - AF
HINT:
OF = "O" mark flange
P = Plate
D = Disc
AF = "A" mark flange
NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.





33. INSTALL NO. 3 BRAKE SNAP RING
(a) Using a screwdriver, install the snap ring.
34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY





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






(b) Install the direct clutch return spring and No. 2 clutch balancer to the direct clutch piston.






(c) Press the direct clutch piston with the clutch return spring and clutch balancer into the reverse clutch piston with both hands.
NOTICE:
Be careful not to damage the O-ring.





(d) Place SST on the direct clutch balancer, and compress the return spring with a press.
SST: 09380-60010
09381-06030
09381-06040
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.

(e) Using SST, install the snap ring.
SST: 09350-30020
09350-07070
NOTICE:
Do not expand the snap ring excessively.





(f) 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.

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.






(c) Pass the clutch drum into the reverse clutch piston with both hands.
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
HINT:
D = Disc
HINT:
P = Plate
HINT:
S/F = Selected flange
HINT:
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.






(c) Coat a new O-ring with ATF, and install it to the No. 1 clutch balancer.






(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.