Part 4

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

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.

(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.

(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.