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Home >> Toyota Truck >> 2008 >> Landcruiser V8-5.7L (3UR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> Transmission Unit >> Reassembly >> Part 1

Part 1








AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

REASSEMBLY

1. BEARING POSITION





Bearing and Race Diameter:






2. INSTALL 1ST AND REVERSE BRAKE PISTON





(a) Coat 3 new O-rings with ATF, and install them to the 1st and reverse brake piston.






(b) Install the 1st and reverse brake piston to the transmission case.

NOTICE:
- Be careful not to damage the O-ring.
- Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston protrusion to the transmission case spline grooves.





3. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Place the brake return spring onto the 1st and reverse brake piston.
SST: 09380-60010
09381-06030
09381-06040
09381-06080
09381-06120
09381-06130
09381-05040
09381-05050
(b) Place SST on the spring retainer, and compress the return spring.
(c) Using SST, install the snap ring.
SST: 09350-30020
09350-07070
4. SELECT NO. 4 BRAKE FLANGE





(a) Measure distance A (from the tip of the 1st and reverse brake piston to the step in the transmission case) in the illustration.*1
HINT: Standard distance A: 27.82 to 28.42 mm (1.09 to 1.12 in.)





(b) Assemble the No. 4 brake flange, 7 No. 4 brake discs and 6 No. 4 brake plates, and measure distance B in the illustration.*2
HINT: Standard distance B: 25.98 to 27.01 mm (1.02 to 1.06 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 No. 4 brake selective flange indicated by the graph point.





(d) Measure length H of the selected flange as shown in the illustration.
HINT: Make sure that when the B measurement and H dimension of the selected flange are subtracted from the A measurement, the value is 0.961 to 1.261 mm (0.0378 to 0.0495 in.).

No. 4 Brake Selected Flange Length H:






5. INSTALL REAR PLANETARY GEAR ASSEMBLY





(a) Install the thrust bearing race.
HINT: Use a small amount of MP grease to make the thrust bearing race stay securely in place.

Bearing Race Diameter:










(b) Install the 2 thrust needle roller bearings to the rear planetary gear.
Bearing Diameter:





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





(c) Install the rear planetary gear assembly.






6. INSTALL BRAKE PLATE STOPPER SPRING
7. INSTALL REAR PLANETARY RING GEAR





(a) Install the rear planetary ring gear flange to the rear planetary ring gear.
(b) Using a screwdriver, install the snap ring.






(c) Install the 3 thrust bearing races, thrust needle roller bearing and planetary ring gear with the rear planetary ring gear flange to the intermediate shaft.
HINT: Use a small amount of MP grease to make the thrust needle roller bearing and races stay securely in place.

Bearing and Race Diameter:










8. INSTALL INTERMEDIATE SHAFT WITH REAR PLANETARY RING GEAR FLANGE AND REAR PLANETARY RING GEAR
(a) Install the intermediate shaft with the rear planetary ring gear flange and rear planetary ring gear to the transmission case.






9. INSTALL NO. 4 BRAKE DISC SET
(a) Install the flange, 7 discs, 6 plates and selected flange.
Install in order:
F - D - P - D - P - D - P - D - P - D - P - D - P - D - S/F
HINT: F = Flange
D = Disc
P = Plate
S/F = Selected flange
NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.





10. INSTALL NO. 3 1-WAY CLUTCH INNER RACE
(a) Install the 1-way clutch inner race to the No. 3 1-way clutch assembly.
NOTE: Do not mistake the direction of the 1-way clutch inner race.

11. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY Transmission Unit

12. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY





(a) Install the 1-way clutch assembly to the transmission case.






(b) Using SST, install the snap ring.
SST: 09350-30020
09350-07060






13. INSTALL NO. 2 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.
NOTE: Be careful not to damage the O-rings.

14. INSTALL NO. 2 BRAKE CYLINDER WITH NO. 2 BRAKE PISTON
(a) Install the No. 2 brake cylinder with piston to the transmission case.





NOTICE:





- When installing the No. 2 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.
- Make sure the No. 2 brake cylinder with piston is securely inserted into the transmission case.

15. SELECT NO. 2 BRAKE FLANGE





(a) Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.
(b) Place SST on the brake flange and compress the brake return spring.
SST: 09380-60010
09381-06010
09381-06020
09381-06050
09381-06070
09381-06090
09381-06120
(c) Using a screwdriver, install the snap ring to the transmission case.






(d) Measure distance A (from the top surface of the snap ring to the top surface of the brake piston return spring retainer) in the illustration.*1
HINT: Standard distance A: 21.00 to 21.76 mm (0.834 to 0.857 in.)





(e) Assemble the 4 discs, 3 plates and flange as shown in the illustration. Then with a fixture of 165.2 mm (6.50 in.) or less placed on the flange, measure distance B.*2
HINT: Standard distance B: 16.54 to 17.15 mm (0.651 to 0.675 in.)

(f) 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 2.20 to 2.50 mm (0.0866 to 0.0984 in.).

Flange Thickness:






(g) Remove the snap ring, flange and No. 2 brake piston return spring from the transmission case.
16. INSTALL NO. 2 BRAKE DISC SET





(a) Install the brake piston return spring, selected flange, 4 discs, 3 plates and flange.
Install in order:
S/F - D - P - D - P - D - P - D - F
HINT: S/F = Selected flange
D = Disc
P = Plate
F = Flange
NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.





(b) Place SST on the brake flange and compress the brake return spring.
SST: 09380-60010
09381-06010
09381-06020
09381-06050
09381-06070
09381-06090
09381-06120
(c) Using a screwdriver, install the snap ring to the transmission case.






17. INSTALL CENTER PLANETARY GEAR ASSEMBLY
(a) Install the center planetary sun gear and center planetary gear to the transmission case.
NOTE: Make sure to install the center planetary sun gear with the groove facing the transmission case.





18. INSTALL NO. 1 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.
NOTE: Be careful not to damage the O-rings.

19. INSTALL NO. 1 BRAKE CYLINDER WITH NO. 1 BRAKE PISTON
(a) Install the No. 1 brake cylinder with piston and brake piston return spring to the transmission case.





NOTICE:





- When installing the No. 1 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.
- Make sure the No. 1 brake cylinder with piston is securely inserted into the transmission case.





(b) Place SST on the brake return spring and compress the brake return spring.
SST: 09380-60010
09381-06010
09381-06020
09381-06050
09381-06060
09381-06090
09381-06100
09381-06110
09381-06120
(c) Using a screwdriver, install the snap ring to the transmission case.
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:














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