Part 3

AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

REASSEMBLY - Continued

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
NOTE: 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
NOTE: Do not expand the snap ring excessively.





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






(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.
NOTE: 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
NOTE: 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
NOTE: Do not expand the snap ring excessively.





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