Part 2

AA80E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

24. INSTALL FORWARD CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR AND MULTIPLE DISC CLUTCH HUB

(a) Install the thrust bearing race, thrust needle bearing and forward clutch assembly with front planetary ring gear and multiple disc clutch hub to the transmission case.

Standard bearing and race diameter:

NOTICE:
* Before installing the forward clutch drum, apply ATF to forward clutch drum bush's sliding surfaces. After the installation, check that the forward clutch drum rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
25. INSTALL NO. 3 CLUTCH PISTON

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

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

(c) Install the piston to the direct clutch drum.

(d) Coat a new O-ring with ATF, and install it to the No. 3 clutch balancer.

(e) Install the overdrive clutch return spring and balancer to the direct clutch drum.

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

SST : 09380-50010

(g) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

NOTICE:
* Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
* Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
* Do not expand the snap ring excessively.
26. INSTALL REVERSE CLUTCH DRUM SUB-ASSEMBLY

(a) Coat 3 new O-rings with ATF, and install them to the drum.

(b) Install the drum to the overdrive direct clutch drum sub-assembly.

27. INSTALL REVERSE CLUTCH PISTON

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

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

(d) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

NOTICE:
* Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
* Stop pressing when the balancer is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent spring sheet deformation.
* Do not expand the snap ring excessively.
28. INSTALL REVERSE CLUTCH DISC SET

(a) Install the cushion plate, 5 plates, 5 discs and flange to the No. 2 reverse clutch drum.

Install in order:

C - P - D - P - D - P - D - P - D - P - D - F

HINT
C = Cushion Plate

P = Plate

D = Disc

F = Flange

NOTICE:
* Assemble the cushion plate by facing its marked side towards the plates.
* Before assembling new discs, soak them in ATF for at least 2 hours.
(b) Temporarily install the snap ring.

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

(d) Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2cm, 28 psi) from 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:

0.75 to 1.05 mm (0.0295 to 0.0354 in.)

Flange thickness:

(e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

29. INSTALL NO. 3 CLUTCH DISC SET

(a) Install the 4 plates, 4 discs and flange to the overdrive direct clutch drum.

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 (distance A) of the clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf2cm, 28 psi) from the oil hole as shown in the illustration. Then choose from the 7 flange thicknesses in the table so that the measured value is within the standard value.

Standard:

0.6 to 0.9 mm (0.0236 to 0.0354 in.)

Flange thickness:

(d) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

30. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary sun gear.

(b) Coat 2 new oil seal rings with ATF, and install them to the planetary gear.

NOTICE:
Do not expand the ring ends excessively.

(c) Coat 3 new oil seal rings with ATF, and install them to the planetary gear.

NOTICE:
Do not expand the ring ends excessively.

(d) Install the planetary carrier thrust washer to the planetary gear.

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

(e) Assemble the front planetary gear assembly with the front planetary sun gear to the overdrive and reverse multiple disc clutch assembly.

31. SELECT NO. 1 BRAKE FLANGE

(a) Measure length A (from the step of the oil pump installation surface of the transmission case to the step of the No. 1 brake flange installation surface) in the illustration. *1

Standard:

59.77 to 60.03 mm (2.3531 to 2.3634 in.)

(b) Measure length B (from the flange face of the oil pump assembly to the tip of the No. 1 brake piston) in the illustration. *2

Standard:

34.636 to 34.964 mm (1.3636 to 1.3765 in.)

(c) Assemble the 5 brake plates, 5 brake discs, and brake flange, and measure length C in the illustration. *3

Standard:

23.84 to 24.36 mm (0.9386 to 0.9591 in.)

(d) Choose a No. 1 brake flange so that the value of measured length A minus lengths B and C (from steps *1, *2, *3) is 0.75 to 1.05 mm (0.0295 to 0.0413 in.).

Flange thickness:

32. INSTALL OVERDRIVE AND REVERSE MULTIPLE DISC CLUTCH ASSEMBLY WITH FRONT PLANETARY GEAR ASSEMBLY

(a) Install the thrust bearing race, thrust needle bearing, overdrive and reverse multiple disc clutch assembly with front planetary gear assembly to the transmission case.

Standard bearing and race diameter:

NOTICE:
* Before installing the overdrive and reverse multiple clutch, apply ATF to the No. 3 clutch drum bush's sliding surfaces. After the installation, check that the No. 3 clutch drum rotates smoothly.
* Use a small amount of MP grease to make the thrust bearing and thrust bearing race stay securely in place.
33. INSTALL NO. 1 BRAKE DISC SET

(a) Install the selected flange, 5 discs and 5 plates to the transmission case.

Install in order:

F - D - P - D - P - D - P - D - P - D - P

HINT
F = Flange

D = Disc

P = Plate

NOTICE:
Before assembling new discs, soak them in ATF for at least 2 hours.

34. INSTALL OIL PUMP ASSEMBLY

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

(b) Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transmission case.

(c) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the No. 3 clutch drum.

(d) Install the 11 bolts.

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

NOTICE:
* Make sure to apply seal packing to the flanges of the bolts.

Seal packing:

Toyota Genuine Seal Packing 1281,

Three Bond 1281 or equivalent

* Do not allow seal packing to contact the bolts' threads.
* During installation, do not allow oil to contact the bolts or the surface of the oil pump body.
35. INSPECT INDIVIDUAL PISTON OPERATION

(a) Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

HINT
C1 = Forward multiple clutch

C2 = No. 2 clutch

C3 = No. 3 clutch

C4 = Reverse clutch

B1 = No. 1 brake

B2 = No. 2 brake

36. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST and a hammer, tap in a new oil seal.

SST : 09350-30020

09350-07110

Standard depth:

0 +/-0.3 mm (0 +/-0.012 in.)

(b) Coat the lip of the oil seal with MP grease.

37. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

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

(b) Install the manual valve lever shaft to the transmission case through the manual valve lever.

(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 a punch.

(e) Make sure that the shaft rotates smoothly.

38. INSTALL PARKING LOCK PAWL SHAFT

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

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

39. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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

40. INSTALL PARKING LOCK PAWL BRACKET

(a) Place the parking lock pawl bracket onto the transmission case. Loosely install the 3 bolts, and then tighten them in the order shown in the illustration.

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

(b) Shift the manual valve lever to the P position, and confirm that the output shaft is correctly locked up by the lock pawl.

41. INSTALL AUTOMATIC TRANSMISSION CASE PLUG

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

(b) Install the case plug to the transmission case.

Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

42. INSTALL SPEED SENSOR

(a) Coat a new O-ring with ATF and install it to the speed sensor NT.

(b) Using a T30 ''TORX'' wrench, install the sensor NT with the bolt.

Torque : 6.8 Nm (69 kgf-cm, 60 in-lbf)

(c) Install the speed sensor SP2 and NC3 with the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

43. INSTALL TRANSMISSION WIRE

(a) Coat a new O-ring with ATF and install it to the transmission wire connector.

(b) Install the transmission wire.

(c) Install the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(d) Connect the 3 speed sensor connectors.

44. INSTALL CHECK BALL BODY

(a) Install the spring and check ball body.

45. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the groove of the manual valve lever with the pin of the manual valve and install the pin.

(b) Install the 17 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

HINT
Each bolt length is indicated below.

Bolt length:

21 mm (0.83 in.) for bolt A

31 mm (1.22 in.) for bolt B

64 mm (2.52 in.) for bolt C

(c) Install the detent spring and detent cover with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Make sure to install the detent spring so that its roller is perpendicularly at the center of the manual valve lever.

(d) Connect the 8 connectors to the solenoid valves.

(e) Coat a new O-ring with ATF and install it to the ATF temperature sensor.

(f) Install the ATF temperature sensor and lock plate with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

46. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

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

NOTICE:
Ensure that the O-ring is not twisted or pinched.

(b) Install the oil strainer to the valve body with the 4 bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

47. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

(a) Install the 3 magnets to the oil pan.

(b) Install a new gasket and the oil pan to the transmission case with the 9 bolts.

Torque : 7.3 Nm (74 kgf-cm, 64 in-lbf)

NOTICE:

* Make sure that there is no oil or foreign matter on the gasket seal surface and oil pan contact surface.
* Install the gasket so that there is no slack in the gasket, and that the seal surface's entire circumference is level.
* Make sure that the 9 gasket drop prevention protrusions are set on the oil pan.
* When tightening the oil pan, make sure that the gasket is not pinched between the gasket tightening area's sleeve and the transmission's seal surface.

48. INSTALL NO. 1 BREATHER PLUG

49. INSTALL OIL COOLER TUBE UNION

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

(b) Install the unions as shown in the illustration.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

50. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the bolt.

(b) Install a new lock washer with the nut.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

(c) Temporarily install the control shaft lever.

(d) Turn the control shaft lever counterclockwise until it stops, and turn it clockwise 2 notches to set it to the N position.

(e) Remove the control shaft lever.

(f) Align the groove with the neutral basic line.

(g) Hold the switch in this position and tighten the bolt.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(h) Using a screwdriver, bend the tabs of the lock washer.

HINT
Bend at least 2 washer tabs.

51. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH

(a) Install the transmission control shaft lever with the nut.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)