Part 4

AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

REASSEMBLY - Continued

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.
NOTE: 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.
NOTE: 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
NOTE: Do not allow seal packing to contact the bolt threads.

(f) Install the 10 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTE: 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.

60. INSTALL B-1 ACCUMULATOR VALVE
(a) Install the 2 springs and accumulator valve to the hole.
Spring Diameter:

61. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat 2 new O-rings with ATF, and install them to the piston.
(b) Install the spring and accumulator piston to the hole.
Spring Diameter:

62. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat 2 new O-rings with ATF, and install them to the piston.
(b) Install the spring and accumulator piston to the hole.
Spring Diameter:

63. INSTALL C-2 ACCUMULATOR PISTON
(a) Coat 2 new O-rings with ATF, and install them to the piston.
(b) Install the spring and accumulator piston to the hole.
Spring Diameter:

64. INSTALL CHECK BALL BODY
(a) Install the spring and check ball body.

65. INSTALL BRAKE DRUM GASKET
(a) Install 3 new brake drum gaskets.

66. INSTALL TRANSMISSION CASE GASKET
(a) Install 3 new transmission case gaskets.
67. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

(a) Align the hole of the manual valve with the pin of the lever.

(b) Install the 19 bolts.
Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Each bolt length is indicated below.
36 mm (1.42 in.) for bolt A
25 mm (0.984 in.) for bolt B
45 mm (1.77 in.) for bolt C
50 mm (1.97 in.) for bolt D

(c) Install the detent spring and detent spring cover with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
68. INSTALL TRANSMISSION WIRE

(a) Install 2 new O-rings to the transmission wires.

(b) Install the transmission wire harnesses.
(c) Install the bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)

(d) Connect the 9 connectors to the solenoid valves.
(e) Connect the 2 ATF temperature sensors with the 2 clamps and 2 bolts.
for bolt A - Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
for bolt B - Torque: 11 Nm (112 kgf-cm, 8 ft-lbf)
HINT: Each bolt length is indicated below.
12 mm (0.472 in.) for bolt A
36 mm (1.42 in.) for bolt B

69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil strainer.
(b) Install the oil strainer with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
70. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

(a) Install the 4 magnets.
(b) Install a new gasket to the oil pan.
(c) Install the oil pan with the 12 bolts.
Torque: 7.4 Nm (75 kgf-cm, 65 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 make sure the entire circumference of the seal surface is level.
- Make sure that the 9 gasket drop prevention protrusions are set on the oil pan.
- When tightening the bolts of the oil pan, make sure that the gasket is not pinched between the gasket tightening area sleeve and the transmission seal surface.

(d) Install the drain plug.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

71. INSTALL TRANSFER CASE ADAPTER RADIAL BALL BEARING
(a) Using SST and a press, press in the bearing until it stops.
SST: 09950-60010
09951-00650
SST: 09950-70010
09951-07150
(b) Using a screwdriver, install the snap ring.

72. INSTALL TRANSMISSION CASE ADAPTOR OIL SEAL
(a) Coat the lip of a new oil seal with ATF.
(b) Using SST and a hammer, tap in the oil seal.
Standard depth:
0 to 1 mm (0 to 0.0394 in.)
SST: 09950-60010
09951-00650
SST: 09950-70010
09951-07150
73. INSTALL REAR ADAPTOR TRANSFER

(a) Clean the threads of the bolts and case with non-residue solvent.
(b) Apply seal packing to the rear adaptor transfer.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or equivalent
Seal diameter:
1.0 to 1.5 mm (0.0394 to 0.0591 in.)

74. INSTALL AUTOMATIC TRANSMISSION HOUSING
(a) Clean the threads of the bolts and case with non-residue solvent.
(b) Install the transmission housing with the 14 bolts.
Torque: 34 Nm (345 kgf-cm, 25 ft-lbf)

75. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE
(a) Coat a new O-ring with ATF and install it to the breather tube.
(b) Install the breather tube with the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)

76. INSTALL TRANSMISSION OIL COOLER ASSEMBLY
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings, transmission oil thermostat and transmission oil cooler to the automatic transmission.
(c) Temporarily install bolt A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt A to the specified torque.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

77. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF, and install them to the speed sensors.
(b) Install the 2 speed sensors.
(c) Install the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
78. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Install the park/neutral position switch to the manual valve lever shaft, and temporarily install the adjusting bolt.
(b) Install a new lock washer and the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 in-lbf)
(c) Temporarily install the control shaft lever RH.

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

(f) Align the groove with the neutral basic line.
(g) Hold the switch in 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.

79. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH
(a) Install the control shaft lever RH with the washer and nut.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)