Part 2

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

31. INSTALL NO. 3 BRAKE PISTON HOLE SNAP RING

(a) Using SST, install the snap ring.

SST : 09350-30020

09350-07060

32. INSTALL NO. 3 BRAKE DISC SET

(a) Install the ''O'' mark flange, 4 discs, 3 plates and ''A'' mark flange to the transmission case.

Install in order:

OF - D - P - D - P - D - P - D - AF

HINT
OF = ''O'' mark flange

P = Plate

D = Disc

AF = ''A'' mark flange

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

33. INSTALL NO. 3 BRAKE SNAP RING

(a) Using a screwdriver, install the snap ring.

34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

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

(b) Install the direct clutch return spring and No. 2 clutch balancer to the direct clutch piston.

(c) Press the direct clutch piston with clutch return spring and clutch balancer into the reverse clutch piston with both hands.

NOTICE:
Be careful not to damage the O-ring.

(d) Place SST on the direct clutch balancer, and compress the return spring with a press.

SST : 09380-60010

09381-06030

09381-06040

09381-06080

NOTICE:
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.

(e) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

NOTICE:
Do not expand the snap ring excessively.

(f) Set the end gap of the snap ring in the balancer as shown in the illustration.

NOTICE:
Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

35. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

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

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

NOTICE:
* Be careful not to damage the O-ring.
* Make sure to align the holes of the reverse clutch piston and clutch drum as shown in the illustration.
* Make sure to align the protrusions of the reverse clutch pistons and the cutout of the clutch drum.

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

NOTICE:
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

NOTICE:
Do not expand the snap ring excessively.

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

NOTICE:
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.

(b) Install the 5 plates, 5 discs and reverse clutch flange on the clutch drum.

Install in order:

P - D - 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.

(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) 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 moving distance (A):

0.72 to 1.02 mm (0.0284 to 0.0401 in.)

Flange Thickness:

(e) Temporarily remove the snap ring, attach 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.

NOTICE:
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, selective flange and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P - D - S/F

HINT
F = Flange

D = Disc

P = Plate

S/F = Selective flange

(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 clutch flange at both ends across the diameter (B) while blowing compressed air (392 kPa, 2.0 kgf/cm2, 57 psi) from 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):

0.46 to 0.76 mm (0.0182 to 0.0299 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.

(d) Install the forward clutch return spring and No. 1 clutch balancer to the input shaft.

NOTICE:
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

NOTICE:
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

NOTICE:
Do not expand the snap ring excessively.

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

NOTICE:
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

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) from 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):

0.51 to 0.81 mm (0.0201 to 0.0318 in.)

Flange Thickness:

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

41. INSTALL NO. 4 1-WAY CLUTCH ASSEMBLY

(a) Install the No. 1 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 clutch drum.

HINT
Use a small amount of MP grease to make the thrust bearing and race stay securely in place.

Bearing and Race Diameter:

44. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC SET

(a) Install the cushion, 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

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) from 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, attach 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's 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 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's 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 and reverse clutch reaction sleeve to the clutch drum.

Install in order:

F - D - P - D - P - D - P - D - P - D - S/F

HINT
F = Flange

D = Disc

P = Plate

S/F = Selected flange

(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.