Part 1

A960E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

1. BEARING POSITION

2. INSTALL NO. 4 BRAKE PISTON

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

(b) Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.

(c) Install the No. 4 brake piston to the reaction sleeve.

NOTICE:
Be careful not to damage the 4 O-rings.

Text in Illustration

3. INSTALL BRAKE REACTION SLEEVE

(a) With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and the No. 4 brake piston to the transmission case.

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

Text in Illustration

4. INSTALL 1ST AND REVERSE BRAKE PISTON

(a) Coat a new O-ring with ATF.

(b) Install the O-ring on the 1st and reverse brake piston.

(c) With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

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

Text in Illustration

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Place the brake return spring onto the brake piston.

(b) Place SST on the brake return spring, and compress the return spring.

SST : 09350-30020

09350-07050

(c) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

6. INSTALL BRAKE APPLY TUBE

(a) Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

7. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the thrust needle roller bearing.

Thrust Needle Roller Bearing Diameter

(b) Install the thrust needle roller bearing race.

Text in Illustration

(c) Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary gear.

Bearing Race Diameter

(d) Install the rear planetary gear assembly.

8. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE Transmission Unit

9. INSTALL NO. 4 BRAKE DISC

(a) Install the 4 plates, the 5 discs and the 2 flanges.

Installation order:

P = Plate, D = Disc, F = Flange

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

10. INSTALL BRAKE PLATE STOPPER SPRING

(a) Install the brake plate stopper spring.

11. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

(a) Install the No. 8 thrust bearing race, the thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange to the intermediate shaft.

Bearing and Race Diameter

Text in Illustration

12. INSTALL NO. 3 ONE-WAY CLUTCH ASSEMBLY

(a) Install the No. 3 one-way clutch assembly and the one-way clutch inner race to the intermediate shaft.

13. INSTALL INTERMEDIATE SHAFT

(a) Install the intermediate shaft with the No. 3 one-way clutch assembly to the case.

(b) Using SST, install the snap ring.

SST : 09350-30020

09350-07050

09350-07060

14. INSTALL CENTER PLANETARY GEAR ASSEMBLY

(a) Install the center planetary gear assembly and the planetary sun gear to the case.

(b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

Race Diameter

15. INSTALL NO. 2 BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.

Text in Illustration

(b) Press the No. 2 brake piston into the No. 2 brake cylinder.

NOTICE:
Be careful not to damage the 2 O-rings.

(c) Install the No. 2 brake piston to the case.

HINT
Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.

(d) Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

16. INSTALL NO. 2 BRAKE DISC

(a) Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.

Installation order:

P = Plate, D = Disc, F = Flange

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

(b) Using SST, a screwdriver and a press, install the No. 2 brake spring snap ring.

SST : 09351-40010

09351-04010

09351-04020

09351-04040

09351-04050

17. INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON Transmission Unit

18. INSTALL NO. 1 BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.

(b) Press the No. 1 brake piston into the No. 1 brake cylinder.

NOTICE:
Be careful not to damage the 2 O-rings.

Text in Illustration

19. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Install the brake piston return spring and the No. 1 brake piston with the No. 1 brake cylinder to the transmission case.

HINT
Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.

(b) Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

20. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

(a) Using SST, a screwdriver and a press, install the brake piston return spring snap ring.

SST : 09351-40010

09351-04010

09351-04030

09351-04040

09351-04050

21. INSTALL CENTER PLANETARY RING GEAR

(a) Install the thrust needle roller bearing to the front planetary ring gear flange.

Thrust Needle Roller Bearing Diameter

(b) Install the center planetary ring gear flange to the center planetary ring gear.

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

(d) Install the center planetary ring gear to the front planetary ring gear.

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

NOTICE:
Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.

22. INSTALL FRONT PLANETARY RING GEAR

(a) Install the front planetary ring gear to the case.

23. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the thrust needle roller bearing and the thrust washer.

Text in Illustration

(b) Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

Thrust Needle Roller Bearing and Race Diameter

24. INSPECT PISTON STROKE OF BRAKE PISTON Transmission Unit

25. INSTALL NO. 1 BRAKE DISC

(a) Install the 3 plates, the 3 discs and the flange.

Installation order:

P = Plate, D = Disc, F = Flange

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

26. INSTALL 2ND BRAKE PISTON

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

Text in Illustration

(b) Press the 2nd brake piston into the 2nd brake cylinder.

NOTICE:
Be careful not to damage the 2 O-rings.

(c) Install the return spring with the snap ring.

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

27. INSTALL 2ND BRAKE CYLINDER

(a) Install the 2nd brake cylinder to the case.

(b) Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.

28. INSTALL ONE-WAY CLUTCH ASSEMBLY

(a) Install the one-way clutch assembly and the thrust washer to the case.

29. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

(a) Using SST, install the snap ring.

SST : 09350-30020

09350-07060

30. INSTALL 2ND BRAKE DISC SET

(a) Install the flange, the 3 discs and the 3 plates to the case.

Installation order:

P = Plate, D = Disc, F = Flange

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

31. INSTALL NO. 3 BRAKE SNAP RING

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

SST : 09350-30020

09350-07060

32. INSTALL NO. 2 ONE-WAY CLUTCH ASSEMBLY

(a) Install the No. 2 one-way clutch assembly and clutch drum thrust washer to the clutch drum and input shaft.

33. INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY Transmission Unit

34. INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY

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

(b) Coat a new O-ring with ATF, and install it to the No. 2 clutch balancer.

(c) Install the No. 2 clutch balancer and the direct clutch return spring to the direct clutch piston sub-assembly.

(d) Press the direct clutch piston into the reverse clutch drum sub-assembly by hands.

NOTICE:
Do not damage the O-rings.

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

SST : 09320-89010

SST : 09350-30020

09350-07070

(f) Install the snap ring with a snap ring expander.

NOTICE:
* Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.
* Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.
(g) Set the end gap of the snap ring in the piston as shown in the illustration.

Text in Illustration

35. INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY

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

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

NOTICE:
Do not damage the O-ring.

36. INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

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

(b) Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.

37. INSTALL NO. 3 CLUTCH BALANCER

(a) Install the No. 3 clutch balancer to the reverse clutch return spring.

(b) Place SST on the No. 3 clutch balancer, and compress the clutch balancer with a press.

SST : 09387-00070

(c) Install the snap ring with a snap ring expander.

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 spring sheet is lowered to the place 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.
(d) Set the end gap of the snap ring in the piston as shown in the illustration.

Text in Illustration

38. INSTALL NO. 2 DIRECT CLUTCH DISC

(a) Install the direct clutch flange, the 5 plates and the 5 discs on the reverse clutch drum sub-assembly.

Installation order:

P = Plate, D = Disc, F = Flange

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

(b) Using a screwdriver, install the 2 hole snap rings on the reverse clutch drum sub-assembly.

39. INSPECT PACK CLEARANCE OF DIRECT CLUTCH Transmission Unit

40. INSTALL REVERSE CLUTCH FLANGE

(a) Install the reverse clutch flange to the reverse clutch drum sub-assembly.