Part 2

A960E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY (Continued)

41. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates to the reverse clutch hub.





Installation order:

P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate

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

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

42. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Transmission Unit

43. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.





(b) Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 reverse clutch discs, and the 3 clutch plates from the reverse clutch hub sub-assembly.





44. INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY

(a) Install the coast clutch piston to the input shaft.





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

(c) Install the new O-ring to the forward clutch.

(d) Install the forward clutch piston sub-assembly

45. INSTALL NO. 1 CLUTCH BALANCER

(a) Coat a new D-ring with ATF and install it on the No. 1 clutch balancer.





(b) Install the No. 1 clutch balancer and the forward clutch return spring sub-assembly.





NOTICE:
Do not damage the D-ring.

(c) Place SST on the No. 1 clutch balancer, and compress the return spring with a press.





SST : 09350-30020

09350-07040

SST : 09316-20011

(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 spring sheet is lowered to the place 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the spring sheet from being deformed.
* Do not expand the snap ring excessively.
(e) Set the end gap of the snap ring in the piston as shown in the illustration.





Text in Illustration





46. INSTALL COAST CLUTCH DISC

(a) Install the flange, the 4 discs and the 4 plates to the forward clutch piston.





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

47. INSPECT PACK CLEARANCE OF COAST CLUTCH Transmission Unit

48. INSTALL NO. 1 CLUTCH DISC

(a) Install the flange, the 4 discs, 4 plates and clutch cushion plate to the input shaft assembly.





Installation order:

P = Plate, D = Disc, F = Flange, C = Cushion Plate

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

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





Text in Illustration





(c) Install the thrust needle roller bearing and the thrust bearing race.









Text in Illustration





49. INSTALL INPUT SHAFT OIL SEAL RING

(a) Coat 4 new oil seal rings with ATF.





(b) Squeeze the ends of the 4 oil seal rings together, and then install them to the input shaft groove.

NOTICE:
Do not expand the ring ends excessively.

HINT
After installing the oil seal rings, check that they rotate smoothly.

50. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Transmission Unit

51. INSTALL INPUT SHAFT

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





(b) Install the thrust needle roller bearing and the thrust bearing race to the reverse clutch drum sub-assembly.





Thrust Needle Roller Bearing and Race Diameter





Text in Illustration





52. INSTALL NO. 4 ONE-WAY CLUTCH ASSEMBLY

(a) Install the clutch hub thrust washer and the No. 4 one-way clutch assembly to the coast clutch hub.





53. INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

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





54. INSTALL CLUTCH HUB SUB-ASSEMBLY

(a) Install the 2 thrust needle roller bearings and No. 2 thrust bearing race to the clutch hub sub-assembly.





Bearing and Race Diameter





Text in Illustration





(b) Install the clutch hub thrust washer and forward clutch hub sub-assembly to the reverse clutch drum sub-assembly.





55. INSTALL NO. 3 CLUTCH DISC

(a) Install the clutch cushion plate, the reverse clutch flange, the 3 plates and the 4 discs to the reverse clutch hub.





Text in Illustration





56. INSTALL REVERSE CLUTCH REACTION SLEEVE

(a) Install the reverse clutch reaction sleeve to the reverse clutch hub.





57. INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Install the reverse clutch hub sub-assembly, the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 No. 3 clutch discs, and the 3 No. 3 clutch plates to the reverse clutch drum sub-assembly.





(b) Using a screwdriver, install the snap ring on the reverse clutch drum sub-assembly and the input shaft assembly.





58. INSTALL CLUTCH DRUM AND INPUT SHAFT

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





Text in Illustration





(b) Coat the washer with petroleum jelly and install them onto the clutch drum and input shaft.

Thrust Needle Roller Bearing Diameter





(c) Install the clutch drum and input shaft into the transmission case.





59. INSTALL OIL PUMP ASSEMBLY

(a) Install the No. 1 thrust bearing race to the oil pump.









Text in Illustration





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

(c) Place the oil pump through the input shaft, 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 to slide the oil seal rings into the overdrive direct clutch drum.

(e) Install the 9 bolts.





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

60. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using SST and a hammer, drive in 2 new oil seals.





SST : 09350-30020

09350-07110

(b) Coat the oil seal lips with MP grease.

61. INSPECT INDIVIDUAL PISTON OPERATION Transmission Unit

62. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

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





Text in Illustration





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

(c) Using a hammer, drive in a new spring pin.





(d) Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.





(e) Make sure that the shaft rotates smoothly.

63. INSTALL PARKING LOCK PAWL SHAFT

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





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

Text in Illustration





64. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

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





65. INSTALL PARKING LOCK PAWL BRACKET

(a) Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.





Torque : 7.3 Nm (74 kgf-cm, 65 in-lbf)

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





Text in Illustration





66. INSTALL B-1 ACCUMULATOR VALVE

(a) Install the spring and the accumulator valve to the hole.





B-1 Accumulator Spring





67. INSTALL C-3 ACCUMULATOR PISTON

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





(b) Install the 2 springs and the accumulator piston to the hole.

C-3 Accumulator Spring (Inner Spring)





C-3 Accumulator Spring (Outer Spring)





Text in Illustration





68. INSTALL B-3 ACCUMULATOR PISTON

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





(b) Install the spring and the accumulator piston to the hole.

B-3 Accumulator Spring





Text in Illustration





69. INSTALL C-2 ACCUMULATOR PISTON

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





(b) Install the spring and the accumulator piston to the hole.

C-2 Accumulator Spring





Text in Illustration





70. INSTALL CHECK BALL BODY

(a) Install the check ball body and the spring.





Text in Illustration