Part 1

AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: REASSEMBLY

1. BEARING POSITION





Bearing and Race Diameter:





2. INSTALL 1ST AND REVERSE BRAKE PISTON





(a) Coat 3 new O-rings with ATF, and install them to the 1st and reverse brake piston.

(b) Install the 1st and reverse brake piston to the transmission case.





NOTICE:
* Be careful not to damage the O-ring.
* Make sure that the parking hole of the brake piston is on the bottom side by engaging the brake piston protrusion to the transmission case spline grooves.

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





(a) Place the brake return spring onto the 1st and reverse brake piston.

SST : 09380-60010

09381-06030

09381-06040

09381-06080

09381-06120

09381-06130

09381-05040

09381-05050

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

(c) Using SST, install the snap ring.

SST : 09350-30020

09350-07070

4. SELECT NO. 4 BRAKE FLANGE





(a) Measure distance A (from the tip of the 1st and reverse brake piston to the step in the transmission case) in the illustration.*1

HINT
Standard distance A: 27.82 to 28.42 mm (1.09 to 1.12 in.)

(b) Assemble the No. 4 brake flange, 7 No. 4 brake discs and 6 No. 4 brake plates, and measure distance B in the illustration.*2

HINT
Standard distance B: 25.98 to 27.01 mm (1.02 to 1.06 in.)





(c) Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the No. 4 brake selective flange indicated by the graph point.





(d) Measure length H of the selected flange as shown in the illustration.

HINT
Make sure that when the B measurement and H dimension of the selected flange are subtracted from the A measurement, the value is 0.961 to 1.261 mm (0.0378 to 0.0495 in.).

No. 4 Brake Selected Flange Length H:





5. INSTALL REAR PLANETARY GEAR ASSEMBLY





(a) Install the thrust bearing race.

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

Bearing Race Diameter:





(b) Install the 2 thrust needle roller bearings to the rear planetary gear.





Bearing Diameter:





HINT
Use a small amount of MP grease to make the thrust needle roller bearings stay securely in place.

(c) Install the rear planetary gear assembly.





6. INSTALL BRAKE PLATE STOPPER SPRING





7. INSTALL REAR PLANETARY RING GEAR





(a) Install the rear planetary ring gear flange to the rear planetary ring gear.

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

(c) Install the 3 thrust bearing races, thrust needle roller bearing and planetary ring gear with the rear planetary ring gear flange to the intermediate shaft.





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

Bearing and Race Diameter:





8. INSTALL INTERMEDIATE SHAFT WITH REAR PLANETARY RING GEAR FLANGE AND REAR PLANETARY RING GEAR





(a) Install the intermediate shaft with the rear planetary ring gear flange and rear planetary ring gear to the transmission case.

9. INSTALL NO. 4 BRAKE DISC SET





(a) Install the flange, 7 discs, 6 plates and selected flange.

Install in order:

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

HINT
F = Flange

D = Disc

P = Plate

S/F = Selected flange

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

10. INSTALL NO. 3 1-WAY CLUTCH INNER RACE





(a) Install the 1-way clutch inner race to the No. 3 1-way clutch assembly.

NOTICE:
Do not mistake the direction of the 1-way clutch inner race.

11. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY Transmission Unit

12. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY





(a) Install the 1-way clutch assembly to the transmission case.

(b) Using SST, install the snap ring.





SST : 09350-30020

09350-07060

13. INSTALL NO. 2 BRAKE PISTON





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

(b) Press the brake piston into the brake cylinder with both hands.

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

14. INSTALL NO. 2 BRAKE CYLINDER WITH NO. 2 BRAKE PISTON

(a) Install the No. 2 brake cylinder with piston to the transmission case.





NOTICE:





* When installing the No. 2 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.
* Make sure the No. 2 brake cylinder with piston is securely inserted into the transmission case.

15. SELECT NO. 2 BRAKE FLANGE





(a) Install the No. 2 brake piston return spring and flange to the No. 2 brake piston.

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

SST : 09380-60010

09381-06010

09381-06020

09381-06050

09381-06070

09381-06090

09381-06120

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

(d) Measure distance A (from the top surface of the snap ring to the top surface of the brake piston return spring retainer) in the illustration.*1

HINT
Standard distance A: 21.00 to 21.76 mm (0.834 to 0.857 in.)





(e) Assemble the 4 discs, 3 plates and flange as shown in the illustration. Then with a fixture of 165.2 mm (6.50 in.) or less placed on the flange, measure distance B.*2

HINT
Standard distance B: 16.54 to 17.15 mm (0.651 to 0.675 in.)





(f) Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the flange indicated by the graph point.





HINT
Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 2.20 to 2.50 mm (0.0866 to 0.0984 in.).

Flange Thickness:





(g) Remove the snap ring, flange and No. 2 brake piston return spring from the transmission case.

16. INSTALL NO. 2 BRAKE DISC SET





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

Install in order:

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

HINT
S/F = Selected flange

D = Disc

P = Plate

F = Flange

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

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

SST : 09380-60010

09381-06010

09381-06020

09381-06050

09381-06070

09381-06090

09381-06120





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

17. INSTALL CENTER PLANETARY GEAR ASSEMBLY





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

NOTICE:
Make sure to install the center planetary sun gear with the groove facing the transmission case.

18. INSTALL NO. 1 BRAKE PISTON





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

(b) Press the brake piston into the brake cylinder with both hands.

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

19. INSTALL NO. 1 BRAKE CYLINDER WITH NO. 1 BRAKE PISTON

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





NOTICE:





* When installing the No. 1 brake cylinder with piston to the transmission case, align and install the cylinder claw to the case top groove.
* Make sure the No. 1 brake cylinder with piston is securely inserted into the transmission case.

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

SST : 09380-60010

09381-06010

09381-06020

09381-06050

09381-06060

09381-06090

09381-06100

09381-06110

09381-06120





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

20. SELECT NO. 1 BRAKE FLANGE





(a) Measure distance A (from the step in the transmission case to the tip of the No. 1 brake piston) in the illustration.*1

HINT
Standard distance A: 19.74 to 20.22 mm (0.777 to 0.796 in.)

(b) Assemble the 4 plates and 4 discs and measure distance B in the illustration.*2

HINT
Standard distance B: 16.72 to 17.19 mm (0.658 to 0.677 in.)





(c) Apply the A and B measurements taken in *1 and *2 to the graph below. Use A for the X axis and B for the Y axis, and then choose the flange indicated by the graph point.





HINT
Make sure that when the B measurement and selected flange thickness are subtracted from the A measurement, the value is 0.56 to 0.86 mm (0.0220 to 0.0339 in.).

Flange Thickness:





21. INSTALL CENTER PLANETARY RING GEAR





(a) Install the front planetary ring gear flange to the center planetary ring gear.

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





22. INSTALL FRONT PLANETARY RING GEAR





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

23. INSTALL FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY AND CENTER PLANETARY RING GEAR





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

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

Bearing and Race Diameter:





(b) Install the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear to the transmission case.

24. INSTALL FRONT PLANETARY GEAR ASSEMBLY





(a) Install the No. 2 planetary carrier thrust washer to the front planetary gear.

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

(b) Install the thrust needle roller bearing, thrust bearing race, front planetary sun gear and front planetary gear.

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





Bearing Diameter:





25. INSTALL 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY





(a) Apply the No. 1 planetary carrier thrust washer to the 1-way clutch inner race, and then install them to the 1-way clutch.

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

26. INSPECT 1-WAY CLUTCH ASSEMBLY Transmission Unit

27. INSTALL 1-WAY CLUTCH ASSEMBLY WITH 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY





(a) Install the 1-way clutch with the 1-way clutch inner race to the transmission case.

28. INSTALL NO. 1 BRAKE 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.

29. INSTALL NO. 3 BRAKE PISTON





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

(b) Press the brake piston into the brake cylinder with both hands.

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

(c) Using SST and a press, compress the return spring and install the snap ring with a screwdriver.

SST : 09380-60010

09381-06020

09381-06040

09381-06060

09381-06100

09381-06110





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

30. INSTALL NO. 3 BRAKE CYLINDER WITH NO. 3 BRAKE PISTON AND NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





(a) Install the No. 3 brake cylinder with the No. 3 brake piston and No. 3 brake piston return spring to the transmission case.

NOTICE:
* Align the oil holes of the No. 3 brake cylinder and transmission case as shown in the illustration.





* Make sure the No. 3 brake piston and cylinder are securely inserted into the transmission case.

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 the 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.