Automatic Transaxle - A760H: Inspection: Reassembly

INSTALL DIRECT CLUTCH PISTON SUB-ASSEMBLY
1. Coat 2 new O-rings with ATF, and install them in the direct clutch piston.
  
  Fig 1: Identifying Direct Clutch Piston Sub-Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch balancer No.2 and the direct clutch return spring to the direct clutch piston sub-assembly.
3. Press the direct clutch piston into the clutch drum.
  NOTE: Do not damage the O-rings.
  
  Fig 2: Identifying Clutch Balancer No. 2 And Direct Clutch Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place SST on the clutch balancer No.2, and compress the return spring with a press.
  SST 09350-30020 (09350-07070), 09518-36020
5. Install the snap ring with a snap ring expander.
  NOTE:
  - Be sure 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 (0.039 to 0.078 in.) from the snap ring groove not to deform the spring sheet.
  - Do not expand the snap ring excessively.
  Fig 3: Compressing Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Set the end gap of the snap ring in the piston as shown in the illustration.
Fig 4: Identifying Snap Ring Stopper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH PISTON SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the clutch drum.
  
  Fig 5: Identifying Reverse Clutch Piston Sub-Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
  
  Fig 6: Identifying Reverse Clutch Piston Sub-Assembly O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Press the clutch drum into the reverse clutch piston.
  NOTE: Do not damage the O-ring.
Fig 7: Identifying Reverse Clutch Piston Sub-Assembly Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Coat a new O-ring with ATF, and install it on the reverse clutch piston sub-assembly.
2. Install the reverse clutch return spring onto the reverse clutch piston sub-assembly.
Fig 8: Identifying Reverse Clutch Piston Sub-Assembly O-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH BALANCER NO.3
1. Place the clutch balancer No.3 on the return spring.
2. Place SST on the clutch balancer No.3, and compress the clutch balancer with a press.
  SST 09387-00050, 09387-00070
3. Install the snap ring with a snap ring expander.
  SST 09350-30020 (09350-07070)
  NOTE:
  - Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
    
    Fig 9: Compressing Clutch Balancer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Stop pressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove not to deform the spring sheet.
  - Do not expand the snap ring excessively.
4. Set the end gap of the snap ring in the piston as shown in the illustration.
Fig 10: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DIRECT CLUTCH DISC
1. Install the reverse clutch flange, the 5 plates and the 4 discs on the clutch drum.
  Install in order:
  
  P = Plate, D = Disc, F = Flange, F - D - P - D - P - D - P - D - P - P
  
  Fig 11: Identifying Reverse Clutch Flange, Plates And Discs On Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the 2 hole snap rings on the clutch drum.
INSPECT PACK CLEARANCE OF DIRECT CLUTCH (See REASSEMBLY )

Fig 12: Installing Hole Snap Rings On Clutch Drum Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH FLANGE
1. Install the reverse clutch flange to the clutch drum.
Fig 13: Identifying Reverse Clutch Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates to the reverse clutch hub.
  Install in order:
  
  P = Plate, D = Disc, F = Flange, S = Sleeve, C = Cushion Plate
  
  S - C - F - D - P - D - P - D - P - D - P - D
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF REVERSE CLUTCH (See REASSEMBLY )

Fig 14: Identifying Plate, Disc, Flange, Sleeve And Cushion Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REVERSE CLUTCH REACTION SLEEVE
1. Using a screwdriver, remove the snap ring from the clutch drum.
  
  Fig 15: Removing Snap Ring From Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the 4 clutch plates from the reverse clutch hub sub-assembly.
Fig 16: Identifying Reverse Clutch Discs And Clutch Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FORWARD CLUTCH PISTON SUB-ASSEMBLY
1. Install the coast clutch piston to the forward clutch piston.
2. Coat a new O-ring with ATF and install it on the forward clutch piston.
3. Install the forward clutch piston sub-assembly to the input shaft.
Fig 17: Identifying Coast Clutch Piston
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH BALANCER NO.1
1. Coat a new O-ring with ATF and install it on the clutch balancer No.1.
  
  Fig 18: Identifying Clutch Balancer No.1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clutch balancer No.1 and the forward clutch return spring sub-assembly.
  NOTE: Do not damage the O-ring.
  
  Fig 19: Identifying Clutch Balancer No 1 And Forward Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Place SST on the clutch balancer No.1, and compress the return spring with a press.
  SST 09350-30020 (09350-07040, 09350-07070)
4. Install the snap ring with a snap ring expander.
  NOTE:
  - 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 (0.039 to 0.078 in.) from the snap ring groove not to deform the spring sheet.
  - Do not expand the snap ring excessively.
  Fig 20: Compressing Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Set the end gap of the snap ring in the piston as shown in the illustration.
Fig 21: Identifying Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COAST CLUTCH DISC
1. Install the flange, the 3 discs and the 3 plates to the forward clutch piston.
2. Using a screwdriver, install the hole snap ring.
INSPECT PACK CLEARANCE OF COAST CLUTCH (See REASSEMBLY )

Fig 22: Identifying Forward Clutch Piston Flange Discs And Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FORWARD CLUTCH HUB CLUTCH DISC

Install the flange, the 4 discs, 4 plates and the cushion plate to the input shaft assembly.
Install in order:

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

Plate

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

Fig 23: Installing Input Shaft Assembly Flange, Discs Plates And Cushion Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using a screwdriver, install the hole snap ring.

Fig 24: Installing Hole Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing and the thrust bearing race.

BEARING SPECIFICATION CHART

	Inside	Outside
Thrust needle roller bearing	21.3 mm (0.839 in.)	41.1 mm (1.618 in.)
Thrust bearing race No.2	22.6 mm (0.890 in.)	44.8 mm (1.764 in.)

Fig 25: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT OIL SEAL RING
1. Coat 4 new oil seal rings with ATF.
2. Squeeze the ends of the 4 oil seal rings together, and then install them to the starter shaft groove.
  NOTE: Do not expand the ring ends excessively.
  
  HINT:
  
  After installing the oil seal rings, check that they rotate smoothly.
INSPECT PACK CLEARANCE OF FORWARD CLUTCH (See REASSEMBLY )

Fig 26: Identifying Input Shaft Oil Seal Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL INPUT SHAFT ASSEMBLY

Install the input shaft assembly to the clutch drum.

Fig 27: Identifying Input Shaft And Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the thrust needle roller bearing to the clutch drum.

Thrust needle roller bearing diameter

BEARING SPECIFICATION CHART

	Inside	Outside
Thrust needle roller bearing	21.3 mm (0.839 in.)	41.1 mm (1.618 in.)

Fig 28: Identifying Thrust Needle Roller Bearing And Clutch Drum

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COAST CLUTCH HUB SUB-ASSEMBLY

Install the clutch hub thrust washer and the input shaft rear thrust bearing race to the coast clutch hub.

Bearing and race diameter

BEARING SPECIFICATION CHART

	Inside	Outside
Input shaft rear thrust bearing race	22.6 mm (0.890 in.)	44.8 mm (1.764 In.)

Fig 29: Identifying Thrust Bearing And Thrust Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the coast clutch hub sub-assembly to the clutch drum.

Fig 30: Identifying Coast Clutch Hub Sub-Assembly And Clutch Drum

INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY

Install the 2 thrust needle roller bearings and thrust bearing race No.3 to the forward clutch hub sub-assembly.

Bearing and race diameter

BEARING SPECIFICATION CHART

	Inside	Outside
Bearing A	42.5 mm (1.673 in.)	61.2 mm (2.409 in.)
Bearing B	35.6 mm (1.402 in.)	56.6 mm (2.228 in.)
Thrust bearing race No.3	35.6 mm (1.402 in.)	56.6 mm (2.228 in.)

Fig 31: Identifying Thrust Bearing Race

Install the forward clutch hub sub-assembly and clutch hub thrust washer to the clutch drum.

Fig 32: Identifying Forward Clutch Hub Sub-Assembly And Thrust Washer

INSTALL REAR CLUTCH DISC
1. Install the clutch cushion plate, the reverse clutch flange, the 4 plates and the 5 discs to the reverse clutch hub.
Fig 33: Identifying Rear Clutch Disc Cushion Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH REACTION SLEEVE
1. Install the reverse clutch reaction sleeve to the reverse clutch hub.
Fig 34: Identifying Reverse Clutch Reaction Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Install the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 reverse clutch discs, and the clutch plates to the clutch drum.
  
  Fig 35: Identifying Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, install the snap ring on the clutch drum and the input shaft assembly.
Fig 36: Installing Snap Ring On Clutch Drum And Input Shaft Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002