Assembly (1)

Exploded View AT-255 (Part 1):

Exploded View AT-257 (Part 1):

Exploded View AT-259 (Part 1):

Assembly (1)





1. As shown in the figure, use a drift [commercial service tool 22 mm (0.87 in) dia.] to drive manual shaft oil seals into the transmission case until it is flush.

CAUTION:
^ Do not reuse manual shaft oil seals.
^ Apply ATF to manual shaft oil seals.





2. Install detent spring and spacer in transmission case, and then tighten detent spring and spacer mounting bolt to the specified torque. Refer to Exploded View AT-255.





3. Install manual shaft to transmission case.





4. Install parking rod to manual plate.





5. Install manual plate (with parking rod) to manual shaft.
6. Install retaining pin into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.





b. Use a hammer to tap the retaining pin into the manual plate.

CAUTION:
^ Do not reuse retaining pin.
^ Drive retaining pin to 2 ± 0.5 mm (0.08 ± 0.020 in) over the manual plate.

7. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.





b. Use a hammer to tap the retaining pin into the transmission case.

CAUTION:
^ Do not reuse retaining pin.
^ Drive retaining pin to 5 ± 1 mm (0.20 ± 0.04 in) over the transmission case.





8. Install O-rings to servo assembly.

CAUTION:
^ Do not reuse O-rings.
^ Apply petroleum jelly to O-rings.





9. Install return spring to servo assembly.





10. Install servo assembly in transmission case.





11. Using pair of snap ring pliers, install snap ring to transmission case.





12. Install D-rings in reverse brake piston.

CAUTION:
^ Do not reuse D-rings.
^ Apply ATF to D-rings.





13. Install reverse brake piston in transmission case.





14. Install needle bearing to drum support edge surface.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





15. Install seal rings to drum support.

CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.





16. Install spring retainer and return spring in transmission case.





17. Set the SST on spring retainer and install snap ring (fixing spring retainer) in transmission case while compressing return spring.

CAUTION: Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.





18. Install reverse brake drive plates, driven plates and dish plates in transmission case.

CAUTION: Take care with order of plates.

^ Snap ring (1)
^ Retaining plate (2)
^ Drive plate (3)
^ Driven plate (4)
^ Dish plate (5)
^ Drive plate/Driven plate: 6/6





19. Assemble N-spring.
20. Install reverse brake retaining plate in transmission case.





21. Install snap ring in transmission case.





22. Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
Specified clearance "A":
Standard: Refer to AT-320, "Reverse Brake". Reverse Brake





23. Install needle bearing to transmission case.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





24. Install revolution sensor to transmission case, and then tighten revolution sensor mounting bolt to the specified torque. Refer to Exploded View AT-255.

CAUTION:
^ Do not subject it to impact by dropping or hitting it.
^ Do not disassemble.
^ Do not allow metal filings, etc. to get on the sensors front edge magnetic area.
^ Do not place in an area affected by magnetism.





25. As shown in the figure, use a drift to drive rear oil seal into the rear extension until it is flush.

CAUTION:
^ Do not reuse rear oil seal.
^ Apply ATF to rear oil seal.





26. Install return spring (1) to parking pawl (2).





27. Install parking pawl (with return spring) and pawl shaft to rear extension.





28. Install parking actuator support to rear extension.





29. Install needle bearing (1) to rear extension.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





30. Install seal rings to output shaft.

CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.





31. Install parking gear to output shaft.





32. Install output shaft in transmission case.

CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)





33. Install bearing race to output shaft.





34. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-46, "Recommended Chemical Products and Sealants".) to rear extension assembly as shown in the figure. Service and Repair

CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces.





35. Install rear extension assembly to transmission case.

CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.





36. Tighten rear extension assembly mounting bolts to the specified torque. Refer to Exploded View AT-255.

CAUTION: Do not reuse self-sealing bolts.





37. Install needle bearing in drum support.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





38. Install direct clutch assembly in reverse brake.

CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.





39. Install high and low reverse clutch assembly in direct clutch.





40. Using a flat-bladed screwdriver, adjust the drive plate.





41. Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly as a unit.





CAUTION: Check that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.





42. Install needle bearing in rear carrier assembly.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





43. Install bearing race in rear carrier assembly.

CAUTION: Apply petroleum jelly to bearing race.





44. Install rear carrier assembly in direct clutch drum.





45. Install needle bearing (rear side) to mid carrier assembly.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





46. Install needle bearing (front side) to mid carrier assembly.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





47. Install mid carrier assembly in rear carrier assembly.





48. Install front carrier assembly, input clutch assembly and rear internal gear as a unit.





49. Install seal rings in input clutch assembly.

CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.





50. Install band servo anchor end pin and lock nut in transmission case.

CAUTION: Do not reuse band servo anchor end pin.





51. Install brake band in transmission case.

CAUTION: Assemble it so that identification to avoid incorrect installation faces servo side.





52. Install front sun gear to front carrier assembly.

CAUTION: Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.





53. Install needle bearing to front sun gear.

CAUTION:
^ Take care with the direction of needle bearing.
^ Apply petroleum jelly to needle bearing.





54. Adjust brake band tilting using clips so that brake band contacts front sun gear drum evenly.





55. Adjust brake band.
a. Loosen lock nut.
b. Tighten band servo anchor end pin to the specified torque.
Torque: 5.0 Nm (0.51 kg-m, 44 in-lb)
c. Back of band servo anchor end pin three turns.
d. Holding band servo anchor end pin, and then tighten lock nut to the specified torque. Refer to Exploded View AT-255.