Part 2
ONE-WAY CLUTCHDisassembly/Inspection/Reassembly
1. Separate countershaft 1st gear from the parking gear by turning the parking gear in the direction shown.
2. Remove the one-way clutch by prying it up with the end of a screwdriver.
3. Inspect the parts as follows:
4. After the parts are assembled, hold countershaft 1st gear and turn the parking gear in the direction shown to be sure it turns freely. Also make sure the parking gear does not turn in the opposite direction.
CLUTCH
Illustrated Index
Disassembly
1. Remove the snap ring, then remove the clutch end plate, clutch discs, and plates.
2. Remove the disc springs.
NOTE: The 1st-hold clutch does not have a disc spring.
3. Install the special tools as shown.
NOTE: For 1st, 3rd, and 1st-hold clutches.
NOTE: For 2nd and 4th clutches.
CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.
4. Compress the return spring.
5. Remove the snap ring. Then remove the special tools, spring retainer and return spring.
6. Wrap a shop rag around the clutch drum, and apply air pressure to the oil passage to remove the piston. Place a finger tip on the other end while applying air pressure.
Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Lubricate all parts with Automatic Transmission Fluid (ATF) before assembly.
1. Inspect the check valve; if it's loose, replace the piston.
2. Install new O-rings on the piston.
3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.
NOTE: Lubricate the piston O-ring with ATF before installing.
CAUTION: Do not pinch the O-rings by installing the piston with too much force.
4. Install the return spring and spring retainer, and position the snap ring on the retainer.
5. Install the special tools as shown.
NOTE: For 1st, 3rd and 1st-hold clutches
NOTE: For 2nd and 4th clutches
CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.
6. Compress the return spring.
7. Install the snap ring.
8. Remove the special tools.
9. Install the disc spring.
NOTE:
- Except 1st-hold clutch: the 1st-hold clutch does not have a disc spring.
- Install the disc spring in the direction shown.
10. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
11. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with the flat side toward the disc.
NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.
12. Install the snap ring.
13. Measure the clearance between the clutch end plate and top disc with a dial indicator.
Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.
NOTE: Measure at three locations.
14. If the clearance is not within the service limits, select a new clutch end plate from the following table.
NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.
2nd And 4th Clutch End Plate
1st Clutch End Plate
3rd Clutch End Plate
1st-Hold Clutch End Plate
1ST-HOLD CLUTCH BEARING
Replacement
1. Remove the 1st-hold clutch bearing using a bearing puller.
2. Install a new bearing using the special tool as shown.
NOTE: Drive in the bearing until it fully bottoms.
SECONDARY DRIVEN GEAR SHAFT
Components
Disassembly
1. Remove the set ring.
2. Remove the extension shaft from the secondary driven gear shaft.
Oil Seal Replacement
1. Remove the oil seal from the secondary driven gear shaft.
2. Install the oil seal into the secondary driven gear shaft using the special tools as shown.
Tapered Roller Bearing Replacement
NOTE:
- The bearing and outer race should be replaced as a set.
- If the bearing is replaced, inspect and adjust the bearing preload.
1. Remove the tapered roller bearings from the secondary driven gear shaft using a press.
2. Install the bearings using the special tool and a press as shown.
NOTE: Press the bearings in squarely until they bottom.
Tapered Roller Bearing Outer Race Replacement
NOTE:
- Replace the bearing with a new one whenever the outer race is to be replaced.
- Do not use shim(s) on the torque converter housing side.
- Adjust preload after replacing the bearing and outer race.
- Coat all parts with Automatic Transmission Fluid (ATF) during installation.
1. Remove the bearing outer race from the transmission housing and torque converter housing by heating the housing to about 212° F (100° C).
CAUTION: Do not heat the housing in excess of 212° F (100° C).
2. Install the outer race in the torque converter housing, using the special tools as shown.
3. Install the thrust shim and outer race in the transmission housing, using the special tools as shown.
Tapered Roller Bearing Preload Adjustment
NOTE: If the transmission housing, torque converter housing, secondary driven gear shaft, tapered roller bearing, outer race or thrust shim were replaced, the bearing preload must be adjusted.
1. Remove the oil seals from both housing.
2. Remove the bearing outer race and thrust shim from the transmission housing by heating the housing to about 212 ° F (100° C) with a heat gun.
CAUTION:
- Do not heat the housing in excess of 212 ° F (100° C).
- Replace the tapered roller bearing when the outer race is to be removed.
- Do not use a shim on the torque converter housing side.
NOTE: Let the transmission housing cool to the room temperature before adjusting the bearing preload.
3. Select the 1.98 mm (0.078 inch) thrust shim from the middle of the table .
4. After installing the thrust shim, install the outer race in the transmission housing using the special tools.
NOTE:
- Install the outer race squarely in the transmission housing.
- Check that there is no clearance between the outer race, shim and transmission housing.
5. Install the sealing bolt to the secondary driven gear shaft and torque it to 20 Nm (2.0 kgf-m, 14 ft. lbs.).
6. With the mainshaft and countershaft removed, install the secondary driven gear shaft, and torque the transmission housing.
NOTE: Install the gasket when checking starting torque.
7. Rotate the secondary driven gear shaft in both directions to seat the bearing.
8. Measure the starting torque of the secondary driven gear shaft with a torque wrench.
NOTE:
- Measure the starting torque at normal room temperature in both directions.
- Changing the shim to the next size will increase or decrease starting torque about 0.3 - 0.4 Nm (3 -4 kgf-m, 3 - 3 inch lbs.).
- To increase the starting torque, increase the thickness of the shim. To decrease the starting torque, decrease the thickness of the shim.