Part 2

CLUTCH

Illustrated Index

Disassembly

1. Remove the snap ring, then remove the clutch end plate, clutch discs and plates.

2. Remove the disc spring.

3. Install the special tools as shown.

CAUTION: If either end of the compressor attachment 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 towel around the clutch drum, and apply air pressure to the fluid 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 ATF before reassembly.

1. Inspect the check valve; if it's loose, replace the piston.

NOTE: Except 1st-hold clutch.

2. Install new O-rings on the clutch 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-ring 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.

6. Compress the return spring.

7. Install the snap ring.
8. Remove the special tools.

9. Install the disc spring.

NOTE: 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 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.

1st, 2nd, 3rd And 4th Clutch End Plate:

1st-Hold Clutch End Plate:

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.

TORQUE CONVERTER HOUSING BEARINGS
Mainshaft Bearing/Oil Seal Replacement

1. Remove the mainshaft bearing and oil seal using the special tools as shown.

2. Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.

3. Install the new oil seal flush with the housing using the special tools as shown.

Countershaft Bearing Replacement

1. Remove the countershaft bearing using the special tools as shown.
2. Install the ATF guide plate.

3. Drive the new bearing into the housing using the special tools as shown.

TRANSMISSION HOUSING BEARINGS
Mainshaft/Countershaft Bearing Replacement

1. To remove the mainshaft and countershaft bearings from the transmission housing, expand each snap ring with snapping pliers, then push the bearing out using the special tools and a press as shown.

NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.

2. Expand each snap ring with snap ring pliers, insert the new bearing part-way into the housing using the special tools and a press as shown. Install the bearing with the groove facing outside the housing.

NOTE: Coat all parts with ATF,

3. Release the pliers, then push the bearing down into the housing until the ring snaps in place around it.

4. After installing the bearing verify the following:
- The snap ring is seated in the bearing and housing grooves.
- The ring end gap is correct.

Sub-Shaft Bearing Replacement

1. To remove the sub-shaft bearing from the transmission housing, expand the snap ring with snap ring pliers, then push the bearing out using the special tools and a press as shown.

NOTE: Do not remove the snap ring unless it's necessary to clean the groove in the housing.

2. Expand the snap ring with snap ring pliers, insert the new bearing part-way into the housing using the special tools and a press as shown. Install the bearing with the groove facing outside the housing.

NOTE: Coat all parts with ATF.

3. Release the pliers, then push the bearing down into the housing until the ring snaps in place around it, using the special tools as shown.

4. After installing the bearing verify the following:
- The snap ring is seated in the bearing and housing grooves.
- The snap ring operates properly.
- The ring end gap is correct.

REVERSE IDLER GEAR
Installation

1. Install the reverse idler gear.

2. Install the reverse idler gear shaft holder and needle bearing into the transmission housing, then tighten the bolts.

PARKING BRAKE STOP
Inspection/Adjustment

1. Set the parking brake lever in the M position.
2. Measure the distance between the parking brake pawl shaft and the parking brake lever roller pin as shown.

3. If the measurement is out of tolerance, select and install the appropriate parking brake stop from the table.
4. After replacing the parking brake stop, make sure the distance is within tolerance.

TRANSMISSION REASSEMBLY

NOTE:
- Coat all parts with Automatic Transmission Fluid (ATF).
- Replace the parts below:
- O-rings
- Lock washers
- Gaskets
- Locknuts
- Conical spring washers
- Sealing washers

TORQUE: 6 x 1.0 mm Bolt 12 Nm(1.2 kgf.m, 8.7 ft. lbs.)

1. Install the suction pipe collar in the torque converter housing.

2. Install the main separator plate with two dowel pins on the torque converter housing. Then install the ATF pump drive gear, driven gear and driven gear shaft.

NOTE: Install the ATF pump driven gear with its grooved and chamfered side facing down.

3. Loosely install the main valve body with four bolts. Make sure the ATF pump drive gear rotates smoothly in the normal operating direction and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions.
4. Install the secondary valve body, separator plate and two dowel pins on the main valve body.
5. Install the control shaft in the housing, with the control shaft and manual valve together.

6. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.
7. Install the servo body and separator plate (six bolts).
8. Install the accumulator cover (three bolts).
9. Install the servo detent base and ATF strainer and new lock washers (three bolts).
10. Tighten the four bolts to 12 Nm (1.2 kgf.m, 8.7 ft. lbs.) on the main valve body.
Make sure the ATF pump drive gear and ATF pump driven gear shaft move smoothly.

11. If the AU pump drive gear and ATF pump driven gear shaft do not move freely, loosen the four bolts on the main valve body and disassemble the valve bodies. Realign the ATF pump driven gear shaft and reassemble the valve bodies, then retighten the bolts to the specified torque.

CAUTION: Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.

12. Install the stator shaft and stop shaft.
13. Install the stop shaft stay on the secondary valve body (one bolt).
14. Install the regulator valve body with the bolt.
15. Install the torque converter check valve, cooler check valve and valve springs in the regulator valve body.
16. Install the lock-up valve body, separator plate, two dowel pins and lubricator plate (eight bolts).
17. Install the ATF feed pipes.

18. Install the sub-shaft assembly in the transmission housing.
19. Install the reverse idler gear and gear shaft holder.
20. Install the differential assembly in the torque converter housing.

21. Assemble the mainshaft and countershaft subassembly, then install them together in the torque converter housing.

22. Turn the shift fork so the large chamfered hole is facing the fork bolt hole, then install the shift fork with the reverse selector and torque the lock bolt. Bend the lock tab against the bolt head.
23. Install the reverse gear with the collar and needle bearing on the countershaft.
24. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.

25. Place the transmission housing on the torque converter housing with a new gasket and the three dowel pins.

26. Install the transmission housing mounting bolts along with the transmission hanger and the connector bracket, then torque the bolts in two or more steps in the sequence shown.

TORQUE: 44 Nm (4.5 kgf.m, 33 ft. lbs.)

27. Install the special tool onto the mainshaft as shown.
28. Install the parking brake lever on the control shaft.
29. Assemble the one-way clutch and the parking gear with the countershaft 1st gear.
30. Install the countershaft 1st gear collar, needle bearing and the countershaft 1st gear/parking gear assembly on the countershaft.

31. Install the parking brake pawl shaft, spring, pawl and pawl stop on the transmission housing, then engage the parking brake pawl with the parking gear.

32. Install the old conical spring washer and locknut on the countershaft. Tighten the old locknut to seat the parking gear to the specified torque, then remove them.

NOTE:
- Do not use an impact wrench, always use a torque wrench to tighten the locknut
- Countershaft locknut has left-hand threads.

33. Install the sub-shaft 1st gear on the sub-shaft.
34. Install the mainshaft 1st gear collar on the main shaft.
35. Wrap the mainshaft splines with tape to prevent damage the O-rings, then install new O-rings on the mainshaft.
36. Assemble the thrust washer, thrust needle bearing, needle bearing and mainshaft 1st gear on the 1st clutch assembly, then install them on the mainshaft.
37. Align the hole of the sub-shaft 1st gear with the hole of the transmission housing, then insert a pin to hold the sub-shaft while tightening the sub-shaft locknut.
38. Install a new conical spring washers and new lock nuts on each shaft.

CAUTION: Install the conical spring washers in the direction shown.

39. Tighten the locknuts to the specified torque.

NOTE:
- Do not use an impact wrench, always use a torque wrench to tighten the locknut.
- Mainshaft and countershaft locknuts have left hand threads.

40. Stake each locknut using a 3.5 mm punch as shown.
41. Set the parking brake lever in the FE] position, then verify that the parking brake pawl engages the parking gear.
42. If the pawl does not engage fully, check the parking brake pawl stop clearance as described.

43. Tighten the lock bolt and bend the lock tab.

44. Install the right side cover.
45. Install the throttle control drum with the drum spring on the throttle control shaft.

TORQUE: 7.8 Nm (0.8 kgf.m, 5.8 ft. lbs.)

46. Install the transmission mount bracket.

TORQUE: 49 Nm (5.0 kgf.m, 36 ft. lbs.)

47. Install the ATF cooler lines with the joint bolts and new sealing washers.

TORQUE: 28 Nm (2.9 kgf.m, 21 ft. lbs.)

48. Install the ATF dipstick.