Part 2

23. Adjust total end play and clutch pack end play as follows:

-Total end play -




a. Remove thrust bearing race from high clutch drum.




b. Install needle bearing on top of oil pump cover.




c. Place Tools (bridge and gauging cylinder) on machined gasket surface of converter housing. Allow gauging cylinder to rest on needle bearing and lock it in place with thumbscrew.




d. Insert Tool (total end play gauging plunger) into gauging cylinder.




e. Place bridge, legs up, onto machined gasket surface of transmission case, allowing gauging plunger to rest on surface where bearing race was removed. Lock plunger in place.




f. Remove bridge and use feeler gauge to measure gap between gauging cylinder and shoulder of gauging plugger.
g. Use your feeler gauge reading to select appropriate bearing race thickness from following chart:

Oil pump housing bearing race: Refer to S.D.S.

- Clutch pack end play -




a. Place Tools (bridge and gauging cylinder) onto machined gasket surface of transmission case and allow cylinder to rest on high clutch drum. Lock cylinder into place.




- You are now measuring dimension "C".




b. Now, insert Tool (clutch pack gauging plunger) into gauging cylinder.




c. Place bridge, gauging cylinder, and gauging plunger onto machined gasket surface of converter housing. Make sure thrust washer is removed. Lock gauging plunger in place.
d. Use feeler gauge to measure gap between gauging cylinder and shoulder of gauging plunger.
e. Use your feeler gauge measurement and following thrust washer chart to select correct washer thickness to give proper clutch pack end play:




Clutch pack thrust washer: Refer to S.D.S.




24. Adjust differential side bearing preload as follows:




a. Remove left side bearing inner cone from transmission case.




b. Place Tools (bridge and gauging cylinder) onto machined gasket surface of transmission case and allow gauging cylinder to rest on bearing mating surface. Lock cylinder into place.




- You are now measuring dimension "E".




c. Put final drive assembly into converter housing, then put side bearing inner cone on differential case.
d. Hold inner bearing cone in place while spinning final drive assembly in order to seat bearings.




e. Insert Tool (differential side bearing gauging plunger) into gauging cylinder.




f. Place bridge, gauging cylinder, and gauging plunger onto machined gasket surface of converter housing and allow gauging plunger to rest on surface of bearing inner cone. Lock plunger in place.
g. Use feeler gauge to measure clearance between gauging cylinder and shoulder of the gauging plunger.
h. Use your feeler gauge reading and following chart to select appropriate side bearing preload shim(s).




Differential side bearing adjusting shim: Refer to Specifications and Adjustments. Specifications




i. Install selected shims and left side bearing inner cone.




25. Install input shaft.




26. Install selected thrust washer and bearing on oil pump cover.







27. Place gasket on transmission case and install converter housing.
Always use new bolts at portions (A), (B), (H) and (I) as they are self-sealing bolts. Apply A.T.F. to thread of other bolts by that fix converter housing to transmission case when installing them.




28. Install O-ring onto input shaft.
29. Adjust output shaft and idler gear bearing preload as follows:




a. Remove side cover temporarily installed.
b. Remove output gear and idler gear bearing outer races and shims. (The races will interchange, so be sure to keep each race with its correct bearing.)




c. Place Tools (bridge and gauging cylinder) onto machined gasket surface of side cover. Allow gauging cylinder to drop into output gear bearing race bore until it bottoms. Lock cylinder in place with the thumbscrew.




- You are now measuring dimension "H".

d. Put correct bearing races on the output gear and idler gear bearings, and turn races to seat bearing.




e. Place Tool (output gauging plunger) into the gauging cylinder.




f. Now, place bridge onto machined gasket surface of transmission case and allow gauging plunger to drop onto rear surface of output gear bearing race.




g. Lock gauging plunger in place with thumbscrew. Use feeler gauge to measure gap between gauging cylinder and shoulder of gauging plunger.
h. Use feeler gauge reading to select the correct shim(s) from following chart:
Output shaft bearing adjusting shim: Refer to Specifications and Adjustments. Specifications




i. Now, measure for the correct preload shims at the idler gear bearing in the same way. Place bridge onto machined surface of side cover and allow gauging cylinder to drop until it contacts idler bearing race mating surface.




- You are now measuring dimension "K".




j. Lock gauging cylinder in place. Insert Tool (gauging plunger) into gauging cylinder and place bridge onto machined surface of case, so that gauging plunger meets idler bearing race rear surface.




k. Lock gauging plunger in place and use feeler gauge to measure gap between gauging cylinder and gauging plunger.
l. Use your measured distance and the following chart to select correct shim(s) for idler gear bearing preload.
Idler gear bearing adjusting shim: Refer to Specifications and Adjustments. Specifications




m. Install selected shim(s) and bearing outer races.




30. Move manual lever until parking pawl engages idler gear. Measure clearance between parking pawl and parking actuator.
It clearance is outside specifications, replace parking pawl.

Parking pawl : Refer to Specifications and Adjustments. Specifications




Example:
When parking pawl with identification letter "E" is used:

Clearance "L" is larger.
Replace with parking pawl with identification letter "D".
Clearance "L" is smaller.
Replace with parking pawl with identification letter "F".




31. Install side cover and gasket.
Always use new bolts at portions (R) and (D) as they are self-sealing bolts. Apply A.T.F. to thread of other bolts by that fix side cover to transmission case when installing them.

Bolts (A) and (C): 19 - 23 N.m (1.9 - 2.3 kg.m, 14 - 11 ft.lb)
Bolts (B) and (D): 21 - 23 N.m (2.1 - 2.3 kg.m, 15 - 17 ft.lb)




32. Insert Tool into final drive portion to see if internal parts rotates smoothly. Rotating in direction "B" is slightly harder than in direction "A".
If abnormalities are noted, proceed with the following:
- Disassemble parts to see if they are properly assembled.
- Readjust bearing preloads of final drive, output shaft and idler gear.




33. Adjust brake band.
a. First tighten anchor end pin.

Anchor end pin: 4 - 6 N.m (0.4 - 0.6 kg.m, 2.9 - 4.3 ft.lb)

b. Back off anchor end pin"N" turns.

Number of returning revolutions for anchor end pin "N": 5.25 turn

c. Tighten lock nut while holding anchor end pin stationary.

Lock nut: With Tightening Torque : 31 - 42 N.m (3.2 - 4.3 kg.m, 23 - 31 ft.lb)




34. Install terminal assembly, paying attention to the direction of its hook.




35. Install accumulator and spring.




36. Insert manual valve to control valve body, then assemble them to transmission case.

Bolt (A): 3.7 - 5.0 N.m (0.38 - 0.51 kg.m, 2.1 - 3.7 ft.lb)
Other bolts: 7 - 9 N.m (0.1 - 0.9 kg.m, 5.1 - 6.5 ft.lb)




- Pay attention to the direction of manual valve groove.




37. Connect harness connectors between terminal assembly and solenoids.




38. Put gasket on transmission case and install valve cover.
Always use new bolts as they are self-sealing bolts.




39. Install control cylinder.




40. Install revolution sensor.




41. Install governor shaft.




42. Install speedometer parts.




43. Pour approx. 2 liters (2 - 1/8 US qt, 1 - 3/4 Imp qt) of automatic transmission fluid into converter housing.
44. Install torque converter to converter housing.
Be careful not to scratch front oil seal.
45. Apply sealant to threads of drain plug and install it in place.
46. Install inhibitor switch to transmission case.
47. Adjust inhibitor switch. Refer to On-vehicle Service.
48. Make sure that manual lever operates smoothly.