Assembly

Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter.

Before assembly, make sure again that all component groups are assembled correctly.

If something wrong is found in a certain component group while assembly, inspect and repair this group immediately.

GENERAL ASSEMBLY NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least two hours.
3. Apply automatic transmission fluid on sliding or rotating surfaces of the parts before assembly.
4. Use petroleum jelly to keep the small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts by blowing with compressed air. Never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.





1. PLACE TRANSMISSION CASE ON CYLINDER
Place the transmission on a cylinder stand for more efficient work.

CAUTION: Place shop rags between the case and stand to avoid damaging the case.





2. INSTALL THRUST WASHER AND BEARING
Install the thrust washer, facing the cup side downward.





3. INSTALL APPLY TUBE ONTO OUTER PISTON OF REAR BRAKE PISTONS
Install the tube, aligning its locking tab (part A) with part B of the case.

NOTE: Make sure that the lips of the tube end are completely inserted onto the outer piston.





4. PARTIALLY INSERT OUTPUT SHAFT ASSEMBLY INTO CASE





5. CHECK CLUTCH PACK CLEARANCE
With the case in upright position, make sure that the clutch pack is lower than the ledge below the snap ring groove.

If the clutch pack is not lower than the ledge, components may be misassembled or there may be excess ATF on the discs.

Standard clearance: 0.56 - 2.29 mm (0.0220 - 0.0902 in.)





6. INSTALL REACTION PLATE
Position the notched tooth of the reaction plate toward the valve body side of the case. Push it into place.

NOTE: The reaction plate is correctly installed if the snap ring groove is fully visible.





7. INSTALL SNAP RING
Use a large screwdriver to compress the snap ring. Push it into place by hand. Work around the case. Visually check to make sure that the ring is fully seated. Make sure that the ends of the snap ring are between the lugs.





8. PUSH CENTER SUPPORT ASSEMBLY INTO CASE
Align the oil hole and bolt hole of the center support with those of the body side and insert the center support.





9. INSTALL TWO CENTER SUPPORT BOLTS WITH WAVE WASHERS
Align the center support with holes in the case and install the two bolts finger tight.





10. INSTALL REAR CLUTCH IN CASE
Rotate the clutch to mesh the hub with the center support.

11. CHECK FOR CORRECT INSTALLATION OF REAR CLUTCH
If the rear clutch is fully meshed with the center support, the splined center of the clutch will be flush with the end of the sun gear shaft.





12. INSTALL THRUST BEARING RACE OVER SPLINED END OF REAR CLUTCH IN CASE
Coat the parts with petroleum jelly to keep them in place. Position the lip of the race toward the rear clutch.





13. INSTALL THRUST BEARING AND RACE ON FRONT CLUTCH
Coat the parts with petroleum jelly to keep them in the place. Position the lip of the race outward.





14. INSTALL FRONT CLUTCH ASSEMBLY IN CASE

Align flukes of the rear clutch discs and mesh them with the front clutch hub. Push the front clutch assembly into the case.

CAUTION: Be careful that the thrust bearing does not fall out.





15. CHECK CORRECT INSTALLATION OF FRONT CLUTCH
Set SST on the transmission case as shown in the figure. Measure the distance between the top surface of SST and front clutch assembly. If the distance corresponds to that during disassembly, the front clutch is installed correctly.

SST 09350-20015 (09370-12010)

Height: Measured value minus SST width = Approx. 2 mm (0.08 in.)





16. INSTALL SST ON CASE
Finger tighten the SST on the transmission case.

SST 09350-20015 (09362-30011)

17. INSTALL THRUST BEARING ON FRONT CLUTCH
Coat the thrust bearing with petroleum jelly and set it into place.





18. INSTALL THRUST WASHER ON OVERDRIVE CASE END
Coat the thrust washer with petroleum jelly and set it into place, facing the lip side toward the overdrive case.





19. INSERT OVERDRIVE CASE INTO TRANSMISSION CASE
Insert the overdrive case gently through the two guide pins with the circled part in the figure facing in the direction indicated.





20. INSTALL TWO THRUST WASHERS
Coat the thrust washers with petroleum jelly. Install one thrust washer on the overdrive planetary carrier and the another one on the overdrive case.

NOTE: The washer lugs should be inserted in the holes.





21. INSTALL OVERDRIVE CLUTCH IN CASE
Align the discs of flukes in the overdrive case. Align the flukes with the slots of the overdrive clutch and press the overdrive clutch into the overdrive case.

CAUTION: Be careful that the thrust washer does not fallout.





22. CHECK CORRECT INSTALLATION OF OVERDRIVE CLUTCH
Set SST on the overdrive case as shown in the figure. Measure the distance between the top surface of SST and overdrive clutch. If the distance corresponds to that during disassembly, the overdrive clutch is installed correctly.

SST 09350-20015 (09370-12010)

Height: Measured value minus SST width = Approx. 3.5 mm (0.138 in.)





23. INSTALL NEW O-RING ON OVERDRIVE CASE
24. INSTALL CONVERTER HOUSING
Install the two 12-mm bolts (B) and four 10-mm bolts (A), and tighten them.

Torque:
A bolts 345 kg.cm (25 ft.lb, 34 N.m)
B bolts 580 kg.cm (42 ft.lb, 57 N.m)





25. INSTALL THRUST WASHER ON OVERDRIVE OVERDRIVE CLUTCH
Coat the thrust washer with petroleum jelly. Install the thrust washer facing the lip side inside.





26. INSTALL BEARING ON OIL PUMP
Coat the bearing with petroleum jelly and install it.





27. INSTALL OIL PUMP
a. Install the oil pump gently through the two guide bolts, being careful that the thrust washer does not fall out.
b. Coat the set bolts with seal packing, and finger tighten them.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

c. Using a screwdriver, remove the SST. In the place of it, install the two set bolts coated with seal packing.

SST 09350-20015 (09362-30011)

d. Tighten the set bolts gradually and evenly.

Torque: 215 kg.cm (16 ft.lb, 21 N.m)





28. TIGHTEN TWO CENTER SUPPORT BOLTS
Tighten the bolts alternately in 70 kg.cm (61 in.lb, 6.9 N.m) increments.

Torque: 260 kg.cm (19 ft.lb, 25 N.m)

NOTE: First tighten the accumulator side bolt.





29. CHECK OPERATION OF PISTONS
Blow low-pressure compressed air into the passages indicated in the photo and listen for noise from piston movement.
1. Overdrive clutch
2. Overdrive brake
3. Front clutch
4. Rear clutch
5. Brake No.1
6. Brake No.2
7. Brake No.3

If the pistons do not move, disassemble and inspect them.





30. CHECK INPUT SHAFT AND OUTPUT SHAFT
a. Make sure that the input shaft has play in axial direction and that it turns.
b. Make sure that the output shaft has thrust play in axial direction.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)





31. IF NECESSARY, INSTALL MANUAL VALVE LEVER SHAFT INTO CASE
a. Assemble the new collar to the manual valve lever.

NOTE: Always replace the collar and roll pin with a new one. Never reuse a pin after it has been removed.

b. Install the manual valve lever shaft to the transmission case through the manual valve lever.
c. Drive in a new roll pin with the slot at a right angle to the shaft.
d. Match the collar hole to the lever calking hollow and calk the collar to the lever.





32. INSTALL PARKING LOCK PAWL, PIVOT PIN AND SPRING IN CASE





33. INSTALL PARKING LOCK PAWL BRACKET ON CASE
Make sure the collar on the control rod is toward the front of the transmission.

Tighten the two bolts. Make sure the pawl moves freely.

NOTE: Be careful, as it is possible for bracket to be installed too far forward, where it will bind the pawl.

Torque: 75 kg.cm (65 in.lb, 7.4 N.m)





34. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the planetary gear output shaft is locked when the manual valve lever is in the "P" range.





35. INSTALL NEW O-RING ON THROTTLE CABLE FITTING
36. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to damage the O-ring. Check for full seating.

CAUTION: In subsequent work, do not roll the case over the cable and break the cable fitting.








37. INSTALL ACCUMULATOR PISTON AND SPRINGS





38. PLACE VALVE BODY ON TRANSMISSION
Make sure the accumulator pistons are pressed fully into the bore. Align the manual valve with the pin on the manual valve lever, and lower valve body into place.





39. LIFT SIDE OF VALVE BODY AND ATTACH THROTTLE CABLE
While holding the cam down by hand, slip the cable end into the slot.





40. INSTALL BOLTS IN VALVE BODY
Install the bolts as shown.

NOTE: Each bolt length (mm) is indicated in the figure.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)





41. INSTALL OIL STRAINER AND BOLTS
Install the small plate and oil strainer.

Torque: 55 kg.cm (48 in.lb 5.4 N.m)





42. INSTALL DETENT SPRING





43. INSTALL OIL TUBES
Using a plastic hammer, install the tubes into the position indicated in the photo.

CAUTION: Be careful not to bend or damage the tubes.

44. INSTALL MAGNETS IN PAN AND INSTALL OIL PAN WITH NEW GASKET





a. Install the magnets in the pan.

CAUTION: Make sure that the magnets do not interfere with the oil tubes.





b. Align the cut part of the gasket and case.
c. Torque the oil pan.

Torque:. 45 kg.cm (39 in.lb, 4.4 N.m)

45. INSTALL DRAIN PLUG WITH NEW GASKET

Torque: 205 kg.cm (15 ft.lb, 20 N.m)





46. INSTALL GOVERNOR LINE STRAINER
a. Install the strainer onto the case.
b. Install the plate.

47. INSTALL GOVERNOR BODY AND SPEEDOMETER DRIVE GEAR ON OUTPUT SHAFT





a. While lifting the retaining clip with a large screwdriver, slide the governor body and insert the retaining clip end into the hole on the output shaft.
b. Install the lock plate and bolt, and then stake the lock plate.

Torque: 40 kg.cm (35 in.lb, 3.9 N.m)





c. Install the snap ring and lock ball.
d. Slide the speedometer gear onto the shaft.
e. Using snap ring pliers, install the outer snap ring.





48. INSTALL REAR EXTENSION HOUSING WITH NEW GASKET
Do not use gasket sealer. Install the housing with four long bolts and two short bolts. Tighten the bolts.

Torque: 345 kg.cm (25 ft.lb, 34 N.m)





49. INSTALL NEW O-RINGS, BUSHING AND SPEEDOMETER DRIVEN GEAR TO SHAFT SLEEVE

50. INSTALL SPEEDOMETER DRIVEN GEAR ASSEMBLY IN EXTENSION HOUSING
Insert the shaft sleeve assembly into the housing. Install the lock plate with the bolt and lock washer.

51. INSTALL NEUTRAL START SWITCH





a. Using the control shaft lever, fully turn the manual lever shaft back and return two notches. It is now in neutral.
b. Insert the neutral start switch onto the manual valve shaft and temporarily tighten the adjusting bolt.





c. Install the lock washer and install and torque the nut.

Torque: 70 kg.cm (61 in.lb, 6.9 N.m)

d. Align the neutral standard line and the switch groove and tighten the adjusting bolt.

Torque: 55 kg.cm (48 in.lb, 5.4 N.m)

e. Bend the tabs of the lock washer.

NOTE: Bend at least two of the lock washer tabs.





52. INSTALL CONTROL SHAFT LEVER

Torque: 160 kg.cm (12 ft.lb, 16 N.m)





53. INSTALL SOLENOID SWITCH
Install the solenoid on the body with new O-rings.