Part 1
ASSEMBLYBefore assembly, make sure again that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended ATF: DEXRON(R) II
GENERAL ASSEMBLY NOTES:
- 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.
- Before assembling new clutch discs, soak them in automatic transmission fluid for at least two hours.
- Apply automatic transmission fluid on the sliding or rotating surfaces of parts before assembly.
- Use petroleum jelly to keep small parts in their places.
- Do not use adhesive cements on gaskets and similar parts.
- When assembling the transmission, be sure to use new gaskets and O-rings.
- Dry all parts by blowing with compressed air. Never use shop rags.
- Be sure to install the thrust bearings and races in the correct direction and position.
1. INSTALL BEARING TO TRANSAXLE HOUSING
a. Using SST and a press, press the bearing into the transaxle housing.
SST 09350-32013 (09351-32090, 09351-32150)
b. Install the bearing stopper.
2. INSTALL OIL TUBE APPLY COVER
3. INSTALL OIL TUBES
Using a plastic hammer, install the three tubes.
CAUTION: Be careful not to bend or damage the tubes.
4. INSTALL OIL TUBE CLAMPS
5. INSTALL BEARING TO TRANSMISSION CASE
Using SST and a press, press in the bearing.
SST 09350-32013 (09351-32090)
6. INSTALL B4 ACCUMULATOR PISTON AND SPRING
7. INSTALL OIL GALLERY COVER AND GASKET
a. Install the oil gallery cover and gasket.
b. Install and tighten the six bolts.
c. Clean the threads of the screws and case with white gasoline.
d. Apply seal packing or equivalent to the three screws.
Seal packing: Part No.08833-00070, THREE BOND 1324 or equivalent
e. Install and tighten the three screws.
8. INSTALL OIL SEAL RINGS TO TRANSMISSION CASE
NOTE: After installing the oil seal rings, check that they move smoothly.
9. INSTALL MANUAL SHAFT AND LEVER
a. Slide in the shaft and install the washer, spacer and manual lever.
b. Install the retaining spring.
NOTE: Make sure there is a washer between the retaining spring and case.
10. INSTALL PIN
Using a punch and a hammer, drive in the pin.
11. STAKE SPACER
Position and stake the spacer.
12. INSTALL CAM GUIDE BRACKET
Install the cam guide bracket and then insert the parking lock rod into the guide bracket.
13. INSTALL PARKING LOCK SLEEVE PROTRUDING PORTION UPWARD
14. PLACE STOPPER PLATE
Place the stopper plate on the protruding portion of lock sleeve.
15. INSTALL GUIDE SLEEVE AND SPRING
16. INSTALL PARKING LOCK PAWL, PAWL SHAFT AND SHAFT CLAMP
17. INSTALL UNDERDRIVE BRAKE PISTON
a. Install new O-rings on the piston. Coat the O-rings with ATF.
b. Place the piston into the case with the cup side up, being careful not to damage the O-rings.
18. INSTALL BRAKE PISTON RETURN SPRING
19. INSTALL PLATES, DISCS AND FLANGE
a. Install in order: Plate-disc-plate-disc-plate-disc
b. Install the flange facing the flat end upward.
20. COMPRESS RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the flange, and compress the return spring with a press.
SST 09350-32013 (09351-32070, 09351-32130)
b. Install the snap ring.
NOTE: Be sure the end gap of the snap ring is not aligned with one of the cutouts.
21. INSTALL UNDERDRIVE ONE-WAY CLUTCH
22. INSTALL ANTI-RATTLE CLIP
In the place shown in the figure (the space between the one-way clutch outer race and case), push the anti-rattle clip in until you hear the "click".
23. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Align the flukes of discs in the underdrive brake.
b. Install the clutch assembly.
c. Turn the clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.
24. CHECK HEIGHT CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the inner race.
Height: 17.3 - 18.2 mm (0.681 - 0.717 in.)
25. INSTALL RACE WITH BEARING
26. INSTALL SNAP RING TO SUN GEAR WITH SNAP RING PLIERS
27. INSTALL SUN GEAR TO CASE
28. INSTALL COUNTER SHAFT ASSEMBLY
a. Align the flukes of the discs in the underdrive clutch.
b. Install the counter shaft assembly.
29. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.
Height: 38.3 - 40.5 mm (1.508 - 1.594 in.)
30. INSTALL THRUST NEEDLE BEARING
31. INSTALL COUNTER DRIVEN GEAR
Using SST and a press, press in the driven gear.
SST 09350-32013 (09351-32100, 09351-32140)
32. TIGHTEN NEW LOCK NUT
Using SST to hold the driven gear, tighten a new lock nut.
SST 09330-00021 and 09350-32013 (09351-32031)
Torque: 1,600 kg.cm. (116 ft.lb., 157 Nm)
33. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.
End play: 0.23 - 0.89 mm (0.0091 - 0.0350 in.)
34. STAKE LOCK NUT
35. INSTALL SNAP RING TO TRANSMISSION CASE
36. INSTALL INTERMEDIATE SHAFT
37. INSTALL TRANSAXLE REAR COVER
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or transmission case.
b. Apply seal packing to the rear cover as shown.
Seal packing: Part No.08833-00090, THREE BOND 1131, LOCTITE 518 or equivalent
c. Install and tighten the thirteen bolts.
Torque: 300 kg.cm. (22 ft.lb., 29 N.m)
NOTE: Each bolt length (mm) is indicated in the figure.
38. INSTALL THRUST WASHER AND GOVERNOR DRIVEN GEAR
39. INSTALL NEW OIL SEALS
Install the two new oil seals.
40. CHECK INTERMEDIATE SHAFT
Make sure that the intermediate shaft turns smoothly.
41. INSTALL FIRST AND REVERSE BRAKE IN CASE
a. Install the inner flange, facing the flat end toward you.
b. Install in order: Disc-plate-disc-plate-disc-plate-disc
c. Install the outer flange, facing the flat end toward the inner side.
42. INSTALL SNAP RING
Be sure the snap ring end gap is not aligned with one of the cutouts.
43. CHECK OPERATION OF FIRST AND REVERSE BRAKE
Apply compressed air into the oil passage with the case and be sure that the piston moves.
44. INSTALL NO.2 PLANETARY CARRIER THRUST WASHER
Coat thrust washer with petroleum jelly and install it onto the planetary carrier.
NOTE: Make sure that the different lug shapes match the openings on the carrier.
45. INSTALL RACES AND BEARING
Coat the races and bearing with petroleum jelly and install them onto the ring gear.
46. INSTALL REAR PLANETARY RING GEAR INTO CASE
a. Align the flukes of the discs.
b. Install the rear planetary ring gear into the case.
47. INSTALL REAR PLANETARY GEAR
Align the spline of the planetary carrier with the flukes of the discs and install the planetary gear into the first and reverse brake discs.
48. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD
a. Place the one-way clutch into the case, facing the shiny side upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350-32013 (09351-32050)
c. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.
49. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise.