Part 2
25. INSTALL OVERDRIVE PLANETARY GEAR AND DIRECT CLUTCH
a. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
NOTE: Bearing and race diameter
b. Coat the race with petroleum jelly and install it onto the planetary gear.
NOTE: Race diameter
c. Install the overdrive planetary gear and direct clutch.
d. Coat the assembled bearing and race with petroleum jelly and install it onto the direct clutch
NOTE: Bearing and race diameter
26. INSTALL FLANGES, DISCS AND PLATES
a. Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the disc.
b. Alternately install the discs and plates. (Disc first)
7M-GE: Four discs and three plates
7M-GTE: Five discs and four plates
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.
d. Install the snap ring.
27. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the oil pump.
NOTE: Race diameter
b. Coat the O-ring with ATF and install it around the pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.
CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.
e. Install the seven bolts.
Torque: 220 kg.cm (16 ft.lb, 22 N.m)
28. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.
29. INSTALL THROTTLE CABLE
a. Coat a new O-ring with the ATF and install it to the cable.
b. Install the cable to the case.
30. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while injecting compressed air into the oil hole indicated in the figure.
1. OD direct clutch
2. Direct clutch
3. Forward clutch
4. OD brake
5. Second coast brake
6. Second brake
7. First and reverse brake
NOTE: When inspecting the direct clutch, check with the c(0) accumulator piston hole closed.
If there is no noise, disassemble and check the condition of the parts.
31. INSTALL ACCUMULATOR PISTON
a. Coat the O-ring with ATF and install it to the piston.
b. Install the three springs and four accumulator pistons to the bore as shown in the figure.
c. Install the two pins and four springs.
32. INSTALL CHECK BALL BODY AND SPRING
33. INSTALL VALVE BODY
a. Align the groove of the manual valve to the pin of the lever.
NOTE: When inspecting the direct clutch, check with the C(o) accumulator piston hole closed.
b. Connect the throttle cable to the cam.
c. Confirm the springs into the accumulator piston are installed correctly.
d. Install the seventeen bolts.
NOTE: Each bolt length mm) is indicated in the figure.
Torque: 100 kg.cm (7 ft.lb, 10 N.m)
34. INSTALL SOLENOID WIRING
a. Coat a new O-ring with ATF, and install it to the solenoid wiring.
b. Insert the solenoid wiring to the case and install the stopper plate.
c. Connect the connectors to the No.1, No.2 and No.3 solenoids.
35. INSTALL OIL TUBES
Using a plastic hammer, install the two tubes into the positions shown in the figure.
CAUTION: Be careful not to bend or damage the tubes.
36. INSTALL OIL STRAINER
a. Install the two new gaskets to the oil strainer.
b. Install and torque the three bolts.
Torque: 100 kg.cm (7 ft.lb, 10 N.m)
c. Clamp the solenoid wire.
37. INSTALL MAGNET IN PAN
CAUTION: Make sure that the magnet does not interfere with the oil tubes.
38. INSTALL OIL PAN
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.
b. Apply seal packing equivalent to the oil pan as shown in the figure.
Seal packing: Part No.. 08826-00090, THREE BOND 1281 or equivalent
NOTE: Install oil pan within 10 minutes after applying seal packing.
c. Install and torque the nineteen bolts.
Torque: 75 kg.cm (65 in.lb, 7.4 N.m)
39. INSTALL SENSOR ROTOR
a. Using snap ring pliers, install the snap ring.
b. Install the sensor rotor and key.
40. INSTALL SPEEDOMETER DRIVE GEAR
a. Install the speedometer drive gear and lock ball.
b. Using snap ring pliers, install the snap ring.
41. INSTALL EXTENSION HOUSING
Install the extension housing with a new gasket to the case. Torque the six bolts.
Torque: 370 kg.cm (27 ft.lb, 36 N.m)
42. INSTALL TRANSMISSION HOUSING
Install and torque the six bolts.
Torque:
10 mm 345 kg.cm (25 ft.lb, 34 N.m)
12 mm 580 kg.cm (42 ft.lb, 57 N.m)
43. INSTALL SPEED SENSOR
a. Install the speed sensor.
Torque: 160 kg.cm (12 ft.lb, 16 N.m)
b. Connect the connector.
44. INSTALL SPEEDOMETER DRIVEN GEAR
Torque: 160 kg.cm (12 ft.lb, 16 N.m)
45. INSTALL THE TWO UNIONS
a. Coat new O-rings with ATF, install them to the two unions.
b. Install the front union as shown in the figure.
Torque: 300 kg.cm (22 ft.lb, 29 N.m)
c. Install the rear union as shown in the figure.
Torque: 300 kg.cm (22 ft.lb, 29 N.m)
46. 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: 130 kg.cm (9 ft.lb, 13 N.m)
e. Bend the tabs of the lock washer.
NOTE: Bend at least two of the lock washer tabs.
47. INSTALL CONTROL SHAFT LEVER
Torque: 160 kg.cm (12 ft.lb, 6 N.m)
48. INSTALL WIRE HARNESS CLAMP AND THROTTLE CABLE CLAMP