Part 1

Before 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:

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 the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep 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 with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.








1. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and the pawl.

2. INSTALL PARKING LOCK ROD




3. INSTALL PARKING LOCK PAWL BRACKET

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




4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P range.




5. INSTALL INTERMEDIATE SHAFT




6. INSTALL TRANSAXLE REAR COVER
Align each bolt hole in the gasket and the case.
Tighten the bolts.

Torque: 250 kg-cm (18 ft-lb, 25 N.m)




7. CHECK INTERMEDIATE SHAFT END PLAY
a. Make sure that the intermediate shaft has thrust play in axial direction.

Thrust play: 0.49 - 1.51 mm (0.0193 - 0.0594 in.)

If the thrust play is not within specification, check the installation of intermediate shaft. (See page AT-57) ZZZZ

b. Make sure that the intermediate shaft turns smoothly.




8. INSTALL FIRST AND REVERSE BRAKE EN CASE
a. Install the inner flange, facing the flat end toward the oil pump side.
b. Install in order:
Disc-Plate-Disc-Plate-Disc-Plate-Disc-Plate-Disc




9. INSTALL SNAP RING
Be sure the end gap of the snaping is not aligned with one of cutouts.




10. CHECK OPERATION OF FIRST AND REVERSE BRAKE
Apply compressed air into the oil passage with the case and be sure that the piston moves.




11. 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.




12. INSTALL RING GEAR INTO CASE
a. Coat the races and bearing with petroleum jelly and install them onto the ring gear.
b. Install the ring gear into the case.




13. INSTALL REAR PLANETARY GEAR INTO CASE
a. Align the flukes of the discs in the first and reverse brake.
b. Align the spline of the planetary carrier with either of the flukes of the discs, and install the planetary gear into the first and reverse brake discs.




14. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD
a. Place the one-way clutch with 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.




15. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise.




16. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of cutouts.




17. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the band guide so that its tip touches the case.




18. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, facing the flat end toward you.
b. Install in order. Disc-Plate-Plate-Disc-Plate-Plate




19. INSTALL PISTON RETURN SPRING ASSEMBLY
Each spring end is installed onto the protrusion with the case.




20. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.




21. INSTALL SNAP RING
a. Place the snap ring into the case so that the end gap is installed into the groove.
b. While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
c. Be sure the end gap of the snap ring is not aligned with one of cutouts.




22. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case. and be sure that the piston moves.




23. INSTALL SECOND BRAKE DRUM GASKET
Drive in a new drum gasket until it makes contact with the second brake drum.




24. INSTALL NO.1 ONE-WAY CLUTCH AND SECOND BRAKE HUB
a. Align the flukes of the discs in the 2nd brake.
b. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.




c. Check the distance between the surface of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)




25. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.




26. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR
a. Coat the races and the bearing with petroleum jelly, and install them onto the ring gear.
b. Coat the race and the bearing with petroleum jelly, and install them onto planetary gear.




c. Install the planetary gear onto the ring gear.

27. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR




a. If the planetary gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.




b. Coat the race with petroleum jelly and install it onto the tip of ring gear flange.

28. INSTALL INTERMEDIATE SHAFT OIL SEAL RING




29. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.




30. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
a. Coat the races and bearing with petroleum jelly, and install them onto both sides of the clutch drum.
b. Coat the clutch drum thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.




c. Align the flukes of discs in the direct clutch.




d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.
e. If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch.




f. Place the direct clutch and forward clutch into the case.
g. While rotate the forward clutch to mesh the front planetary ring gear and discs.




h. Check the distance between the A and B as shown in the illustration.
Distance: Approx. 3 mm (0.118 in.)