Assembly

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.

GENERAL ASSEMBLY NOTE:
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 them 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 THRUST WASHER AND BEARING
Install the thrust washer, facing the cup side downward.




2. INSTALL REAR PLANETARY RING GEAR




3. INSTALL NO.3 BRAKE CUSHION PLATE, DISC AND PLATE
Be sure to assemble the brake cushion plate in the correct direction.




4. INSTALL THRUST BEARING
Coat the race with petroleum jelly and stick it onto the ring gear.




5. INSTALL REAR PLANETARY GEAR AND THRUST WASHER
a. After aligning the notch and tab, coat the thrust washer with petroleum jelly and stick it onto the planetary gear.




b. Before assembling the planetary gear, align the disc flukes.




c. Install the rear planetary gear.




6. MEASURE NO.3 BRAKE CLEARANCE
To prevent the plate from tilting while measuring, hold it down with two hammer handles.

Standard clearance: 10.04 - 11.30 mm (0.3953 - 0.4449 in.)




7. INSTALL REACTION PLATE
Align the portion of the reaction plate marked "A" with the "B" portion of the transmission case.

NOTE: Groove "B" is larger than the other grooves.

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





8. INSTALL SNAP RING
Use a large screwdriver to compress the snap ring. Push it into the 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.




9. 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.




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

11. TIGHTEN TWO CENTER SUPPORT BOLTS
a. 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)




b. Confirm that the sun gear turns lightly in clockwise direction and heavily in counterclockwise direction.




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

NOTE: Confirm that the B1 brake is securely meshed with the rear clutch drum. Approx 4 mm (0.1 6 in.) depth from sun gear to shaft.




13. INSTALL THRUST BEARING RACE




14. INSTALL OUTPUT SHAFT AND FRONT PLANETARY GEAR




15. INSTALL THRUST BEARING AND RACE





16. INSTALL FRONT CLUTCH ASSEMBLY IN CASE
Align the flukes of the rear clutch discs and mesh them with the front clutch hub. Push the front clutch assembly into the case.

17. 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 the case and front clutch assembly. If the distance corresponds to specification, the front clutch is installed correctly.
SST 09350-20013 (09370-12010)

Height: 0.6 - 1.6 mm (0.024 - 0.063 in.)







18. INSTALL THRUST BEARING AND RACE




19. INSTALL O-RING ON CASE




20. INSTALL THRUST WASHER ON FRONT SUPPORT
Coat the thrust washer with petroleum jelly and set it into place, facing the lip side toward the front support.

21. INSTALL FRONT SUPPORT ON CASE




a. Install the front support to the case and confirm that there is no clearance between the surfaces of the support and case when pressing down with your hand.

NOTE: If there is a clearance, the front clutch is not completely installed.




b. Confirm that there is thrust play on the input shaft and tighten the bolts in diagonal order.




c. Tighten the bolts a little at a time in two or three stages and in diagonal order.

Torque: 195 kg-cm (14 ft-lb, 19 N.m)




22. CHECK FRONT CLUTCH INPUT SHAFT AND OUTPUT SHAFT
a. Make sure that the front clutch input shaft has play in axial direction and that it turns.

Thrust play: 0.24 - 0.96 mm (0.0094 - 0.0378 in.)

b. Make sure that the output shaft has thrust play in axial direction.

Thrust play: 0.31 - 1.53 mm (0.0122 - 0.0602 in.)




23. INSTALL BEARING ON DRIVE SPROCKET

24. INSTALL THRUST RACE ON CASE
Coat the thrust race with petroleum jelly and install the lip side toward the case.




25. INSTALL INPUT SHAFT, DRIVE SPROCKET CHAIN AND DRIVEN SPROCKET




26. INSTALL SNAP RING

27. CHECK CLEARANCE BETWEEN SNAP RING AND DRIVEN SPROCKET

Thrust clearance: 0.11 - 0.69 mm (0.0043 - 0.0272 in.)




28. INSTALL THRUST RACE ON OIL PUMP
Coat the thrust race with petroleum jelly and install the lip side toward the pump body.




29. INSTALL OIL PUMP
Tighten the set bolts gradually and evenly.

Torque: 185 kg-cm (13 ft-lb, 18 N.m)




30. CHECK OIL PUMP
Confirm that the drive gear rotates smoothly.

NOTE: Do not damage the oil seal lip.




31. CHECK INPUT SHAFT
Make sure that the input shaft has play in axial direction and that it turns.

Thrust play: 0.10 - 0.70 mm (0.0039 - 0.0276 in.)




32. INSTALL TUBE AND O-RING




a. Temporarily tighten the suction tube bracket.

NOTE: Always use a new O-ring.

Drive in the tube until it makes contact with either the bulge or the stopper.




b. After installing the O-ring on the delivery tube, install the tube into the transmission case.




33. INSTALL MANUAL VALVE LEVER SHAFT INTO CASE
a. Assemble a new spacer to the manual valve lever.

NOTE: Always replace the spacer and slotted spring pin with a new one. Never reuse a slotted spring pin after it has been removed.




b. Install the manual valve lever.
c. While holding the ditent ball with the plate, install the manual valve shaft.




d. Drive in the slotted spring pin.
e. After assembly, turn the spacer 900 and stake it.




34. INSTALL PARK PAWL, PIVOT PIN AND SPRING IN CASE




35. INSTALL PARK PAWL BRACKET ON CASE
Make sure the collar on the parking lock rod is facing toward the front of the transmission.
Tighten the two bolts. Make sure the pawl moves freely.

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

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




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




37. INSTALL ACCUMULATOR PISTON AND SPRINGS
a. Be sure to install the accumulator spring and piston in correct direction.
b. Fully install the pistons into the cylinder by hand.




c. Be sure to assemble the gasket in correct direction.
d. Install the cover.

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




38. INSTALL STEEL BALL

39. INSTALL VALVE BODY PLATE, GASKET VALVE BODY AND OIL STRAINER




a. Before installing the gasket, make sure the vibrating stopper is installed.




b. Do not interchange the upper and lower gaskets.




c. Before assembling the valve body, confirm that the cut back plug lock pin has not fallen out.




d. Connect the oil pump suction pipe and assemble the valve body to the upper case.




e. Gradually tighten the bolts in diagonal order.

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

NOTE: Also tighten the suction pipe bracket bolt.

40. INSTALL FRONT VALVE BODY AND ROD




a. Connect the manual valve connecting rod and manual valve, and then assemble the valve body.




b. Gradually tighten the bolts in 3 or 4 stages.

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




41. INSTALL THROTTLE LEVER
a. Assemble one regular washer and one wave washer on the inside of the throttle lever and one regular washer on the outside.
b. Check the thrust clearance after assembling the throttle lever.
Thrust clearance: Less than 0.50 mm (0.0197 in.)
If the clearance is more than 0.50 mm (0.0197 in.). insert a washer on the outer side.

c. Install the throttle cover.




42. INSTALL OIL TUBES
Press the tubes by hand into the positions indicated in the figure.

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




43. INSTALL MAGNETS IN PAN AND INSTALL OIL PAN WITH NEW GASKET
a. Clean the magnets and install a new gasket in the proper position.
b. Prior to installing the oil pan, confirm that the tube will not interfere with it.




c. Tighten the bolts.

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

44. INSTALL DRAIN PLUG WITH NEW GASKET

Torque: 300 kg-cm (22 ft-lb, 29 N.m)




45. INSTALL TRANSAXLE GASKET AND GOVERNOR APPLY GASKET
Before assembling the transaxle, confirm that the governor apply gasket has not fallen out.

46. ASSEMBLE TRANSAXLE
Tighten the transmission mounting bolts.

Torque: 195 kg-cm (14 ft-lb, 19 N.m)





47. INSTALL OUTPUT SHAFT SLEEVE
a. Install the oil seal ring to the output shaft sleeve.
b. Install the output shaft sleeve to the output shaft.
Push in the oil seal ring with a screwdriver.




48. INSTALL SPEEDOMETER DRIVE GEAR AND SNAP RING




49. INSTALL REAR EXTENSION HOUSING WITH NEW GASKET

Torque: 195 kg-cm (14 ft-lb, 19 N.m)




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

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




52. INSTALL NEUTRAL START SWITCH
a. Slide the neutral start switch onto the control shaft.
b. Install the grommet facing the groove toward the switch body and then install the washer and nut.
c. Move the switch so that the slit in the switch and neutral base line match. Tighten the bolt and nut.

Torque:
Nut 70 kg-cm (61 in.-lb, 6.9 N.m)
Bolt 130 kg-cm (10 ft-lb 13 N.m)

53. INSTALL SHIFT HANDLE




54. INSTALL FILLER TUBE
a. Replace the O-ring and push the tube into place.
b. Install the filler tube with the bolt.




55. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR
Set up a dial indicator and measure the drive plate runout.

If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts.

Torque: 650 kg-cm (47 ft-lb, 64 N.m)




56. MEASURE TORQUE CONVERTER SLEEVE RUNOUT
a. Temporarily mount the torque converter to the drive plate. Set up a dial indicator.

If runout exceeds 0.30 mm (0.0118 in.), try to correct by reorienting the installation of the converter. If excessive runout cannot be corrected, replace the torque converter.

NOTE: Mark the position of the converter to ensure correct installation.

b. Remove the torque converter.





57. INSTALL TORQUE CONVERTER IN TRANSMISSION

58. CHECK TORQUE CONVERTER INSTALLATION
Using calipers and a straight edge, measure from the installed converter center piece surface to the front surface of the transmission housing.

Correct distance: More than 8 mm (0.31 in.)