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.

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.

1mNOTE: 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 - 0.0379 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.