Part 2

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 (0.01 97 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 INTERMEDIATE SHAFT
a. Install the intermediate shaft to the transmission.
b. Install the bearing race, bearing and bearing race.

48. INSTALL EXTENSION HOUSING AND GASKET

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

49. INSTALL SPEEDOMETER DRIVEN GEAR
50. INSTALL 4WD CHANGE-OVER SOLENOID




51. 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)

52. INSTALL SHIFT HANDLE




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




54. 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)




55. 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 (0.011 8 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.




56. INSTALL TORQUE CONVERTER IN TRANSMISSION

57. 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.)