Part 1
COMPONENT PARTS INSTALLATIONDisassembly, inspection and assembly of each component group have been indicated. 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 II
General 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 ATF for at least 15 minutes.
3. Apply ATF on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
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. When working with FIPG material, you must observe the following.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
Bearings And Races Installation Position And Direction
Transmission Assembly
1. INSTALL COMPONENTS OF 1st AND REVERSE BRAKE PISTON
a. Coat 3 now O-rings with ATF.
b. Install the 2 O-rings on the No.1 piston.
c. Install the O-ring on the reaction sleeve.
d. Install the No.1 piston to the reaction sleeve.
e. Coat a new O-ring with ATF and install it on the No. 2 piston.
f. Install the No.1 piston with the reaction sleeve onto the No.2 piston.
g. Align the teeth of the No.2 piston into the proper grooves.
h. Being careful not to damage the O-rings, press in the No.2 and No.1 1st and reverse brake pistons into the transmission case.
i. Place the piston return spring onto the No.2 piston.
j. Set SST as shown, and compress the return spring with SST.
k. Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
2. CHECK PISTON STROKE OF 1st AND REVERSE BRAKE
Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
3. INSTALL LEAF SPRING
4. INSTALL REAR PLANETARY GEAR UNIT WITH 2ND BRAKE DRUM, 1st AND REVERSE BRAKE PACK AND OUTPUT SHAFT
a. Install the flange, the rounded edge facing forward.
b. Reinstall the plates and discs.
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P-D-P-D-P
c. Install the 2nd brake drum assembly.
d. Coat the assembled bearing and race with petroleum jelly and install it onto the case.
Assembled bearing and race diameter
e. Align the teeth of the 2nd brake drum, flange, discs and plates.
f. Align the splines of the transmission case and the assembled rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft, indicated by A.
g. Hold the output shaft with wooden blocks or equivalents.
h. Using SST, install the snap ring.
5. CHECK PACK CLEARANCE OF 1ST AND REVERSE BRAKE
Using a feeler gauge, measure clearance between the plate and second brake drum.
Clearance: 0.70 - 1.22 mm (0.0276 - 0.0480 inch)
If the values are non-standard, select another flange.
HINT: There are 6 different thicknesses for the flange.
Flange thickness
6. INSTALL 2ND BRAKE PISTON SLEEVE
7. INSTALL NEW BRAKE DRUM GASKET
8. INSTALL NO.1 ONE-WAY CLUTCH
9. INSTALL FLANGE, PLATES AND DISCS OF 2ND BRAKE
a. Install the 1.8 mm (0.071 inch) thick plate with the rounded edge side of the plate facing the disc.
b. Install the plates and discs.
Plate thickness: 2.5 mm (0.098 inch)
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P
c. Using a screwdriver, install the snap ring.
10. CHECK PACK CLEARANCE OF 2ND BRAKE
Using a feeler gauge, measure the clearance between the snap ring and flange.
Clearance: 0.62 - 1.98 mm (0.0244 - 0.0780 inch)
If the values are non-standard, check for an improper installation.
11. INSTALL PLANETARY SUN GEAR
While turning the planetary sun gear clockwise, install it into the No.1 one-way clutch.
HINT: Confirm the thrust washer is installed correctly.
12. INSTALL FRONT PLANETARY GEAR
a. Coat the bearing and race with petroleum jelly and install them onto the front planetary gear.
Bearing and race diameter
b. Install the front planetary gear to the sun gear.
c. Using SST, install the snap ring.
d. Remove the wooden blocks or equivalent under the output shaft.
e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.
Race diameter
13. INSTALL 2ND COAST BRAKE BAND
a. Install the 2nd coast brake band to the case.
b. Install the pin through the brake band.
c. Using needle-nose pliers, install the E-ring to the pin.
14. INSTALL FRONT PLANETARY RING GEAR TO FORWARD AND DIRECT CLUTCH
a. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.
Bearing and race diameter
b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.
Race diameter
c. Align the flukes of the discs in the forward clutch.
d. Align the splines of the front planetary ring gear with the flukes of the discs and install the front planetary ring gear to the forward clutch.
15. INSTALL ASSEMBLED DIRECT CLUTCH, FORWARD CLUTCH AND FRONT PLANETARY RING GEAR INTO CASE
a. Coat the bearing and race with petroleum jelly and install them onto the ring gear.
Bearing and race diameter
b. Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission case.
c. Using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum.
Height: 5.3 - 7.3 mm (0.209 - 0.287 inch)
If the values are non-standard, check for an improper installation.
d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.
Assembled bearing and race diameter
16. INSTALL 2ND COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING
a. Coat 2 new O-rings with ATF and install them to the cover.
b. Install the spring, piston assembly and cover to the case.
c. Using SST, install the snap ring.
17. CHECK PISTON ROD STROKE OF 2nd COAST BRAKE
a. Place a mark on the 2nd coast brake piston rod.
b. Using SST, measure the stroke while applying and releasing compressed air (392-785 kPa, 4-8 kgf/cm', 57-114 psi).
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)
If it is still more than standard value, replace the brake band with a new one.
18. INSTALL O/D SUPPORT ASSEMBLY
a. Coat the race with petroleum jelly and install it onto the O/D support assembly.
Race diameter
b. Using 2 bolts of SST, aim the bolt and oil holes of the O/D support toward the valve body side, and align them with the bolt holes of the transmission case and insert.
c. Temporarily tighten the 2 bolts.
d. Using SST, install the snap ring.
HINT: Install the snap ring open end toward the valve body.
e. Torque the 2 bolts.
Torque: 25 Nm (260 kgf.cm, 19 ft. lbs.)
19. CHECK OUTPUT SHAFT
a. Using a dial indicator, measure the end play of the output shaft with hand.
End play: 0.27 - 0.86 mm (0.0106 - 0.0339 inch)
If the values are non-standard, check for an improper installation.
b. Check to see that output shaft rotates smoothly.
20. INSTALL FLANGES, PLATES AND DISCS OF O/D BRAKE
a. Install the 4.0 mm (0.157 inch) thick flange (flat ring) with the rounded edge side of the flange facing the discs.
b. Install the plates and discs.
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.
d. Using a screwdriver, install the snap ring.
21. CHECK PISTON STROKE OF O/D BRAKE
a. Place SST and a dial indicator onto the O/D brake piston.
b. Measure stroke while applying and releasing compressed air (392-785 kPa, 4-8 kgf/cm, 57-114 psi).
Piston stroke: 1.75 - 2.05 mm (0.0689 - 0.0807 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again
If the piston stroke is non-standard, select another flange.
HINT: There are 7 different thicknesses for the flange.
Flange thickness
22. INSTALL O/D PLANETARY GEAR UNIT WITH O/D DIRECT CLUTCH AND ONE-WAY CLUTCH
a. Coat the assembled bearing and race with petroleum jelly and install it onto the O/D support.
Assembled bearing and race diameter
b. Install the O/D planetary ring gear.
c. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
Bearing and race diameter
d. Coat the race with petroleum jelly and install it onto the planetary gear.
Race diameter
e. Install the O/D planetary gear with the O/D direct clutch and one-way clutch.
f. Place SST on the transmission case.
g. Using calipers, measure distance between the tops of SST and the clutch drum.
Standard distance: 15.5 - 16.5 mm (0.610 - 0.650 inch)
If the values are non-standard, check for an improper installation.
h. Coat the assembled bearing and race with petroleum jelly and install it onto the O/D direct clutch.
Assembled bearing and race diameter
