Part 2

23. . INSTALL OIL PUMP INTO CASE



a. Coat the race with petroleum jelly and install it onto the oil pump.

Bearing diameter





b. Coat a new O-ring with ATF and install it around the pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the O/D direct clutch drum.

NOTICE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.




e. Install the 7 bolts.

Torque: 22 Nm (220 kgf.cm, 16 ft. lbs.)

24. CHECK INPUT SHAFT ROTATION



Make sure the input shaft rotates smoothly.


25. INDIVIDUAL PISTON OPERATION INSPECTION



Check for the sound of operation while applying compressed air into the oil hole indicated in the illustration.

HINT: When inspecting the O/D direct clutch, check with the C0 accumulator piston hole closed.

If there is no noise, disassemble and check the installation condition of the parts.
1. O/D direct clutch
2. Direct clutch
3. Forward clutch
4. O/D brake
5. 2nd coast brake
6. 2nd brake
7. 1st and reverse brake

26. . INSTALL SPEED SENSOR ROTOR AND KEY
a. Install the key on the output shaft.
b. Align the groove of the sensor rotor with the key, install the sensor rotor.



c. Using snap ring pliers, install the snap ring.

27. INSTALL TRANSFER CASE
a. Clean contacting surface of any residual packing material using gasoline alcohol.



b. Apply FIPG to the case. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





c. Install the case and torque the 8 bolts.
HINT: Each bolt length is indicated in the illustration.

Torque: 34 Nm (345 kgf.cm, 25 ft. lbs.)


28. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEALS



a. Using SST and a hammer, drive in 2 new oil seals.
b. Coat an oil seal lip with MP grease.





c. Install a new spacer to the manual valve lever.
d. Install the manual valve lever shaft to the transmission case through the manual valve lever.





e. Using a hammer, drive in a new spring pinch





f. Match the manual valve lover indentation with the spacer hole and caulk them the punch.
g. Make sure the shaft rotates smoothly.





29. INSTALL PARKING LOCK PAWL AND ROD
a. Install the E-ring to the shaft.
b. Install the parking lock pawl, shaft and spring.





c. Connect the parking lock rod to the manual valve lever.





d. Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.

Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)





e. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly locked up by the lock pawl.

30. INSTALL ACCUMULATOR SPRINGS AND PISTONS
a. Coat new O-rings with ATF and install them to the pistons.






b. Install the 4 springs and pistons to the bore.





31. INSTALL CHECK BALL BODY AND SPRING





32. INSTALL THROTTLE CABLE
a. Coat a now O-ring with ATF and install it to the cable.
b. Install the cable to the case.





33. INSTALL VALVE BODY
a. Align the groove of the manual valve to pin of the lover.
b. Connect the throttle cable to the cam.
c. Confirm the springs into the accumulator pistons are installed correctly.





d. Install the 17 bolts.
HINT: Each bolt length is indicated in the illustration.

Bolt length:
Bolt A: 23 mm (0.91 inch)
Bolt B: 32 mm (1.26 inch)

Torque: 10 Nm (100 kgf.cm, 7 ft. lbs.)






34. INSTALL TRANSMISSION SOLENOID WIRING
a. Coat a new O-ring with ATF and install it to the grommet.
b. Insert the solenoid wiring to the case and install the stopper plate.





c. Connect the connectors to the shift solenoid valve No. 1, No.2 and SL.





35. INSTALL OIL PIPE
Using a plastic hammer, install the pipe into position.

NOTICE: Be careful not to bond or damage the pipe.


36. INSTALL OIL STRAINER AND GASKETS



Install the oil strainer and torque the 4 bolts.

Torque: 10 Nm (100 kgf.cm, 7 ft. lbs.)
Bolt length:
Bolt A: 16 mm (0.63 inch)
Bolt B: 20 mm (0.79 inch)
Bolt C: 28 mm (1.10 inch)


37. INSTALL OIL PAN



a. Install the 3 magnets.
b. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.



c. Apply FIPG to the oil pan. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





d. Install and torque the 11 bolts.

Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)

38. INSTALL TRANSFER AND PROPELLER SHAFT UPPER DUST COVER TO TRANSMISSION WITH NEW GASKET
a. Apply MP grease to the adaptor oil seal.
b. Place a new gasket to the transfer adaptor.



c. Install the transfer to the transmission.

HINT: Take care not to damage the oil seal by the input gear spline when installing the transfer.





d. Install and torque the bolts with the propeller shaft upper dust cover.

Torque: 36 Nm (370 kgf.cm, 27 ft. lbs.)

e. Install the dust cover bolt to the bracket.

Torque: 23 Nm (230 kgf.cm, 17 ft. lbs.)





39. INSTALL ENGINE REAR MOUNTING

Torque: 25 Nm (260 kgf.cm, 19 ft. lbs.)





40. INSTALL DYNAMIC DAMPER

Torque: 37 Nm (380 kgf.cm, 27 ft. lbs.)

41. INSTALL TRANSMISSION HOUSING



Install and torque the 6 bolts.

Torque: 10 mm bolt 34 Nm (345 kgf.cm, 25 ft. lbs.)
14 mm bolt 67 Nm (580 kgf.cm, 42 ft. lbs.)

42. INSTALL VEHICLE SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the sensor.



b. Install the vehicle speed sensor.
c. Install the stopper plate.

Torque: 16 Nm (160 kgf.cm, 12 ft. lbs.)






43. INSTALL UNION AND ELBOW
a. Coat the new O-rings with ATF and install them to the union and elbow.





b. Install the rear elbow.

Torque: 29 Nm (300 kgf.cm, 22 ft. lbs.)





44. INSTALL ATF TEMPERATURE SENSOR
a. Coat a new O-ring with ATF and install it to the sensor.
b. Install and torque the ATF temperature sensor.





45. INSTALL [1][2]PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch onto the manual valve lever shaft and temporarily tighten the adjusting bolt.
b. Install the grommet and a new lock washer. Install and torque the nut.

Torque: 6.9 Nm (70 kgf.cm, 61 inch lbs.)





c. Using the control shaft lever, fully turn the manual lever shaft back and return 2 notches. It is now in neutral.





d. Align the neutral basic line and the switch groove, and tighten the adjusting bolt.

Torque: 13 Nm (130 kgf.cm, 9 ft. lbs.)

HINT: Bend at least 2 of the lock washer tabs.





47. INSTALL TRANSMISSION CONTROL SHAFT LEVER

Torque: 16 Nm (160 kgf.cm, 12 ft. lbs.)