AUTOMATIC TRANSMISSION ASSEMBLY

id051300261900


Exploded View

b5r5za00000382
b5r5za00000383
b5r5za00000384

1
Torque converter installation nut
2
Torque converter
3
Input shaft
4
Fluid pump seal
5
Fluid pump seal ring
6
Bolt and washer
7
Fluid pump cover
8
Fluid pump adapter plate
9
Fluid pump gasket
10
Seal ring
11
Stator support seal
12
Fluid pump support
13
O-ring
14
Fluid pump control valve
15
Fluid pump component
16
Bolt
17
Seal ring
18
Thrust washer (No.1)
19
Intermediate and overdrive brake band anchor strut
20
Intermediate and overdrive brake band
21
Intermediate and overdrive brake band apply strut
22
Intermediate and overdrive brake band adjusting screw
23
Locknut
24
Overdrive brake drum
25
Direct clutch and coast clutch piston outer seals
26
Direct clutch and coast clutch piston inner seals
27
Direct clutch and coast clutch pistons
28
Direct clutch and coast clutch piston spring
29
Direct clutch and coast clutch piston spring retainer
30
Retaining ring
31
Coast clutch external spline plate (steel)
32
Coast clutch internal spline friction plate (friction)
33
Direct clutch and coast clutch pressure plate
34
Retaining ring (select fit)
35
Carrier adapter
36
Overdrive sun gear
37
Overdrive planetary gear carrier component
38
Thrust bearing (No.2)
39
Overdrive ring gear
40
Overdrive one-way clutch
41
Overdrive center shaft
42
Retaining ring
43
Overdrive center shaft and ring gear component
44
Thrust bearing (No.3, No.5, No.8 and No.9)
45
Retaining ring
46
Center support
47
Nut and cage component
48
Bolt
49
Thrust bearing (No.4)
50
Intermediate brake drum
51
Direct clutch external spline plate (steel)
52
Direct clutch internal spline plate (friction)
53
Forward clutch cylinder
54
Forward clutch piston
55
Forward clutch piston spring component
56
Retaining ring
57
Forward clutch external spline plate (steel)
58
Forward clutch internal spline plate (friction)
59
Forward clutch pressure plate
60
Retaining ring (select fit)
61
Thrust bearing (No.6A)
62
Thrust washer (No.6B)
63
Retaining ring
64
Forward ring gear hub
65
Forward ring gear
66
Thrust bearing (No.7)
67
Forward planetary component
68
Input shell and sun gear component
69
Spacer
70
Retaining ring
71
Lower/reverse planetary component
72
Output shaft sleeve
73
Retaining ring
74
Output shaft ring gear
75
Output shaft hub
76
Retaining ring
77
Output shaft hub seal
78
Thrust bearing (No.10)
79
Low/reverse brake drum and one-way clutch component
80
Low/reverse brake band
81
Output shaft needle bearing
82
Thrust washer (No.11)
83
Parking gear
84
Output shaft (4×2)
85
Parking pawl
86
Parking pawl return spring
87
Parking pawl shaft
88
Extension housing gasket
89
Extension housing (4×2)
90
Bolt (4×2)
91
Extension housing seal (4×2)
92
Output shaft (4×4)
93
Extension housing (4×4)
94
Extension housing seal (4×4)
95
Bolt (4×4)
96
Fluid pipe connector component
97
Retaining ring
98
Overdrive brake servo cover seal
99
Overdrive brake servo cover
100
Overdrive brake servo piston
101
Spring
102
Retaining ring
103
Intermediate brake servo cover seal
104
Intermediate brake servo cover
105
Intermediate brake servo piston
106
Transmission case
107
TSS sensor, ISS sensor and OSS sensor
108
O-ring
109
Bolt
110
Vent tube (4×2)
111
Low/reverse brake actuating lever
112
Low/reverse brake band actuating lever shaft
113
Pressure tap plug (pressure control solenoid C circuit)
114
Fluid fill plug
115
Manual shaft retaining pin
116
Parking pawl actuating rod
117
Manual shaft outer and inner nut
118
Manual valve inner lever
119
Manual shaft seal
120
Manual shaft
121
Digital TR sensor
122
Bolt and washer
123
Manual shaft lever
124
Reverse brake servo component
125
Reverse brake servo plate
126
Spring
127
Reverse brake servo piston and seal
128
O-ring
129
Reverse brake servo cover
130
Bolt
131
Control valve spring retainer
132
Spring
133
Reverse brake servo check valve
134
Bolt
135
Separating plate (bonded)
136
Lower control valve body
137
Bolt
138
Bolt
139
Detent spring
140
Bolt
141
Bolt
142
Control valve body component
143
O-ring
144
Solenoid body
145
Bolt
146
Bolt
147
Transmission fluid filter
148
Transmission fluid pan gasket
149
Magnet
150
Bolt
151
Transmission fluid pan
152
Drain plug
153
Bolt
154
Fluid level indicating plug (short hex)
155
Overdrive brake and coast clutch drum component
156
Intermediate brake and direct clutch drum component
157
Forward clutch component
158
Overdrive brake servo
159
Intermediate brake servo


Assembly

1.  Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.

2.  Inspect the transmission case for the following:

b5r5za00000186

•  Stripped bolt hole threads
•  Gasket and mating surfaces for burrs or nicks
•  Obstructions to vent and fluid passages
•  Cracks or warpage

3.  Inspect the extension housing for cracks, burrs or warpage.(4×2)

b5r5za00000187

4.  Inspect the extension housing for cracks, burrs or warpage.(4×4)

b5r5za00000188

5.  Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.

b5r5za00000189

Warning
•  Make sure the lockpin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.

6.  Using the SST, install the transmission into the bench with the converter housing facing up.

b5r5za00000532

7.  Using the SST, install the manual shaft seal and lubricate it with petroleum jelly.

b5r5za00000400

8.  Install the parking lever rod.

b5r5za00000192

9.  Install the manual control lever.

b5r5za00000193

10.  Assemble the manual valve inner lever and parking lever actuating rod as shown.

b5r5za00000194

Caution
•  Align the flats on the manual valve inner lever with the flats on the manual shaft.

11.  Install the manual shaft.

b5r5za00000195

12.  Install the manual valve inner lever onto the manual shaft and loosely install the nut.

b5r5za00000196

Caution
•  Use care not to damage the transmission fluid pan rail surface when installing the retaining pin.

13.  Install the manual shaft retaining pin.

b5r5za00000197

•  Tap the manual shaft retaining pin into the transmission case.

Note
•  Align the manual shaft alignment groove with the manual shaft retaining pin bore in the transmission case.
Caution
•  To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.

14.  Tighten the nut.

b5r5za00000198

Tightening torque
41—54 N·m {4.2—5.5 kgf·m, 31—39 ft·lbf}

Caution
•  Make sure band is resting on the 2 anchor pins in the case.

15.  Install the low/reverse brake band.

b5r5za00000203

16.  Install the low/reverse brake drum and one-way clutch component.

b5r5za00000388

•  Rotate the low/reverse brake drum clockwise to install.

17.  Install the low/reverse brake band actuating lever into the low/reverse brake band.

b5r5za00000204

Note
•  The reverse band actuating lever must fit into the notches in the band.

18.  Install the low/reverse brake band actuating lever shaft into the case and into the low/reverse brake band actuating lever.

b5r5za00000389

19.  Install the thrust bearing (No.10) into the case.

b5r5za00000390

Caution
•  Do not damage the seal against the case during assembly.

20.  Install the output shaft ring gear, hub and seal.

b5r5za00000391

Caution
•  The tabs on the output shaft thrust washer (No.11) point into the case. Make sure the thrust washer is correctly seated.

21.  Install the output shaft thrust washer (No.11).

b5r5za00000199

•  Coat the output shaft thrust washer with petroleum jelly.

22.  Install the park gear on the output shaft.

b5r5za00000200

23.  Install the output shaft and park gear.

b5r5za00000201

Caution
•  Always install a new retaining ring.

24.  Install a new retaining ring.

b5r5za00000208

25.  Install the output shaft sleeve.

b5r5za00000209

Note
•  Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.

26.  Install the thrust bearing (No.9) onto the output shaft ring gear and hub component.

b5r5za00000210

Caution
•  Make sure the needle bearings stay in place.

27.  Install the low/reverse planetary component.

b5r5za00000211

Caution
•  The low/reverse brake drum must be pulled forward to install the retaining ring.

28.  Install the retaining ring.

b5r5za00000212

29.  Install the thrust bearing (No.8).

b5r5za00000213

30.  Install the spacer on the input shell, using petroleum jelly to hold it in place.

b5r5za00000214

31.  Install the input shell and sun gear component.

b5r5za00000215

32.  Install the forward planetary component.

b5r5za00000216

Note
•  The bearing (No.13) must be correctly seated in the forward planet component so the sun gear can be installed correctly.

33.  Install the thrust bearing (No.7) into the forward ring gear and hub component. Use petroleum jelly to hold the bearing in place.

b5r5za00000217

34.  Install the thrust washer (No.6B) onto the forward ring gear hub.

b5r5za00000218

35.  Install the forward ring gear and hub as an assembly.

b5r5za00000219

36.  Install the thrust bearing (No.6A) into the forward ring gear and hub.

b5r5za00000220

37.  Install the forward clutch cylinder.

b5r5za00000221

38.  Install the thrust bearing (No.5).

b5r5za00000222

39.  Install the intermediate brake servo piston and spring.

b5r5za00000223

•  Lubricate the servo bore with clean ATF.

40.  Using the SST, install the intermediate brake servo cover and retaining ring.

b5r5za00000512

41.  Install the intermediate brake and direct clutch drum component.

b5r5za00000225

42.  Using a depth micrometer with an appropriate length extension, measure from the top of the gauge bar to the center support ledge in the case at 4 places 90 degrees apart.

b5r5za00000513

•  Add the 4 measurements, divide by 4 and record as dimension A.

Caution
•  The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

43.  Install the SST.

b5r5za00000514

(1)  Install the SST and the bolts using the 2 pump bolt locations at approx. 6 and 12 o'lock positions.
Tightening torque
15 N·m {1.5 kgf·m,11 ft·lbf}
(2)  Tighten the center bolt.
Tightening torque
1.13 N·m {11.5 kgf·cm,10.0 in·lbf}

44.  Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat the measurement 180 degrees on the opposite side of the SST and record as dimension C.

b5r5za00000515

Note
•  Align the disc holes on SST with the slot in gauge bar for correct measurement.

45.  Add dimension B to C, divide by 2 and record as dimension D.

46.  Subtract A from D and record as dimension E.

47.  Select the bearing from the following chart, using dimension E.

Thrust bearing (No.4) size (intermediate brake drum)

Dimension E

Bearing Thickness

Identification (Notches)
1.69—1.87 mm {0.066—0.074 in}
2.65—2.80 mm {0.104—0.110 in}
None
1.88—2.04 mm {0.073—0.080 in}
2.83—2.98 mm {0.111—0.116 in}
1
2.05—2.22 mm {0.081— 0.088 in}
3.01—3.16 mm {0.118—0.124 in}
2
2.23—2.43 mm {0.088—0.096 in}
3.21—3.36 mm {0.126—0.132 in}
3

48.  Install the intermediate brake band.

b5r5za00000229

Note
•  Make sure that the intermediate brake band apply strut is aligned with the band notch.
•  If the intermediate brake band is reused, it must be installed in the same position as it was when removed.
•  The new intermediate brake band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Caution
•  To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.

49.  Install the intermediate brake band anchor strut.

b5r5za00000230

(1)  Band/case side of anchor (small U notch).
(2)  Main control side of anchor (large U notch).

Caution
•  If the strut is installed incorrectly, transmission damage will occur.

50.  Check to make sure that the intermediate brake band anchor strut is installed in the correct orientation to the case and adjustment screw.

b5r5za00000231

51.  Loosely install the screw.

b5r5za00000232

52.  Install the intermediate brake band apply strut.

b5r5za00000233

Caution
•  If the strut is installed incorrectly, transmission damage will occur.

53.  Check to make sure that the intermediate brake band apply strut is installed in the correct orientation to the case and piston rod.

b5r5za00000234

54.  Install the selected thrust bearing (No.4) on the direct clutch drum.

b5r5za00000235

•  Coat the thrust bearing with petroleum jelly.

55.  Install the center support.

b5r5za00000236

Note
•  Align the center support bolt hole with correct case hole.

56.  Install the nut and cage.

b5r5za00000237

57.  Loosely install the bolt.

b5r5za00000238

Caution
•  Install the retaining ring with the tapered side facing up.
•  Make sure the notch opening is not obstructed by the retaining ring.

58.  Install the retaining ring.

b5r5za00000239

(1)  Make sure the retaining ring is installed with the tapered side facing up.
(2)  Make sure the opening of the retaining ring is positioned correctly.

59.  Install the thrust bearing (No.3).

b5r5za00000240

60.  Install the overdrive ring gear, overdrive one-way clutch and center shaft component.

b5r5za00000241

Caution
•  Do not bend the trigger wheel. Make sure that the thrust bearing (No.2) is in this assembly.

61.  Install the overdrive planetary gear carrier.

b5r5za00000242

62.  Install the overdrive brake and coast clutch drum component.

b5r5za00000243

63.  Install the overdrive brake servo piston and spring.

b5r5za00000244

•  Lubricate the servo bore with clean ATF.

64.  Using the SST, install the overdrive brake servo cover and retaining ring.

b5r5za00000516

65.  Install the overdrive brake band.

b5r5za00000246

Note
•  If the overdrive brake band is reused, it must be installed in the same position as when removed.
•  Make sure that the overdrive brake band apply strut is aligned with the band notch.
•  The new overdrive brake band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Caution
•  To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.

66.  Install the overdrive brake band anchor strut.

b5r5za00000298

(1)  Band/case side of anchor (small U notch).
(2)  Main control side of anchor (large U notch).

Caution
•  If the strut is installed incorrectly, transmission damage will occur.

67.  Check to make sure that the overdrive brake band anchor strut is installed in the correct orientation to the case and adjustment screw.

b5r5za00000231

68.  Loosely install the screw.

b5r5za00000247

69.  Install the overdrive brake band apply strut.

b5r5za00000248

Caution
•  If the strut is installed incorrectly, transmission damage will occur.

70.  Check to make sure that the overdrive brake band apply strut is installed in the correct orientation to the case and piston rod.

b5r5za00000249

Caution
•  The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

71.  Install the SST.

b5r5za00000517

(1)  Install the SST and the bolts using the 2 pump bolt locations at approx. 6 and 12 o'lock positions.
Tightening torque
15 N·m {1.5 kgf·m, 11 ft·lbf}
(2)  Tighten the center bolt.
Tightening torque
1.13 N·m {11.5 kgf·cm, 10.0 in·lbf}

72.  Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat the measurement 180 degrees on the opposite side of the SST and record as dimension B.

b5r5za00000518

Note
•  Align the disc holes on SST with the slot in gauge bar for correct measurement.

73.  Add dimension A to B, divide by 2 and record as dimension C.

74.  Subtract the thickness of the gauge bar 17.78 mm {0.70 in} from dimension C and record as dimension D.

75.  Select the thrust washer (No.1) from the following chart using dimension D.

Thrust washer (No.1) size (overdrive brake drum)

Dimension D

Bearing Thickness

Identification (Color/ID)
38.05—38.13 mm {1.50 in}
1.55—1.60 mm {0.061—0.063 in}
White
38.14—38.28 mm {1.50—1.51 in}
1.75—1.80 mm {0.069—0.071 in}
Green
38.29—38.42 mm {1.51 in}
1.85—1.90 mm {0.073—0.075 in}
Red
38.43—38.61 mm {1.51—1.52 in}
2.05—2.10 mm {0.081-0.083 in}
Black
38.63—38.74 mm {1.52—1.53 in}
2.15—2.20 mm {0.095—0.097 in}
Yellow

76.  Install the selected thrust washer (No.1).

b5r5za00000252

•  Coat the thrust washer with petroleum jelly.

77.  Install the pump gasket.

b5r5za00000254

Caution
•  Make sure that the fluid pump inlet thrust washer (No.1), selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring remain in the correct position throughout this step.

78.  Install the fluid pump.

b5r5za00000023

Tightening torque
22—28 N·m {2.3—2.8 kgf·m, 17—20 ft·lbf}

Caution
•  Do not allow overdrive brake band adjustment screw to back out. Band strut could fall out of position.
•  Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

79.  Install a new locknut on the band adjustment screw.

b5r5za00000259

Caution
•  The overdrive servo must be installed prior to band adjustment.

80.  Tighten the intermediate brake band adjustment screw.

b5r5za00000519

Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123 in·lbf}
•  Then back off the screw exactly 2 turns and hold that position.

81.  Tighten the locknut.

b5r5za00000261

(1)  Hold the overdrive brake band adjustment screw stationary.
(2)  Tighten the locknut.
Tightening torque
47—61 N·m {4.8—6.2 kgf·m, 35—44 ft·lbf}

Caution
•  Do not allow the intermediate brake band adjusting screw to back out. Band strut could fall out of position.
•  Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

82.  Install a new locknut on the band adjustment screw.

b5r5za00000262

Caution
•  The intermediate brake servo must be installed prior to band adjustment.

83.  Tighten the overdrive brake band adjustment screw.

b5r5za00000520

Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123 in·lbf}
•  Then back off the screw exactly 2 turns and hold that position.

84.  Tighten the locknut.

b5r5za00000264

(1)  Hold the intermediate brake band adjustment screw stationary.
(2)  Tighten the locknut.
Tightening torque
47—61 N·m {4.8—6.2 kgf·m, 35—44 ft·lbf}

85.  Tighten the center support bolt.

b5r5za00000265

Tightening torque
9—13 N·m {92—132 kgf·cm, 80—115 in·lbf}

86.  Install the main control valve body and loosely install the bolts.

b5r5za00000268

(1)  Install the short bolt.
(2)  Install the bolt with the larger head.
(3)  Install the remaining bolts.

87.  Tighten the bolts in the sequence shown.

b5r5za00000270

Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}

88.  With the manual lever in the N position, install the detent spring.

b5r5za00000271

Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}

89.  Install new O-rings on the solenoid body connector. Lubricate the O-rings with clean ATF.

b5r5za00000272

Caution
•  Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.

90.  Install the solenoid body. Tighten bolts in the sequence shown.

b5r5za00000273

Tightening torque
7—9 N·m {72—91 kgf·cm, 62—79 in·lbf}

91.  Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.

b5r5za00000274

Tightening torque
5 N·m {51 kgf·cm, 44 in·lbf}
10—12 N·m {102—122 kgf·cm, 89—106 in·lbf}

Caution
•  Lubricate the transmission fluid filter seals with clean ATF or they may be damaged.

92.  Lubricate the seals and install the transmission fluid filter.

b5r5za00000275

Tightening torque
9—11 N·m {92—112 kgf·cm, 80—97 in·lbf}

Note
•  Make sure that the transmission fluid filter seals are correctly seated on the filter.

93.  Install the transmission fluid pan and gasket, magnet and loosely install the bolts.

b5r5za00000276

Note
•  The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

94.  Tighten the bolts in a crisscross sequence.

b5r5za00000276

Tightening torque
9.5—11.5 N·m {97—117 kgf·cm, 85—101 in·lbf}

95.  Install the parking pawl component and gasket.

b5r5za00000277

(1)  Install the parking pawl shaft.
(2)  Install the parking pawl return spring.
(3)  Install the parking pawl.
(4)  Install a new gasket.

96.  Install the extension housing.(4×2)

b5r5za00000278

Tightening torque
28—32 N·m {2.9—3.2 kgf·m, 21—23 ft·lbf}

97.  Using the SST, install the extension housing seal.(4×2)

b5r5za00000402

98.  Install the extension housing.(4×4)

b5r5za00000012

Tightening torque
28—32 N·m {2.9—3.2 kgf·m, 21—23 ft·lbf}

99.  Using the SST, install the extension housing seal.(4×4)

absggw00001953

Caution
•  The digital TR sensor must fit flush against the boss on the case to prevent damage to the switch.

100.  Install the digital TR sensor and loosely install the bolts.

b5r5za00000392

Caution
•  Tightening one bolt before tightening the other may cause the sensor to bind or become damaged.

101.  Using the SST, align the digital TR sensor and tighten the bolts in an alternating sequence.

b5r5za00000401

Tightening torque
6.5—9.5 N·m {67—96 kgf·cm, 58—84 in·lbf}

Note
•  The manual lever must be in the N position.

102.  Install the manual shaft lever.

Tightening torque
41—54 N·m {4.2—5.5 kgf·m, 31—39 ft·lbf}
b5r5za00000394

Caution
•  The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.

103.  Install the input shaft.

b5r5za00000284

Caution
•  Do not damage the fluid pump gear O-ring when installing torque converter.
•  Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.
•  If the torque converter slides out, the hub seal may be damaged.

104.  Lubricate the converter hub with clean ATF.

b5r5za00000286

Warning
•  The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.

105.  Install the torque converter by pushing and rotating.

b5r5za00000395

106.  Lubricate the torque converter pilot hub with multi-purpose grease.

b5r5za00000288

107.  Using one of the sensor holes, fill the transmission with 8.5 L {9.0 US qt, 7.5 lmp qt} of ATF.

b5r5za00000291

Note
•  Inspect O-rings for damage. Install new O-rings if damaged. Lubricate the O-rings with petroleum jelly to prevent damage to the O-rings.

108.  Install the sensors.

b5r5za00000396

Tightening torque
TSS sensor, ISS sensor:
8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
OSS sensor:
12—16 N·m
{123—163 kgf·cm, 107—141 in·lbf}