Part 1

AT Main Case

REMOVAL
1) Remove the transmission assembly from the vehicle.
2) Pull out the torque converter clutch assembly.
3) Remove the input shaft.





4) Lift up the lever on the rear side of transmission harness connector, and then disconnect it from the stay.
5) Disconnect the inhibitor switch connector from the stay.
6) Disconnect the air breather hose.
7) Remove the oil charge pipe.
8) Remove the ATF cooler inlet pipe and outlet pipe.
9) Separate the converter case from the transmission case.
10) Remove the oil pump housing.
11) Take out the high clutch, thrust needle bearing and reverse clutch assembly.





12) Take out the high clutch hub and thrust needle bearing.





13) Take out the front sun gear and thrust needle bearing.





14) Remove the snap ring and thrust needle bearing.





15) Take out the retaining plate, drive plate and driven plate of the 2-4 brake.





16) Take out the thrust needle bearing, planetary gear assembly and low clutch assembly.





17) Remove the 2-4 brake seal.





18) Remove the snap ring.





19) Take out the 2-4 brake spring retainer.





20) Remove the 2-4 brake piston and 2-4 brake piston retainer while taking care not to damage them.





21) Pull out the leaf spring of the low & reverse brake while being careful not to bend it.





22) Remove the snap ring.





23) Take out the retaining plate, drive plate, driven plate and dish plate of the low & reverse brake.





24) Turn the transmission case upside down, and then take out the socket bolts while holding the one-way clutch inner race by hand.





25) Remove the spring retainer.





26) Take out the return spring.





27) Apply compressed air.





28) Take out the low & reverse brake piston.





INSTALLATION
1) Apply ATF to the lips of the low & reverse brake piston, and install the piston.

NOTE:
Take care not to damage the lip seal.





2) Install the return spring.





3) Install the spring retainer.





4) Install the one-way clutch inner race.
5) Tighten the socket head bolts evenly from the rear side of transmission case.





6) Place the front side of transmission body up.
7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
9) Set the dial gauge to the retaining plate, and read its scale.

NOTE:
The value, which is read in the dial gauge at this time, is zero point.

10) Scale and record the weight "Z" of the flat board that will be placed on the retaining plate.

NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board weighing less than 8.5 kgf (18.7 lb).

11) Put the flat board on retaining plate.





12) Using the following formula, read the push/pull gauge, and calculate "N".
N = 83 N (8.5 kgf, 18.7 lb) - Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb) : Load applied to clutch plate
Z: Flat board weight
13) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height "A". Measure at three or more locations spaced by equal distances and take the average value.

NOTE:
If measuring in three locations, measure every 120 degrees.
If measuring in four locations, measure every 90 degrees.





14) Installation of the low & reverse brake:
Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.

NOTE:
Pay attention to the orientation of the dish plate.





15) Apply compressed air intermittently to check for operation.





16) Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance "B".

NOTE:
Do not push in the shim down with force to a point where the waves on the drive plate will be crushed.





17) Piston stroke calculation
Calculate from the recorded dimension A and B, and if the service limit is exceeded, replace the drive plate with a new part, and select a retaining plate to make an adjustment so that it is within standard.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring





18) Install the leaf spring of the low & reverse brake.





19) Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.





20) Install the 2-4 brake piston spring retainer to the transmission case.





21) Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.
ST 498677100 COMPRESSOR





22) Install the planetary gear and low clutch assembly to the transmission case.

NOTE:
Install carefully while rotating the low clutch and planetary gear assembly slowly, being careful not to damage the seal ring.





23) Measure the amount of drive plate compression and record that value. (non-turbo model)
1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2) Set the dial gauge to the clutch, and read its scale.

NOTE:
The value, which is read in the dial gauge at this time, is zero point.

3) Scale and record the weight "Z" of the flat board that will be placed on the retaining plate.

NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board weighing less than 10.2 kg (22.5 lb).

4) Put the flat board on retaining plate.





5) Using the following formula, read the push/ pull gauge, and calculate "N".
N = 100 N (10.2 kgf, 22.5 lb) - Z
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 lb) : Load applied to clutch plate
Z: Flat board weight
6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height "A". Measure at three or more locations spaced by equal distances and take the average value.

NOTE:
If measuring in three locations, measure every 120 degrees. If measuring in four locations, measure every 90 degrees.





24) Install pressure rear plate, drive plate of 2-4 brake, driven plate, retaining plate, and snap ring.





25) Install a new 2-4 brake seal to the transmission case.





26) After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.





27) Check the piston stroke. (non-turbo model)
1) Measure clearance "B" between the retaining plate and snap ring.
At this time, do not press down the retaining plate.





2) Piston stroke calculation
Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within standard values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring





28) Check the clearance between the retaining plate and snap ring. (turbo model)

NOTE:
If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate to make the clearance fall within initial standard values.








29) Install the thrust needle bearing in the correct direction.





30) Install the front sun gear and the thrust needle bearing.





31) Apply Vaseline, and attach the thrust needle bearing to the high clutch hub, then engage the splines of the front planetary carrier correctly to install the high clutch hub.
32) Install the thrust needle bearing in the correct direction.





33) Install the high clutch assembly and reverse clutch assembly.





34) Adjust the total end play.
35) Install the thrust needle bearing in the correct direction.





36) Install a new gasket along with the oil pump housing assembly.
37) Install the converter case to the transmission case assembly.
38) Insert the inhibitor switch connector and transmission harness connector onto the stay.





39) Install the air breather hose.
40) Install the ATF cooler pipe.
41) Install the oil charge pipe together with an O-ring.
42) Apply ATF to the O-ring, insert the input shaft while rotating the shaft slowly by hand, and check the amount of protrusion.

NOTE:
Use new O-rings.





43) Install the torque converter clutch assembly.
44) Install the transmission assembly to the vehicle.

DISASSEMBLY

HIGH CLUTCH AND REVERSE CLUTCH
1) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.





2) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.





3) Using the ST1 and ST2, remove the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT





4) Take out the clutch cover, spring retainer, high clutch piston and reverse clutch piston.





5) Remove the seal ring and lip seal from the high clutch piston and reverse clutch piston.





PLANETARY GEAR AND LOW CLUTCH
1) Remove the snap ring from low clutch drum.





2) Take out the front planetary carrier.





3) Take out the rear sun gear.





4) Take out the rear planetary carrier, washer and thrust needle bearing.





5) Take out the rear internal gear.





6) Remove the snap ring from low clutch drum.





7) Compress the spring retainer of the low & reverse brake, and remove the snap ring from the low clutch drum using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR





8) Remove the one-way clutch.
9) Install the one-way clutch inner race to the low clutch drum, and then apply compressed air to remove the low clutch piston.





10) Remove the one-way clutch inner race.
11) Remove the one-way clutch after taking out the snap ring.





12) Remove the needle bearing after taking out the snap ring.





2-4 BRAKE
Separate the 2-4 brake piston and piston retainer.





ONE-WAY CLUTCH INNER RACE
1) Remove the seal ring.





2) Remove the needle bearing using ST.
ST 398527700 PULLER ASSY

ONE-WAY CLUTCH OUTER RACE
1) Remove the one-way clutch after taking out the snap ring.





2) Remove the needle bearing after taking out the snap ring.