Part 1
Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. 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(R) II.
GENERAL ASSEMBLY 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 and brake bands, soak them in automatic transmission fluid for at least thirty minutes.
3. Apply automatic transmission fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
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. Be sure to install the thrust bearings and races in the correct direction and position.
ASSEMBLY
1. INSTALL REAR PLANETARY GEAR, SECOND BRAKE DRUM AND OUTPUT SHAFT
a. Coat the assembled bearing and race with petroleum jelly and install it onto the case.
NOTE: Assembled bearing and race diameter
b. Align the teeth of the second brake drum, flanges, discs and plates as shown in the figure.
c. Align the splines of the transmission case and the assembled rear planetary gear, second brake drum and output shaft, indicated by A.
d. Hold the output shaft with wooden blocks.
e. Using SST, install the snap ring.
SST 09350 - 30020 (09350 - 07060)
2. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE
Using a thickness gauge, measure the clearance between the plate and second brake drum as shown in the figure.
Clearance:
7M-GE 0.73 - 2.25 mm (0.0287 - 0.0886 in.)
7M-GTE 0.94 - 2.51 mm (0.0370 - 0.0988 in.)
If the values are nonstandard, check for an improper installation.
3. INSTALL SECOND BRAKE PISTON SLEEVE
4. INSTALL BRAKE DRUM GASKET
Using SST, install the gasket
SST 09350 - 30020 (09350 - 07100)
Gasket depth: 43.7 mm (1.720 in.)
5. INSTALL PARKING LOCK PAWL AND SHAFT
Install the spring, parking lock pawl and shaft.
6. INSTALL PARKING LOCK ROD
a. Connect the parking lock rod to the manual valve lever.
b. Install the parking lock pawl bracket.
Torque the bolts.
Torque: 75 kg.cm (65 in.lb, 7.4 N.m)
c. Shift the manual valve lever to the P position, and confirm the planetary ring gear is locked up lock pawl correctly.
7. INSTALL ONE-WAY CLUTCH
8. INSTALL FLANGE, DISCS AND PLATES
a. Install the 1.8 mm (0.071 in.) thick plate with the rounded edge side of the plate facing the disc.
b. Alternately install the five discs and four plates. (Disc first)
c. Install the flange with the rounded edge of the flange facing the disc.
d. Install the snap ring.
9. CHECK PACK CLEARANCE OF SECOND BRAKE
Using a thickness gauge, measure the clearance between the snap ring and flange as shown in the figure.
Clearance: 0.62 - 1.98 mm (0.0244 - 0.0780 in.)
If the values are nonstandard, check for an improper installation.
10. INSTALL SUN GEAR INPUT DRUM
While turning the sun gear input drum clockwise, install it into the one-way clutch.
NOTE: Confirm the thrust washers are installed correctly.
11. INSTALL FRONT PLANETARY GEAR TO SUN GEAR
a. Install the front planetary gear to the sun gear.
NOTE: Confirm the bearing and race is installed correctly.
b. Using SST, install the snap ring.
SST 09350 - 30020 (09350 - 07070)
c. Remove the wooden blocks under the output shaft.
d. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.
NOTE: Bearing race diameter
12. INSTALL SECOND COAST BRAKE BAND
a. Insert the second coast brake band to the case.
b. Install the pin through the brake band.
c. Install the E-ring to the pin.
13. INSTALL FRONT PLANETARY RING GEAR TO FORWARD CLUTCH
a. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.
NOTE: Bearing and race diameter
b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.
NOTE: Race diameter
c. Align the flukes of the discs in the forward clutch.
d. Align the spline of the front planetary gear with the flukes of the discs and install the front planetary gear to the forward clutch.
14. 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.
NOTE: 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 as shown in the figure.
Height: 6.3 - 8.3 mm (0.248 - 0.328 in.)
If the values are nonstandard, check for an improper installation.
d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.
NOTE: Assembled bearing and race diameter
15. ASSEMBLE SECOND COAST BRAKE PISTON
a. Coat the oil seal ring with ATF and install it to the second coast brake piston.
b. Install the washer, spring and piston to the piston rod.
c. Install the E-ring.
16. INSTALL SECOND COAST BRAKE PISTON
a. Coat two new O-rings with ATF and install them to the piston cover.
b. Install the spring, second coast brake piston assembly and piston cover to the case.
c. Using SST, install the snap ring.
SST 09350 - 30020 (09350 - 07060)
17. CHECK PISTON STROKE OF SECOND COAST BRAKE
a. Place a mark on the second coast brake piston rod as shown in the figure.
b. Using SST, measure the stroke applying the compressed air (4 - 8 kg/sq.cm, 57 114 psi or 392 - 785 kPa) as shown in the figure.
SST 09240 - 00020
Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)
If the values are nonstandard, check for an improper installation.
18. INSTALL OVERDRIVE SUPPORT ASSEMBLY
a. Coat the race with petroleum jelly and install it onto the overdrive support assembly
NOTE: Race diameter
b. Aim the bolt and oil holes of the overdrive support toward the valve hole side, and align them with the bolt hole of the transmission case and insert.
c. Using SST, install the snap ring as shown in the figure.
SST 09350 - 30020 (09350 - 07060)
d. Install and torque the two bolts.
Torque: 260 kg.cm (19 ft.lb. 25 N.m)
19. CHECK END OF OUTPUT SHAFT
Using a dial indicator, measure the end play of the output shaft by hand.
End play: 0.27 - 0.86 mm (0.0106 - 0.0339 in.)
20. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt If the disc is worn or burnt, replace all discs.
Then check that the sliding surfaces of plate and flange are not worn or burnt.
If necessary, replace them.
21. INSTALL FLANGES, DISCS AND PLATES
a. Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the disc.
b. Alternately install the discs and plates. (Disc first)
7M-GE: Four discs and three plates
7M-GTE: Five discs and four plates
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.
d. Install the snap ring.
22. CHECK PISTON STROKE OF OVERDRIVE BRAKE
a. Place SST and a dial indicator onto the overdrive brake piston as shown in the figure.
SST 09350 - 30020 (09350 - 06120)
b. Measure the stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kpa) as shown in the figure.
Piston stroke:
7M-GE: 1.40 - 1.70 mm (0.0551 - 0.0669 in.)
7M-GTE: 1.75 - 2.05 mm (0.0689 - 0.0807 in.)
If the piston stroke is less than the limit, parts may be misassembled and reinstall them.
If the piston stroke nonstandard, select another flange.
NOTE: There are seven flanges.
23. REMOVE FLANGES, PLATES AND DISCS
a. Remove the snap ring.
b. Remove the flanges, plates and discs.
24. INSTALL OVERDRIVE PLANETARY RING GEAR
a. Coat the bearing and races with petroleum jelly and install them onto the overdrive support.
NOTE: Bearing and races diameter
b. Install the overdrive planetary ring gear.