Part 1
COMPONENT PARTS INSTALLATIONDisassembly, 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 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 automatic transmission fluid for at least 15 minutes.
3. Apply automatic transmission fluid 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 Formed In Place Gasket (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 Installation
1. INSTALL TRANSMISSION CASE
Install the transmission case in the overhaul attachment.
2. INSTALL BEARING AND RACE
a) Coat the assembled bearing and race with petroleum jelly.
b) Install it onto the case.
Bearing And Race Diameter:
3. INSTALL LEAF SPRING
4. INSTALL REAR PLANETARY GEAR WITH FIRST AND REVERSE BRAKE PACK AND OUTPUT SHAFT
a) Install the flange, the rounded edge facing upward.
b) Install the 6 plates and 6 discs.
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P-D-P
c) Align the teeth on the flange, discs and plates.
d) face the snap ring upward (front side) and install the second brake drum to the planetary gear.
NOTICE: Face the oil hole in the drum towards the lower side of the transmission case (the side the valve body is installed).
e) Align the splines of the transmission case and the assembled rear planetary gear, first and reverse brake and output shaft, indicated by A.
f) Install the assembled output shaft.
g) Rest the output shaft on wooden blocks.
h) Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
5. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE
Using a feeler gauge, measure the clearance between the plate and second brake drum.
Clearance: 0.60 - 1.12 mm (0.0236 - 0.0441 inch)
If the values are non-standard, select another flange.
HINT: There are 6 different thicknesses for the flange.
Flange Thicknesses:
6. INSTALL SECOND BRAKE PISTON SLEEVE
7. INSTALL NEW BRAKE DRUM GASKET
a) Coat the gasket with ATF.
b) Install a new brake drum gasket.
8. INSTALL NO.1 ONE-WAY CLUTCH
a) Install the No. 1 thrust washer onto the second brake.
b) Install the No.1 one-way clutch.
9. INSTALL FLANGE. PLATES AND DISCS OF SECOND 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 5 plates and 5 discs.
Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P
c) Install the flange with the rounded edge of the flange facing the disc.
d) Using a screwdriver, install snap ring.
10. CHECK PACK CLEARANCE OF SECOND BRAKE
Using a feeler gauge, measure the clearance between the snap ring and flange.
Clearance: 0.62 - 1.98 mm (0.02" - 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 input drum.
c) Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
d) Remove the wooden blocks under the output shaft.
e) Coat the bearing race with petroleum jelly and install it onto the front planetary gear.
Race Diameter:
13. INSTALL SECOND COAST BRAKE BAND
a) Install the second coast brake band to the case.
b) Install the E-ring to the pin.
c) Install the pin through the brake band.
14. INSTALL FRONT PLANETARY RING GEAR TO FORWARD AND DIRECT CLUTCH
Bearing And Race Diameter:
a) Coat the bearing and race with petroleum jelly and install them onto the forward clutch.
Race Diameter:
b) Coat the race with petroleum jelly and install it onto the front planetary ring gear.
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, as shown in the illustration.
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.
16. INSTALL SECOND COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING
a) Coat the 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.
SST 09350-30020 (09350-07060)
17. CHECK PISTON ROD STROKE OF SECOND COAST BRAKE
a) Place a mark on the second coast brake piston rod.
b) Using SST, measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kg-cm2, 57 - 114 psi).
SST 09240-00020
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)
If the stroke is more than specified, replace the piston rod.
Piston rod length:
71.4 mm (2.811 inch)
72.9 mm (2.870 inch)
If it is still more than standard value, replace the brake band with a new one.
18. INSTALL OVERDRIVE SUPPORT ASSEMBLY
a) Coat the bearing and race with petroleum jelly and install it onto the overdrive support assembly. Bearing and race diameter mm (inch)
Bearing And Race Diameter:
b) Confirm the thrust washer is installed correctly.
HINT: Make sure that the lug shape matches the hole on the O/D support.
c) Using 2 bolts of SST, aim the bolt and oil holes of the overdrive support toward the valve body side, and align them with the bolt holes of the transmission case and insert.
SST 09350-30020 (09350-07020)
d) Temporarily tighten the 2 bolts.
e) Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
HINT: Install the snap ring open end toward the valve body.
f) Torque the 2 bolts.
Torque: 25 Nm (260 kg-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 OVERDRIVE 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
PREVIA: D-P-D-P-D
OTHERS: D-P-D-P-D-P-D
c) Install the flange (stopped ring) with the flat side of the flange facing the disc.
d) Using a screwdriver, install the snap ring.
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
a) Place SST and a dial indicator onto the overdrive brake piston.
SST 09350-30020 (09350-06120)
b) Measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kg-cm2, 57 - 114 psi).
Piston stroke:
PREVIA: 1.40 - 1.70 mm (0.0551 - 0.0669 inch)
OTHERS: 1.40 - 1.70 mm (0.0551 - 0.0669 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.
