Part 2
CLUTCH1st/4th Clutch Assembly:
1st-Hold/3rd Clutch Assembly:
2nd Clutch Assembly:
Illustrated index
Disassembly
1. Remove the snap rings, then remove the clutch end plate, clutch discs and plates.
2. Remove the disc spring.
NOTE: For 1st-hold and 2nd clutches.
3. Install the special tools as shown.
CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.
4. Compress the clutch return spring.
5. Remove the circlip. Then remove the special tool, spring retainer and return spring.
6. Wrap a shop rag around the clutch drum, and apply air pressure to the fluid passage to remove the piston. Place a finger tip on the other end while applying air pressure.
Reassembly
NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air.
- Blow out all passages.
- Lubricate all parts with ATF before assembly.
1. Inspect the check valve; if it's loose, replace the piston.
2. Install a new O-ring on the clutch piston.
3. Be sure that the disc spring is securely staked.
NOTE: For 1st, 3rd and 4th clutches.
4. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.
NOTE: Lubricate the piston O-ring with ATF before installing.
CAUTION: Do not pinch O-ring by installing the piston with force.
5. Install the return spring and spring retainer, then position the circlip on the retainer.
6. Install the special tools as shown.
CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.
7. Compress the clutch return spring.
8. Install the circlip.
9. Remove the special tools.
10. Install the disc spring.
NOTE:
- For 1st-hold and 2nd clutches.
- Install the disc spring in the direction shown.
11. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.
12. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the disc.
NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.
13. Install the snap ring,
14. Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered, and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.
NOTE: Measure at three locations.
End Plate-to-Top Disc Clearance:
15. If the clearance is not within the service limits, select a new clutch end plate from the following table.
NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.
Clutch End Plate
1ST-HOLD CLUTCH BEARING
Replacement
1. Remove the 11st-hold clutch bearing using a bearing puller.
2. Install a new bearing using the special tools as shown.
NOTE: Drive in the bearing until it is fully seated.
TORQUE CONVERTER HOUSING BEARINGS
Mainshaft Bearing/Oil Seal Replacement
1. Drive out the mainshaft bearing and oil seal using the special tools as shown.
2. Drive in the new mainshaft bearing until it bottoms in the housing using the special tools as shown.
3. Install the new oil seal flush with the housing using the special tools as shown.
Countershaft Bearing Replacement
1. Remove the countershaft bearing using the special tools as shown.
2. Replace the ATF guide plate.
3. Drive the new bearing into the housing using the special tools as shown.
Secondary Shaft Bearing Replacement
1. Remove the secondary shaft bearing using the special tools as shown.
2. Replace the ATF guide plate.
3. Drive the new bearing into the housing using the special tools as shown.
TRANSMISSION HOUSING BEARINGS
Replacement
1. To remove the mainshaft, countershaft and secondary shaft bearings from the transmission housing, expand each snap ring with the snap ring pliers, then push the bearing out.
NOTE: Do not remove the snap rings unless it's necessary to clean the grooves in the housing.
2. Expand each snap ring with the snap ring pliers, insert the new bearing part-way into it, then release the pliers. Push the bearing down into the transmission until the ring snaps in place around it.
REVERSE IDLER GEAR
Installation
1. Install the reverse idler gear.
2. Set the spring in the reverse idler shaft. Push the spring in with the steel ball, then install the needle bearing.
NOTE: The steel ball is under spring pressure. Take care not to let it pop out.
3. Install the reverse idler shaft holder into the transmission housing, then tighten the bolts.
MANUAL VALVE DETENT SPRING
Replacement/Adjustment
NOTE: Select the appropriate manual valve detent spring when these parts are replaced:
- Manual Valve
- Manual Valve Detent Spring
- Manual Valve Lever of Control Shaft
1. Install the main valve body, including the ATF pump gears, onto the torque converter housing, and tighten the main valve body bolts to 12 Nm (1.2 kg/m; 8.7 ft.lbs.).
2. Install the control shaft.
3. Install the manual valve detent spring on the main valve body and tighten the spring bolt to 14 Nm (1.4 kgf-m, 10 ft.lbs.).
4. Set the manual valve to the [N] position.
5. Measure the distance between the main valve body and manual valve as shown.
DISTANCE: 28.0 - 29.0 mm (1.102 - 1.142 inch)
6. If the measurement is out of tolerance, select the appropriate manual valve detent spring using the table below, then install it and recheck it.
PARKING BRAKE STOPPER
Inspection/Adjustment
1. Set the parking brake lever in the [P] position.
2. Measure the distance between the face of the parking pawl shaft and face of the parking shift arm roller pin as shown.
DISTANCE: 52.1 - 53.1 mm (2.051 - 2.091 inch)
3. If the measurement is out of tolerance, select and install the appropriate parking brake stopper from the table below.
4. After replacing the parking brake stopper, make sure the distance is within tolerance.
TRANSMISSION REASSEMBLY
NOTE: Coat all parts with ATF.
1. Reassemble the valve bodies in the following numbered sequence.
CAUTION: To prevent stripping the threads, press down on the accumulator cover while installing the bolts.
TORQUE:
6 x 1.0 mm: all bolts except (50): 12 Nm (1.2 kg/m; 8.7 ft.lbs.)
6 x 1.0 mm: (50): 14 Nm (1.4 kgf-m, 10 ft.lbs.)
2. Assemble the transmission housing in the following numbered sequence.
3. Assemble the transmission in the following numbered sequence.
NOTE: Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
4. Set the parking brake lever in the [P] position, then verify that the parking brake pawl engages the parking gear.
5. If the pawl does not engage fully, check the parking brake pawl stopper clearance.
6. Tighten the lock bolt, then bend over the lock tab.
7. Install the special tool as shown, then shift to [P] position.
8. Install a new conical spring washer and a new lock nut on each shaft.
CAUTION: Install the conical spring washers in the direction shown.
9. Tighten the locknuts to the specified torque.
TORQUE: 137 Nm (14.0 kg/m; 101 ft.lbs.)
NOTE: The countershaft locknut has left-hand threads.
10. Stake each locknut into its shaft using a 3.5 mm punch.
11. Install the feed pipes and the ball bearing in the left side cover, aligning the lugs of the 1st and 1st-hold clutch feed pipes with the grooves in the cover.
12. Install the snap ring.
13. Install the left side cover.
TORQUE: 12 Nm (1.2 kg/m; 8.7 ft.lbs.)
14. Install the countershaft and mainshaft speed sensors, vehicle speed sensor cover, and linear solenoid.
TORQUE: 12 Nm (1.2 kg/m; 8.7 ft.lbs.)
NOTE:
- Install the countershaft speed sensor with the countershaft speed sensor washer. The mainshaft speed sensor has no washer.
15. Install the control lever, new lock washers, change shaft, and change shaft cap on the other end of the control shaft. Tighten the bolts, then bend the tab against the bolt head.