Transmission Installation
INSTALLATION1. Flush the ATF cooler as described.
2. Install the torque converter assembly on the mainshaft with a new O-ring.
3. Install the 14 mm dowel pins in the torque converter housing.
4. Install the starter on the torque converter housing.
5. Place the transmission on a jack, and raise it to engine level.
6. Attach the transmission to the engine, then install the rear mount/bracket bolts and intake manifold bracket bolts.
7. Install the transmission housing mounting bolts.
8. Face the dot on the breather tube up.
9. Install the stud bolt on the transmission housing, then install the transmission mount. Tighten the bolt loosely, and tighten the nuts to the specified torque, then tighten the bolt to the specified torque.
10. Remove the transmission jack.
11. Tighten the front mount bracket bolts.
12. Attach the torque converter to the drive plate with eight bolts. Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely.
13. Tighten the crankshaft pulley bolt as necessary.
14. Install the control lever with the shift cable on the control shaft. Do not bend the shift cable excessively.
15. Install the lock bolt with a new lock washer, then bend the lock washer tab against the bolt.
16. Install the engine stiffener.
17. Install the shift cable cover, then install the shift cable holder on the shift cable cover.
NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing.
18. Install a new set ring on the intermediate shaft.
19. Install the intermediate shaft in the differential.
During installation, do not allow dust or other foreign particles to enter the transmission.
NOTE: Clean the areas where the intermediate shaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air.
20. Install a new set ring on the right driveshaft.
21. Install the right and left driveshafts in the differential and the intermediate shaft. During installation, do not allow dust or other foreign particles to enter the transmission.
NOTE:
^ Clean the areas where the driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air.
^ Turn the right and left steering knuckle fully outward, and slide the driveshaft into the differential until you feel its spring clip engage the side gear.
22. Install the right damper fork with the damper pinch bolt on the damper.
23. Install the right radius rod.
NOTE: Check radius rod rubber bushings for deterioration and damage.
24. Install the damper forks, then install the ball joints on each lower arms with the castle nuts and new cotter pins.
25. Install the center beam.
26. Install the splash shield.
27. Connect the 2nd clutch pressure switch connector. Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 2nd clutch pressure switch connector.
28. Connect the connectors to the shift control solenoid valves B and C, and install the clamp on the clamp bracket.
29. Connect the ATF cooler hoses to the cooler lines.
30. Connect the lock-up control solenoid valve/shift control solenoid valve A assembly connector.
31. Connect the connector to the countershaft speed sensor and A/T gear position switch, and install the harness clamps on the clamp bracket and A/T gear position switch connector on the connector brackets.
32. Install the transmission ground cable terminal.
33. Connect the connectors to the mainshaft speed sensor, A/T clutch pressure control solenoid valve A/B assembly, and 3rd clutch pressure switch, and install the harness clamps on the clamp brackets. Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 3rd clutch pressure switch connector.
34. Install the starter cables with the crimped side of the ring terminal facing out.
35. Install the harness clamps on the clamp brackets.
36. Install the radiator hose on the clamp.
37. Install the breather tube on the clamp with the dot on the tube facing up.
38. Install the battery base.
39. Install the battery cable clamps on the battery base.
40. Install the battery tray and battery, then secure the battery with its hold-down bracket.
41. Install the intake air duct and air cleaner housing assembly.
42. Refill the transmission with ATF.
43. Connect the battery positive terminal, then connect the negative terminal.
44. Set the parking brake. Start the engine, and shift the transmission through all gears three times.
45. Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment.
46. Check and adjust the front wheel alignment.
47. Let the engine reach normal operating temperature (the radiator fan comes on) with the transmission in [P] or [N] position, then turn it off and check the ATF level.
48. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
49. Perform a road test.
50. Loosen the front mount bracket bolts after the road test, then retighten the bolts to the specified torque.