Part 1

AUTOMATIC TRANSAXLE





COMPONENTS

REASSEMBLY





1. Use drift to punch the oil seal (2).





2. Assembly the manual shaft and the manual plate parking road.





3. Punch the spring pin that attaches the manual plate to the manual shaft.
Use the punch or something similar to fit with the holes.
Make sure that the spring pin can be pulled out.
Leave 2 ± 0.5 mm (0.0787 - 0.0197 inch) of the tip.





4. Use the punch or something similar to locate the hole of the spring pin that attaches the manual shaft to the case.





5. Attach the manual shaft to the case.
Punch the spring pin.
Leave 5 ± 1 mm (0.1 969 - 0.0394 inch).





6. Apply Vaseline to the terminal assembly installation hole.





7. Insert the terminal assembly to the installation hole.





8. Attach the terminal connector to the bracket. The position for each connector is as in figure.





9. Attach the servo piston, servo retainer, and servo stem return spring to the case.





10. Attach the snap ring of the servo.





11. Fix the detent spring.
12. Apply Vaseline to the outer O-ring of the reverse brake piston.





13. Assembly the reverse brake piston. Apply the drum support bearing to install.





14. Assembly the return spring of the reverse brake piston and the spring retainer.
Use the clutch compressor to install the snap ring that installs the spring retainer.
Use the driver to make sure since the tension of the snap ring is somewhat weak.





15. Assembly the reverse brake clutches.





16. Assembly SPG to prevent shattering.





NOTE:
Adjust the gap between reverse - brake.
Check L dimension using a thickness gauge and adjust it to become 0.7 - 1.1 mm (0.0276 - 0.0433 inch) using the retainer plate.
When L dimension is not within the aforesaid values, check the thickness of the retainer plate and select the proper part of the table and replace it.





17. Assembly the snap ring that is for fixing the reverse brake plates.





18. Install the bearing that Vaseline has been applied to the rear case surface.





19. Scratch off the sealant.





20. Wipe the surface that is in contact with the extension with an oil whetstone lightly and remove the sealant completely
Tap the seal bolt slit lightly
Apply the washer fluid to wipe with the whetstone so that the removed gasket not to become sticking.





21. Scratch off the sealant that is attached to the surface that is contact with the case.





22. Wipe the surface conjoined with the case with oil whetstone lightly and remove the sealant completely
Tap the seal bolt slit lightly
Apply the washer fluid to wipe with the whetstone so that the case not to become sticking after cleaning.





23. Install the return spring to the parking pole.
See the figure when mounting.





24. Install the parking pole, return spring shaft.





25. Install the actuator support.





26. Assemble the output shaft.

CAUTION: Note that the shapes of the front and back are similar. (Front side is where the tip outer diameter is narrower (Torque converter side))

See the shape figure.





27. Install the revolution sensor.
28. Apply the sealant to the surface in contact with the extension case.

CAUTION:
Use Loctite 518 = part number. 313A98E000 made by Loctite Inc. In Japan.
Remove the fluid gasket from the case contact surface, EXT contact surface and wipe the contact surface with washer not to have any harmful oil or dusts.

29. Assembly the output shaft to the case.





30. Tighten the output shaft & companion flange installation bolts provisionally.
Tighten and attach the bracket that is fixing the terminal assembly connector at the same time.





31. Tighten the output shaft companion flange installation bolts at 50-54.9 Nm (9) using the torque meter. The seal bolt part is tightened at 58 - 63 Nm (1).





32. Apply Vaseline to the seal ring of the drum support, and then assemble the direct clutch.





33. Make sure that both the drum support surface and the inner BOSS side of the clutch come almost to the same position.





34. Mount the bearing with Vaseline applied to the drum support surface.





35. Assemble the high & low reverse clutch.

CAUTION: Use the one with the same part number when replacing the high & low reverse clutch.





36. Align the spool lines of the high & low reveres clutch drive plate with a driver.





37. Assemble the rear sun gear and the high & low re verse clutch hub to the middle sun gear, and then fix it with the snap ring.
Mount the bearing race and bearing. (called "Middle gear sun-sub assembly")

CAUTION: Use the one with the same part number when replacing the middle sun gear.





38. Assemble the middle sun gear-sub assembly.
Turn the middle sun gear right to left and press it until it fits to the position.





39. Check the flange-combined part of the rear sun gear is approximately 2 mm (0.0787 inch) lower than the high & low reverse clutch drum surface.
If there is no about 2 mm (0.0787 inch) of step height, it won't fit to the position. Remove it and try again.





40. Apply Vaseline to the bearing race, mount the rear carrier, and then assemble the rear carrier assembly.





41. Apply Vaseline to the bearing, and then assemble the middle carrier assembly.





42. Assemble the input clutch, front carrier, and rear internal gear.





43. Assemble the input clutch to the rear internal gear.








44. Assemble the front carrier.





45. Insert the snap ring to the slit in the front carrier.





46. Tighten the snap ring with the snap ring pliers, and then combine the front carrier to the rear internal gear. Loosen the snap ring and fix the front carrier and the rear internal gear at the same time.





47. Assemble the input clutch pack.





48. Apply Vaseline to the seal ring of the input shaft.





49. Exchange the end anchor pin, and attach provision ally.
Assemble the brake band provisionally.
For band assembly, check "Brake band assembly adjustment tips".





50. Assemble the front sun gear.
Apply ATF to the bush section of the front sun gear and the end bearing section of the one-way clutch.