Part 1 of 2

COMPONENT PARTS INSTALLATION (Part 1 of 2)

NOTICE:
- Before installation, make sure again that all component groups are assembled correctly.
- If a problem is found in a certain component group during assembly, inspect and repair this group immediately.

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 surface with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the packing FIPG material must be removed and reapplied.


BASIC SUBASSEMBLY REASSEMBLY





1. Install 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.
Assembled Bearing And Race Diameter.
Inside: 39.0 (1.535)
Outside: 57.7 (2.272)





3. Install leaf spring.





4. Install rear planetary gear unit with first and reverse brake 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 of 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 pack and output shaft, indicated by A.





f. Install the assembled rear planetary gear, first and reverse brake pack and output shaft.





g. Rest the output shaft on wooden blocks.





h. Using SST 09350-30020 (09350-07060), install the snap ring.





5. Check pack clearance of first and reverse brake.
Using a feeler gauge, measure the clearance between the plate and second brake drum.
- Clearance: 0.60-0.90 mm (0.0236-0.0354 inch)
If the values are non-standard, select another flange.

HINT: There are 8 different flange thickness.

Flange No: Thickness.
No.68: 5.4 mm (0.213 inch)
No.67: 5.2 mm (0.205 inch)
No.50: 5.0 mm (0.197 inch)
No.51: 4.8 mm (0.189 inch)
No.52: 4.6 mm (0.181 inch)
No.53: 4.4 mm (0.173 inch)
No.54: 4.2 mm (0.165 inch)
No.55: 4.0 mm (0.157 inch)





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: D-P-D-P-D-P-D-P-D-P (P=Plate D=Disc)
c. Install the flange with the rounded edge of the flange facing the disc.





d. Using a screwdriver, install the snap ring.





10. Check pack clearance of second brake using a feeler gauge.
Measure the clearance between the snap ring and flange.
Clearance: 0.49-1.11 mm (0.0193-0.0437 inch)
If the values are non-standard, check for improper installation.





11. Install planetary sun gear.
While turning the planetary sun gear clockwise, install it into 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.
Assembled Bearing Diameter.
Inside: 35.4 mm (1.394 inch)
Outside: 48.0 mm (1.890 inch)
Assembled Race Diameter.
Inside: 33.5 (1.319)
Outside: 47.8 mm (1.882 inch)





b. Install the front planetary gear to the sun gear input drum.





c. Using SST 09350-30020 (09350-07070), install the snap ring.
d. Remove the wooden blocks under the output shaft.





e. Coat the race with petroleum jelly and install it onto the front planetary gear.
Assembled Race Diameter.
Inside: 53.3 mm (2.098 inch)
Outside: 63.6 mm (2.504 inch)





13. Install second coast brake band.
a. Install the second coast brake band to the transmission case.





b. Install the E-ring to the pin.
c. Install the pin through the brake band.





d. Install the E-ring to the pin.





14. Install direct clutch to forward clutch.





15. Install front planetary ring gear to for ward and direct clutch.
a. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.
Assembled Bearing Diameter.
Inside: 25.9 mm (1.020 inch)
Outside: 48.9 mm (1.925 inch)





b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.
Assembled Bearing And Race Diameter.
Inside: 25.9 mm (1.020 inch)
Outside: 53.7 mm (2.114 inch)





c. Align the flukes of the discs in the forward crutch.





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.





16. 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.
Assembled Bearing And Race Diameter.
Inside: 49.7 mm (1.957 inch)
Outside: 64.7 mm (2.547 inch)





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.
Height: 9.8-11.8 mm (0.386-0.465 inch)
If the values are non-standard, check for improper installation.





d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.
Assembled Bearing And Race Diameter.
Inside: 33.5 mm (1.319 inch)
Outside: 47.8 mm (1.882 inch)





17. Install second coast brake cover, piston assembly and spring-
a. Coat 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 09350-30020 (09350-07060), install the snap ring.





18. Check piston rod stroke of second coast brake.
a. Place a mark on the second coast brake piston rod.





b. Using SST 09240-00020, measure the stroke while applying and releasing compressed air (392-785 kPa or 57-114 psi).
Piston Rod Stroke: 1.0-2.0 mm (0.039-0.079 inch)
If the stroke is more than specified, replace the piston rod with a longer one.
Piston Rod Length:
70.7 mm (2.783 inch)
71.4 mm (2.811 inch)
72.2 mm (2.843 inch)
72.9 mm (2.870 inch)
If it is still more than standard value, replace the brake band with a new one.





19. Install overdrive support assembly.
a. Coat the assembled bearing and races with petroleum jelly and install them onto the overdrive support assembly.
Assembled Bearing And Race Diameter.
Inside: 33.6 mm (1.323 inch)
Outside: 50.3 mm (1.980 inch)
Race Diameter.
Inside: 37.0 mm (1.457 inch)
Outside: 51.0 mm (2.008 inch)





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 09350-30020 (09360-07020), aim the bolt and oil holes of the overdrive support toward the valve body side, align them with the bolt holes of the transmission case.
d. Temporarily install the 2 bolts.





e. Using SST 09350-30020 (09350-07060), install the snap ring.





f. Install and torque the 2 bolts.
Torque: 25 Nm (260 kgf/cm, 19 ft. lbs.)





20. Check output shaft.
a. Using a dial indicator, measure the end play of the output shaft.
End Play: 1.63-2.89 mm (0.0642-0.1138 inch)
If the values are non-standard, check for improper installation.
b. Check to see that output shaft rotates smoothly.





21. 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 disc.
b. Install the 4 plates and 4 discs.
Install in order: D-P-D-P-D-P-D-P (P=Plate D=Disc)
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.





d. Using a screwdriver, install the snap ring.





22. Check piston stroke of overdrive brake.
a. Place SST 09350-30020 (09350-06120) and a dial indicator onto the overdrive brake piston.





b. Measure the stroke while applying and releasing compressed air (392-785 kPa or 57-114 psi).
Piston Stroke: 1.75-2.05 mm (0.069-0.081 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
If the piston stroke is non-standard, select another flange.

HINT: There are 7 different flange thicknesses.

Flange No: Thickness.
No.77: 3.3 mm (0.130 inch)
No.78: 3.5 mm (0.138 inch)
No.79: 3.6 mm (0.142 inch)
No.80: 3.7 mm (0.146 inch)
No.81: 3.8 mm (0.150 inch)
No.82: 3.9 mm (0.154 inch)
No.83: 4.0 mm (0.157 inch)





23. Install overdrive planetary gear unit with overdrive direct clutch and one-way clutch.
a. Coat the race with petroleum jelly and install it onto the overdrive planetary ring gear.
Race Diameter.
Inside: 37.0 mm (1.457 inch)
Outside: 59.0 mm (2.323 inch)





b. Install the overdrive planetary ring gear.





c. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
Bearing Diameter.
Inside: 25.9 mm (1.020 inch)
Outside: 47.0 mm (1.850 inch)
Race Diameter.
Inside: 24.0 mm (0.945 inch)
Outside: 48.0 mm (1.890 inch)





d. Coat the race with petroleum jelly and install it onto the planetary gear.
Race Diameter.
Inside: 27.2 mm (1.071 inch)
Outside: 42.0 mm (1.654 inch)





e. Install the overdrive planetary gear with the overdrive direct clutch and one-way clutch.





f. Coat the assembled bearing and race with petroleum jelly and install them onto the overdrive direct clutch.
Assembled Bearing And Race Diameter.
Inside: 28.8 mm (1.134 inch)
Outside: 50.4 mm (1.984 inch)