Part 3
13. CHECK OUTPUT SHAFT
a. Using a dial indicator, measure the end play of the output shaft with hand.
End play: 1.63 - 2.89 mm (0.064 - 0.114 inch)
If the values are non-standard, check for improper installation.
b. Check to see that output shaft rotates smoothly.
14. INSTALL FLANGES, PLATES AND DISCS OF O/D 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 O/D brake pack.
HINT:
1UZ-FE: 3 plates, 4 discs and 2 flanges
2JZ-GE: 2 plates, 3 discs and 2 flanges
Install in order: P = Plate, D = Disc
1UZ-FE: D - P - D - P - D - P - D
2JZ-GE: D - P - D - P - D
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.
d. Install the spring to the case.
e. Using a screwdriver, install the snap ring.
NOTICE: Be sure the end gap of the snap ring is not aligned with cutout portion of the brake drum.
15. CHECK PISTON STROKE OF O/D BRAKE
a. Place SST and a dial indicator onto the O/D brake piston.
SST 09350-30020 (09350-06120)
b. Measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).
Piston Stroke:
1UZ-FE: 1.40 - 1.70 mm (0.055 - 0.067 inch)
2JZ-GE: 1.32 - 1.62 mm (0.052 - 0.064 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 thickness for the flange.
Flange thickness: mm (inch)
16. INSTALL O/D PLANETARY GEAR UNIT WITH O/D DIRECT CLUTCH & O/D ONE-WAY CLUTCH
a. Coat the race with petroleum jelly and install it onto the O/D planetary ring gear.
Race diameter: mm (inch)
b. Install the O/D planetary ring gear.
c. Install the bearing and race onto the O/D planetary ring gear.
Bearing and race diameter: mm (inch)
d. Coat the race with petroleum jelly and install it onto the O/D planetary gear.
Race diameter: mm (inch)
e. Install the O/D planetary gear with the O/D direct clutch & O/D one-way clutch.
f. Install the assembled bearing & race onto the O/D direct clutch.
Assembled bearing & race diameter: mm (inch)
17. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the oil pump.
Race diameter: mm (inch)
b. Coat a new O-ring with ATF and install it around the pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.
NOTICE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.
e. Install the 7 bolts.
Torque: 21 Nm (215 kgf.cm, 16 ft. lbs.)
18. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.
19. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil holes indicated in the illustration.
HINT: When inspecting the O/D direct clutch, check with the C0 accumulator piston hole closed. If there is no noise, disassemble and check the installation condition of the parts.
(1) Forward clutch
(2) Direct clutch
(3) O/D brake
(4) 3rd coast brake
(5) 3rd brake
(6) 2nd brake
(7) 1st & reverse brake
20. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEAL
a. Using SST, drive in a 2 new oil seals.
SST 09350-30020 (09350-07110)
b. Coat the oil seal lip with MP grease.
c. Install a new spacer to the manual valve lever.
d. Install the manual valve lever shaft to the transmission case through the manual valve lever.
e. Using a hammer, drive in a new spring pin.
f. Match the manual valve lever indentation with the spacer hole and stake them together with the punch.
g. Make sure the shaft rotates smoothly.
21. INSTALL PARKING LOCK PAWL AND ROD
a. Install the E-ring to the shaft.
b. Install the parking lock pawl, shaft and spring.
c. Connect the parking lock rod to the manual valve lever.
d. Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.
Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)
e. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly locked up by the lock pawl.
22. INSTALL ACCUMULATOR SPRINGS AND PISTONS
a. Coat new O-rings with ATF and install them to the pistons.
b. Install the 4 springs and 4 accumulator pistons to the holes.
HINT: The pistons are marked in relief with either C0, B0, C2 or B2 to discriminate each other.
Accumulator spring:
23. INSTALL SPRING AND CHECK BALL BODY
24. INSTALL VALVE BODY
a. Align the groove of the manual valve with the pin of the [ever.
b. Install the 20 bolts.
Torque: 9.8 Nm (100 kgf.cm, 7 ft. lbs.)
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 23 mm (0.866 inch)
Bolt B: 28 mm (1.102 inch)
Bolt C: 36 mm (1.417 inch)
Bolt D: 55 mm (2.165 inch)
25. INSTALL TRANSMISSION WIRE
a. Coat a new O-ring with ATF and install it to the transmission wire.
b. Insert the transmission wire to the case and install the stopper plate with the bolt.
Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)
c. Connect the 7 solenoid connectors.
d. Install the ATF temperature sensor.
e. Install the clamp and bolt.
Torque: 6.4 Nm (65 kgf.cm, 56 inch lbs.)
26. INSTALL OIL STRAINER AND GASKET
a. Install new 3 gaskets to oil strainer.
b. Install the oil strainer with the 4 bolts.
Torque: 9.8 Nm (100 kgf.cm, 7 ft. lbs.)
27. INSTALL OIL PAN
a. Install the 3 magnets in the oil pan.
b. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.
c. Apply FIPG to the oil pan.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
d. Install and torque the 19 bolts.
Torque: 7.4 Nm (75 kgf.cm, 65 inch lbs.)
HINT: Replace the only "A" bolt with a new one.
28. INSTALL ONE-WAY CLUTCH
a. Install the retainer and the No.2 one-way clutch.
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
29. INSTALL VEHICLE SPEED SENSOR ROTOR
Install the vehicle speed sensor rotor and 2 washers.
30. INSTALL EXTENSION HOUSING
a. Install the gasket from the extension housing.
HINT: Take care not to drop the gasket.
b. Clean the threads of the bolts and case with white gasoline.
c. Apply FIPG to the extension housing.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
d. Install the extension housing with new 6 bolts.
Torque: 34 Nm (345 kgf.cm, 25 ft. lbs.)
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 45 mm (1.772 inch)
Bolt B: 35 mm (1.378 inch)
31. INSTALL TRANSMISSION OUTPUT FLANGE
a. Using SST, install a new oil seal to the output flange.
SST 09950-60010 (09951-00350) 09950-70010 (09951-07100)
b. Install the output flange.
c. Using a deeper socket wrench of 30 mm, install a new nut.
Torque: 126 Nm (1,280 kgf.cm, 92 ft. lbs.)
HINT: Shift the manual valve lever to the P position.
d. Using a hammer and chisel, stake the nut.
32. REMOVE TRANSMISSION CASE FROM OVERHAUL ATTACHMENT
33. INSTALL TRANSMISSION HOUSING
a. Clean the threads of the bolts and case with white gasoline.
b. Apply seal packing or equivalent to the 6 bolts.
Seal packing: Part No. 08833-00070, THREE BOND 1324 or equivalent.
c. Install the transmission housing with the 6 bolts.
Torque:
A (14 mm bolt): 34 Nm (345 kgf.cm, 25 ft. lbs.)
B (17 mm bolt): 57 Nm (580 kgf.cm, 42 ft. lbs.)
34. INSTALL VEHICLE SPEED SENSORS
a. Coat 2 new O-rings with ATF and install it to the speed sensor.
b. Install the 2 vehicle speed sensors.
c. Install the bolts.
Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)
35. INSTALL UNION AND ELBOW
a. Coat 2 new O-rings with ATF, install them to union and elbow.
b. Install the union.
Torque: 29 Nm (300 kgf.cm, 22 ft. lbs.)
c. Install the elbow.
Torque: 29 Nm (300 kgf.cm, 22 ft. lbs.)
36. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the adjusting bolt.
b. Install the grommet and a new lock washer. Install and torque the nut.
Torque: 6.9 Nm (70 kgf.cm, 61 inch lbs.)
c. Using the control shaft lever, fully turn the manual lever shaft back and return 2 notches. It is now in neutral.
d. Align the neutral basic line with the switch groove, and tighten the adjusting bolt.
Torque: 13 Nm (130 kgf.cm, 9 ft. lbs.)
e. Using a screwdriver, bend the tabs of the lock washer.
HINT: Bend at least 2 of the lock washer tabs.
37. INSTALL CONTROL SHAFT LEVER Install the washer and nut to the control shaft lever.
Torque: 16 Nm (160 kgf.cm, 12 ft. lbs.)
38. INSTALL BREATHER PIPE
a. Install the breather pipe and bolt.
Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)
b. Install the breather hose and bolt.
Torque: 5.4 Nm (55 kgf.cm, 48 inch lbs.)
HINT:
GS 400: Breather hose 205 mm (8.071 inch)
GS 300: Breather hose 400 mm (15.748 inch)
c. Install the breather plug.