Part 1
EXTENSION HOUSINGEXTENSION HOUSING INSPECTION
INSPECT EXTENSION HOUSING BUSHING
Using a cylinder gauge, measure the inside diameter of the extension housing bushing.
Maximum inside diameter: 40.09 mm (1.5783 inch)
If the inside diameter is greater than the maximum, replace the extension housing.
COMPONENT PARTS INSTALLATION
Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure again that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended ATF: DEXRON(r) II
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 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 surfaces with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
BEARINGS AND RACES INSTALLATION POSITION AND DIRECTION
TRANSMISSION INSTALLATION
1. INSTALL TRANSMISSION CASE
Install the 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
3. INSTALL LEAF SPRING
4. INSTALL REAR PLANETARY GEAR UNIT WITH FIRST AND REVERSE BRAKE PACK AND OUTPUT SHAFT
a. Reinstall the original 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. Align the splines of the transmission case and the assembled rear planetary gear, first and reverse brake pack and output shaft, indicated by A.
e. Install the assembled rear planetary gear, first and reverse brake pack and output shaft.
f. Rest the output shaft on wooden blocks.
5. INSTALL SECOND BRAKE DRUM
a. 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).
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
6. 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 - 1.12 mm (0.024 - 0.044 inch)
If the clearance is non-standard, select another flange.
HINT: There are 6 different thicknesses for the flange.
Flange Thickness
7. INSTALL SECOND BRAKE PISTON SLEEVE
8. INSTALL NEW BRAKE DRUM GASKET
a. Coat the gasket with ATF.
b. Install a new brake drum gasket.
9. 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.
10. 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: P = Plate D = Disc D-P-D-P-D-P-D-P-D-P
c. Install the flange with the rounded edge of the flange facing the disc.
d. Using a screwdriver, install the snap ring.
11. CHECK PACK CLEARANCE OF SECOND BRAKE
Using a feeler gauge, measure the clearance between the snap ring and flange.
Clearance: 0.62 - 1.98 mm (0.0244 - 0.0780 inch)
If the clearance is non-standard, check for improper installation.
12. 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.
13. INSTALL FRONT PLANETARY GEAR
a. Coat the bearing and race with petroleum jelly and install them onto the front planetary gear.
b. Install the front planetary gear to the sun gear input drum.
c. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
d. Remove the wooden blocks (or equivalent) under the output shaft.
e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.
@lx98a340e_at-100f
2G1mRace Diameter0m
@lx98a340e_at-100d
1G14.5GINSTALL SECOND COAST BRAKE BAND 5Ga.8GInstall the second coast
brake band to the transmission case.
@lx98a340e_at-100e
5Gb.8GInstall the E- ring to the pin. 5Gc.8GInstall the pin through
the brake band.
@lx98a340e_at-101a
5Gd.8GInstall the E-ring to the pin.
@lx98a340e_at-101b
1G15.5GINSTALL FRONT PLANETARY RING GEAR TO FORWARD AND DIRECT CLUTCH
5Ga.8GCoat the bearing and race with petroleum jelly and install them
onto the forward clutch.
@lx98a340e_at-101c
5Gb.8GCoat the race with petroleum jelly and install it onto the front
planetary ring gear.
@lx98a340e_at-101d
5Gc.8GAlign the flukes of the discs in the forward clutch.
@lx98a340e_at-101e
5Gd.8GAlign 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.
Bearing and Race Diameter
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: 5.3 - 7.3 mm (0.209 - 0.287 inch)
If the height is non-standard, check for an improper installation.
d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.
Assembled Bearing and Race Diameter
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, install the snap ring.
SST 09350-30020 (09350-07060)
18. CHECK PISTON ROD STROKE OF SECOND COAST BRAKE
a. Place a mark on the second coast brake piston rod as shown.
b. Using SST, measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09240-00020
Piston rod stroke: 2.0 - 3.0 mm (0.079 - 0.118 inch)
If the stroke is more than specified, replace the piston rod with a longer one.
Piston rod length:
71.4 mm (2.811 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.
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, aim the bolt and oil holes of the overdrive support toward the valve body side, and align them with the bolt holes of the transmission case and install the bolts.
SST 09350-30020 (09350-07020)
d. Temporarily tighten the 2 bolts.
e. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
HINT: Install the snap ring open end toward the valve body.
f. Tighten 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 with hand.
End play: 0.27 - 0.86 mm (0.0106 - 0.0339 inch)
If the end play is 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 discs.
b. Install the plates and discs.
Install in order: P = Plate D = Disc D-P-D-P-D-P-D
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 and a dial indicator onto the overdrive brake piston.
SST 09350-30020 (09350-06120)
b. Measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
Piston stroke: 1.40 - 1.70 mm (0.0551 - 0.0669 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 thicknesses for the flange.
Flange Thickness