Part 2

10. INSTALL 3RD 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 and cover to the case.





c. Using SST, install the snap ring. SST 09350-30020 (0935-07060)





11. CHECK PISTON ROD STROKE OF 3RD COAST BRAKE
a. Place a mark on the 2nd coast brake piston rod.









b. Using SST, measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi). SST 09240-00020

Piston rod stroke: 2.0-3.0 mm (0.079-0.118 in.)

If the stroke is more than the specified, replace the piston rod with a longer one. If it is still more than standard value, replace the brake band with a new one.









12. INSTALL O/D SUPPORT ASSEMBLY
a. Coat the assembled bearing & race and thrust washer with petroleum jelly and install them onto the O/D support assembly.





b. Coat the thrust washer with petroleum jelly and install it onto the O/D support assembly.

HINT: Make sure that the lug shapes match the holes on the O/D support.





c. Using 2 bolts of SST, face the bolt and oil holes of the O/D support toward the valve body side, align them with the bolt holes of the transmission case and install the bolts. SST 09350-30020( 09350-07020)





d. Install the 2 bolts.

Torque: 25 Nm (260 kgf-cm, 19 ft. lbs)





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





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 in.)

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 in.) thick flange (flat ring )with the rounded-edge side of the flange facing the disc.

b. Install the O/D brake pack.

HINT: 3 plates, 3 discs and flange Install in order: P = Plate, D = Disc P-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 cut-out 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: 1.32-1.62 mm (0.052-0.064 in.)





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.









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.





b. Install the O/D planetary ring gear.









c. Install the bearing and race onto the O/D planetary ring gear.









d. Coat the race with petroleum jelly and install it onto the O/D planetary gear.





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.









17. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto the oil pump.
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