Assembly Procedure

Assembly procedure





1. Install new seal rings to the low one-way clutch inner race.





2. Measure the clearance between the seal rings and the seal ring grooves.
^ If the clearance is not within the specification, replace the low one-way clutch inner race.

Specification:
0.10-0.25 mm (0.0040-0.0098 in)





3. Set the SSTs in the order shown.





4. Install the low one-way clutch inner race and the bearing.





5. Set the SSTs in the order shown.





6. Hand tighten the bolts as shown in the figure.
7. Remove the SSTs.





8. Tighten the bolts evenly and gradually.

Tightening torque:
21-26 Nm (2.1-2.7 kgf-m, 16-19 ft. lbf.)





9. Install the carrier component.





10. Verify that the top of the low clutch drum is lower than surface A (receiving surface of the 2-4 brake plate) of the transmission case.

Note: Install the thickest driven plate after the retaining plate.





11. Apply ATF to the retaining plate, driven plates, and the drive plates, and install them to the transmission case in the following order:
Retaining-Driven-Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive-Driven-Driven-Drive





12. Install the spring.

Caution: If the dished plate is not installed in the specified direction, it may be damaged or not operate properly. Install the plate exactly as shown in the figure.





13. Install the retaining plate and the dished plate.





14. Install new seal rings to the 2-4 brake piston.





15. Install the 2-4 brake piston to the 2-4 brake retainer.





16. Align the fluid passage and install the return spring, 2-4 brake retainer, and the snap ring.

Caution: Be sure to center the SSTs on the transmission case. Otherwise, the return spring can be damaged.





17. Set the SSTs to the transmission case.

Caution: Do not compress the 2-4 brake retainer excessively. Doing so can damage the return spring.





18. Compress the 2-4 brake retainer using the SST.
19. Install the snap ring.
20. Remove the SSTs.





21. Install the sleeve and a new seal ring.

Caution:
^ Applying compressed air to the assembled clutch pack for more than 3 s at a time will damage the seal.
^ Do not apply compressed air for more than the aforementioned time when testing the system.





22. Apply compressed air to the part indicated in the figure and inspect the 2-4 brake operation.
^ If there is any malfunction, inspect the seal rings.

Air pressure:
390 kPa (4.0 kgf-cm2, 57 psi) max.





23. Measure the clearance between the 2-4 brake retainer and the snap ring.
^ If the clearance is not within the specification, adjust the clearance by installing the correct retaining plate.

Specification:
1.0-1.4 mm (0.0394-0.0551 in)

Retaining plate sizes








24. Install the bearing race, front sun gear, and the bearing.





25. Install the bearing race and the high clutch hub.





26. Install the bearing to the reverse and high clutch drum with the black surface facing rear side.





27. Install the reverse and high clutch drum and the bearing.
28. Use the following procedure to adjust the total end play.





1) Install the bearing race (oil pump installation race) to the reverse and high clutch drum and measure dimension A shown in the figure.





2) Measure the dimension B shown in the figure.
3) Calculate the total end play by using the formula below.





^ If the total end play is not within the specification, adjust the total end play by selecting the correct bearing race (oil pump installation race).

Formula:
Total end play= dimension A-dimension B

Specification:
0.25-0.55 mm (0.0099-0.0216 in)

Bearing race sizes








29. Install the input shaft.

Note: Install large seal rings to the front side and small seal rings to the rear side.





30. Install new seal rings to the oil pump.





31. Measure the clearance between the seal rings and the seal ring grooves.
^ If the clearance is not within the specification, replace the oil pump cover.

Specification:
0.10-0.25 mm (0.0040-0.0098 in)





32. Install a new O-ring to the oil pump.





33. Install the bearing race to the oil pump.
34. Apply sealant to the oil pump installation bolts.
35. Apply ATF to the O-ring around the oil pump.





36. Install the oil pump.

Tightening torque:
55-60 Nm (5.7-6.1 kgf-m, 42-44 ft. lbf.)





37. Install a new O-ring to the input shaft.





38. Install the torque converter housing.

Tightening torque:
50-55 Nm (5.1-5.6 kgf-m, 37-40 ft. lbf.)





39. Install a new oil seal using the SST.





40. Install the detent spring.

Tightening torque:
6.4-8.3 Nm (66-84 kgf-cm, 58-72 in. lbf.)





41. Install the manual shaft, manual plate and parking rod as shown in the figure.
42. Rotate the manual plate until the detent spring catches on the indented part of the manual plate.





43. Install a new roll pin using a pin punch.
44. Apply ATF to a new O-ring, and install it to the harness component.





45. Install the harness component.

Tightening torque:
5.0-7.0 Nm (51-71 kgf-cm, 43-61 in. lbf.)

Note: Do not move the manual valve in the direction of arrow to prevent the pin for the manual valve rotation prevention from falling from the control valve body.





46. Align the manual valve and the manual plate, and set the control valve body.





47. Tighten the bolts evenly and gradually.





Tightening torque:
6.9-8.8 Nm (71-89 kgf-cm, 62-77 in. lbf.)





48. Connect the connector.

Note: Do not reuse the oil pan installation bolts as they are coated.

49. Install a new gasket and the oil pan with new bolts.

Tightening torque:
7.0-9.0 Nm (72-91 kgf-cm, 63-78 in. lbf.)





50. Install the actuator support.





51. Install the parking pawl, shaft, spring, and the spacer.





52. Install new seal rings to the output shaft component.





53. Measure the clearance between the seal rings and seal ring grooves.
^ If the clearance is not within the specification, replace the output shaft.

Specification:
0.10-0.25 mm (0.0040-0.0098 in)

Note: Install the bearing to the transmission case with the black surface facing the rear side.





54. Install the bearing and the output shaft component.
55. Apply ATF to a new oil seal.

Note: When installing the oil seal to the extension housing, tap the SSTs until the stopper on the oil seal circumference contacts the extension housing.





56. Install the oil seal to the extension housing using the SSTs.





57. Install the bearing to the extension housing.





58. Apply a light coat of sealant to the contact surfaces of the transmission case and the extension housing. (For the four locations indicated in the figure, apply sealant to the entire circumference of the bolt holes.)





59. Install the extension housing.

Tightening torque:
50-55 Nm (5.1-5.6 kgf-m, 37-40 ft. lbf.)





60. Install the TR switch, and hand-tighten the mounting bolts.

Caution: Improper adjustment of the TR switch will cause abnormal operation of the automatic transmission. Be sure to use the SST to adjust the TR switch correctly.





61. Using the SST and by turning the TR switch, adjust the positions of the manual shaft and the TR switch neutral hole.
62. Tighten the TR switch installation bolts.

Tightening torque:
4.4-6.5 Nm (45-66 kgf-cm, 40-57 in. lbf.)

63. Remove the SST.
64. Apply ATF to new O-rings and install them to the VSS and the turbine sensor.





65. Install the VSS and the turbine sensor.

Tightening torque:
5.0-7.0 Nm (51-71 kgf-cm, 43-61 in. lbf.)

66. Pour ATF into the torque converter.
67. Shake the torque converter to clean the inside and pour out the solvent.
68. Pour ATF into the torque converter.
69. Install the torque converter.





70. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.
^ If the distance is not within the specification, install the torque converter correctly.

Specification:
50 mm (1.97 in) or more