Part 1 of 2

REASSEMBLY

CAUTION:
- Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
- Never use grease other than blue petrolatum jelly and white Vaseline.
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- Never apply sealant or adhesive to gaskets.
- When replacing a bushing, replace the assembly which it belongs to.
- During the work, always use bare hands or vinyl gloves. Do not use cotton gloves. Use nylon cloth or paper towels when necessary. Do not use shop towel.
- Change the oil in the cooler system.

CAUTION: Never reuse a gasket.





1. Install a new gasket and output shaft support.








2. Tighten the eight output shaft support mounting bolts to the specified torque.





CAUTION: Take care not to mistake the thrust bearing mounting direction.





3. Install the bearing retainer and thrust bearing number 13 onto the output shaft.





4. Install new seal rings (two large pieces and two small pieces) onto the output shaft.





5. Insert the output shaft into the output shaft support.

CAUTION: Take care not to mistake the thrust bearing number 12 mounting direction.





6. Apply Vaseline or petrolatum jelly on the thrust bearing number 12, and then install on the front end of the output shaft.





7. Install the underdrive clutch.





CAUTION: Take care not to mistake the thrust bearing number 11 mounting direction.





8. Apply Vaseline or petrolatum jelly on the thrust bearing number 11, and then install on the front end of the underdrive clutch retainer.





9. Install the underdrive clutch hub.





CAUTION: Take care not to mistake the thrust bearing number 10 mounting direction.





10. Apply Vaseline or petrolatum jelly on the thrust bearing number 10, and then install on the underdrive clutch hub.





11. Install the output flange.





CAUTION: Take care not to mistake the thrust bearing number 9 mounting direction.





12. Apply Vaseline or petrolatum jelly on the thrust bearing number 9, and then install on the output flange.





CAUTION: Measure and record the thickness of the thrust race number 8 to be assembled.





13. Apply Vaseline or blue petrolatum jelly on the thrust race number 8 being used, and then install on the rear side of the center support.

CAUTION:
- Install the center support so that the oil holes shown in the illustration face the lower side of the transmission case.
- Make sure that the thrust race number 8 attached to the rear side of the center support does not fall off.

14. Install the center support.





15. Remove the two output shaft support mounting bolts.
16. Using the two removed bolts, install special tool MB996103 to the specified torque.
17. Select the thrust race number 8 with the following procedure:





1. Fix a dial gauge to special tool MB991603.
2. Alternately press in the output shaft and output flange, and measure the end play of the output shaft.

NOTE:
- When pressing in the output shaft, make sure that the center support does not move.
- When pressing in the output flange, use special tool MD998304.





3. Select the thrust race number 8 installed in step 13 so that the end play of the output shaft is at the standard value. Then, reassemble.

NOTE: Refer to the thickness recorded in step 13.

Standard value: 0.25 - 0.55 mm (0.0098 - 0.0217 inch)
4. Measure the end play again, and confirm that it is within the standard value.

NOTE: Carry this step out with special tool MB991603 and dial gauge installed.

18. Using the following steps, select the snap ring for fixing the center support.





1. Install the snap ring used for fixing the center support used.





2. Alternately press in the output shaft and center support, and measure the end play of the center support.

NOTE: When pressing in the output shaft, make sure to press it in fully so that the center support contacts the snap ring.





3. Select the snap ring for fixing the center support installed in step 18 (1) so that the end play of the center support is at the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm (0 - 0.063 inch)
4. Measure the end play again, and confirm that it is within the standard value.
19. Using the following steps, select the snap ring for adjusting the brake reaction plate end play and second brake end play, and the pressure plate for adjusting the low/reverse brake end play.





1. Install the wave spring onto the low/reverse brake piston.








2. Install special tool MB991632 onto the position shown in the illustration instead of the pressure plate for the low/reverse brake. Install the brake disc, brake plate and snap ring.





CAUTION: Take care to the assembly direction of the reaction plate.

3. Install the reaction plate and snap ring that was used.
4. Install a dial gauge onto special tool (MD998913) so that the end contacts the brake reaction plate. Measure the end play by moving special tool MB991632.
5. Select the snap ring installed in step 19 (3) so that the end play is within the standard value. Then, reassemble.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)





6. Measure the end play again, and confirm that it is within the standard value.

CAUTION: Take care to the shape and assembly direction of the brake plate installed at section "A" shown in the illustration.

7. Next, install special tool MB991632 instead of the pressure plate for the second brake. Install the four brake discs and three brake plates.
8. Install the return spring, second brake and snap ring.








9. Install a dial gauge onto special tool MD998913 so that the end contacts the special tool. Move special tool MB991632 and measure the moving amount.
Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
End play standard value (reference): 1.49 - 1.95 mm (0.0587 - 0.0768 inch)
10. Remove the snap ring, second brake, return spring and special tool MB991632 installed in step (8).
11. lnstall the pressure plate selected in step (9), and install the return spring, second brake and snap ring again.











12. Install a dial gauge onto special tool MD998913 so that the end contacts the special tool. Move special tool MB991632 and measure the moving amount. Select a pressure plate with a thickness that corresponds to the measured moving amount from the following table.
End play standard value (reference):
1.35 - 1.81 mm (0.0531 - 0.0713 inch)
1.65 - 2.11 mm (0.0650 - 0.0831 inch)

13. Remove the parts installed in steps 19 (1) to (12).

CAUTION: Take care not to mistake the thrust bearing number 7 mounting direction.

20. Apply Vaseline or petrolatum jelly on the thrust bearing number 7, and then install on the rear side of the low/reverse annulus gear.

CAUTION: Make sure that the thrust bearing number 7 attached to the rear side of the low/reverse annulus gear does not fall Off.

21. Install the low/reverse annulus gear.

22. Install the reverse sun gear.





23. Install the wave spring to the low/reverse brake piston.








24. Install the pressure plate, brake disc and brake plate selected in step 19 (12).





25. Install the snap ring.





CAUTION: Take care not to mistake the reaction plate installation direction.

26. Install the reaction plate.





27. Install the snap ring selected in step 19 (5).





CAUTION: Take care not to mistake the brake plate (reaction plate side) installation direction.

28. Install the brake disc, brake plate and pressure plate selected in step 19 (9).





CAUTION: Install the return spring end coil side so that it faces the back of the transmission. (Only for one side end coil type)





29. Install the return spring and second brake.





30. Install the snap ring.





CAUTION: Take care not to mistake the thrust bearing number 4 installation direction.





31. Apply Vaseline or petrolatum jelly on the thrust bearing number 4, and then install on the reverse sun gear.





CAUTION: Take care not to mistake the thrust bearing number 3 mounting direction.





32. Apply Vaseline or petrolatum jelly on the thrust bearing number 3, and then install on the overdrive clutch hub.
33. Install the overdrive clutch hub.





CAUTION: Take care not to mistake the thrust bearing number 2 mounting direction.





34. Install the reverse and overdrive clutch.
35. Apply Vaseline or petrolatum jelly on the thrust bearing number 2, and then install on the reverse and overdrive clutch.