Assembly
When installing/assembling needle bearing and bearing race, use the illustration above as a guide to installation procedures and locations.
1. Lubricate outer diameter part of oil pump assembly. Install oil pump assembly and thrust bearing.
2. Lubricate low and reverse brake piston seal then install piston by tapping it evenly using a wooden block.
3. Install low and reverse brake piston retainer.
After installing piston retainer, make sure that its piston seal is not turned over by the application of air pressure to low and reverse brake circuit.
4. Install parking pawl, return spring and parking pawl shaft.
5. Install brake band.
6. Lubricate band servo piston O-ring and install band servo piston O-ring, return spring and snap ring holding piston with a small vice.
7. Lubricate seals in oil pump housing, then install plastic thrust washer and high-reverse clutch (Front) assembly.
Check seal rings to ensure that they have not expanded. If they have, high-reverse clutch (Front) assembly will be hard to install.
Check band servo operation using air.
8. Install thrust needle bearing & race, thrust washer and forward clutch (Rear) assembly.
9. Install needle bearing, bearing races and front planetary carrier assembly with front internal gear.
10. Install sun gear assembly, thrust needle bearing and bearing race.
11. Install low and reverse brake driven & drive plates and retaining plate, then secure with snap ring.
Available Retaining Plates:
12. After low and reverse brake has been completely assembled, measure clearance between snap ring and retaining plate. If measurement exceeds specifications, it can be adjusted by replacing retaining plate with one of a different thickness.
Low and reverse brake clearance:
Standard 1.80 - 2.20 mm (0.0709 - 0.0866 in.)
Allowable limit .2 mm (0.126 in.)
13. Install bearing race on rear planetary carrier.
14. Install one-way clutch assembly to rear planetary carrier.
15. Install thrust washer on rear carrier.
16. Install one-way clutch with rear planetary carrier by turning rear carrier clockwise.
17. Install snap ring.
Ensure that its bent end is positioned so that it does not interfere with parking pawl.
18. Apply petroleum jelly to bearing race, then attach it to rear internal gear.
19. Install rear internal gear.
20. Install governor shaft assembly.
21. Install governor shaft retaining bolt.
22. Install seal bushing.
Never forget to install seal bushing to prevent sun gear and output shaft from becoming jammed.
23. If transmission case, output shaft, tapered roller bearing or front cover is replaced, output shaft should be adjusted by means of shims.
a. Lubricate bearing outer race.
b. Press bearing outer race into converter housing.
c. Install two or three shims on front cover, and press bearing outer race into front cover.
d. Install gasket and front cover on converter housing.
Clean all front cover securing bolts and apply locking sealant to threads of arrowed bolt. Apply sealant to threads of other bolts.
e. Measure output shaft preload.
Specified output shaft bearing preload: 0.35 - 0.47 N.m (3.6 - 4.8 kg-cm, 3.1 - 4.2 in-lb)
- Turn output shaft at least 10 times before measuring output shaft bearing preload.
- Ensure that output shaft turns smoothly without binding.
- If any abnormalities are noted above, or output shaft bearing preload is outside specified range, disassemble and reassemble again.
Available shims: Refer to Specifications.
24. Adjust idler bearing preload as follows:
a. Clean threads of bolts and converter housing with solvent.
b. Apply locking sealant to threads of bolts and install them into place.
c. Install lock washer and idler gear bolt, and tighten bolt temporarily.
Temporary torque: 26 - 36 N.m (2.7 - 3.7 kg-m, 20 - 27 ft-lb)
Be sure to align lock washer with groove on converter housing.
d. After tightening bolt, turn output shaft five complete rotations. Loosen idler gear bolt, then tighten it to specified torque.
Specified torque: 3.0 - 4.0 N.m (0.31 - 0.41 kg-m, 2.2 - 3.0 ft-lb)
e. Bend lock washer.
f. Turn output shaft to make sure it operates smoothly.
25. After adjusting output shaft bearing preload, adjust output shaft end play as follows:
a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket). Position bridge legs so the short ends of the legs are down, and adjust legs to fit onto housing properly. Allow gauging cylinder to rest on center machined surface or rear internal gear and lock it in place with thumbscrew.
b. Insert J34291-6 (output shaft end-play gauging plunger) into gauging cylinder. Lock gauging plunger by tightening thumbscrew.
c. Remove output shaft end play adjusting shim at end of output shaft.
d. Place bridge, gauging cylinder, and gauging plunger onto machined surface of converter housing. Loosen plunger set screw and allow plunger to rest on inner bearing race of output shaft. Now lock plunger setscrew.
e. Use feeler gauge to measure gap between gauging cylinder and shoulder of gauging plunger.
Output Shaft End Play Adjusting Shims:
f. Use your feeler gauge measurement and following adjusting shim chart to select correct shim thickness to give you proper output shaft end play.
End play: 0.25 - 0.55 mm (0.0098 - 0.0217 in.)
26. Attach output shaft shim to output shaft.
27. Put gasket on transmission case.
28. Install converter housing assembly on transmission case.
29. Turn parking gear (rear internal gear) clockwise with screwdriver while supporting converter housing assembly by hand, until output shaft splines, front carrier, and rear internal gear are engaged properly.
30. Tighten converter housing securing bolts to the specified torque.
Before installing the six bolts marked <- in figure at left, ensure that bolt threads are clean and that sealant has been applied. Apply A.T.F. to threads of other bolts. Ensure that the transmission case has been cleaned with solvent.
31. Apply petroleum jelly to lathe cut ring, then install return spring and accumulator piston on transmission case.
32. Adjust brake band as follows:
a. First torque anchor end pin.
Anchor end pin: Tightening Torque: 4 - 6 N.m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-lb)
b. Back off anchor end pin 2.5 turns.
c. Tighten lock nut while holding anchor end pin lock nut stationary.
Lock nut:
Tightening Torque: 16 - 22 N.m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)
33. Assemble parking actuator support and install it on transmission case.
34. Install throttle wire to transmission case and tighten lock nut.
35. Apply grease and petroleum jelly to manual shaft.
36. Secure manual shaft with retaining pin.
Always install retaining pin with cleavage facing transmission case.
37. Install throttle lever, manual plate, and parking rod assembly, then tighten manual shaft securing nuts.
38. Connect throttle wire to throttle lever.
39. Insert manual valve to control valve body, then install them on transmission case.
Pay attention to the direction of manual and detent valves' grooves.
40. Before installing oil pan, check alignment and operation of manual lever and parking pawl engagement. Blow mechanism with air to clean.
41. Install two magnets into oil pan. Install oil pan with new gasket and oil pan guard.
42. Install seal ring and governor cap, then secure it with snap retainer.
When installing snap retainer, pay attention to its direction.
43. Install inhibitor switch.
44. Adjust inhibitor switch - Refer to "ON-VEHICLE SERVICE".
45. Install O-ring on input shaft.
Then install input shaft.
46. Install oil pump shaft.
47. Install drain plug.
Apply sealant to drain plug.
48. Carefully inspect torque converter for damage. Check converter hub for grooves caused by hardened seals. Also check bushing contact area.
49. Lubricate oil pump lip seal and converter neck before installing converter.
50. Pour approx. 2-liters (2-1/8 US qt, 1-3/4 Imp qt) of A.T.F. into torque converter.
51. Install torque converter.
Be careful not to scratch front cover oil seal.
52. Measure distance "A" to check torque converter is in proper position.
Distance "A": 21.1 mm (0.831 in.) or more
53. Make sure that manual shaft operates smoothly.