Assembly - Part 1

Assembly




1. Install manual shaft components.
a. Install oil seal onto manual shaft.
- Apply A.T.F. to oil seal.
- Wrap threads of manual shaft with masking tape.
b. Insert manual shaft and oil seal as a unit into transmission case.
c. Remove masking tape.




d. Push oil seal evenly and install it onto transmission case.




e. Align groove in shaft with drive pin hole, then drive pin into position as shown in figure at left.




f. Install detent spring and spacer.
g. While pushing detent spring down, install manual plate onto manual shaft.




h. Install lock nuts onto manual shaft.




2. Install accumulator piston.
a. Install O-rings onto accumulator piston.
- Apply A.T.F. to O-rings.

Accumulator Piston O-rings:

Accumulator Piston O-rings




b. Install return spring for accumulator A onto transmission case.

Free Length Of Return Spring:

Free Length Of Return Spring




c. Install accumulator pistons A, B, C and D.
- Apply A.T.F. to transmission case.




3. Install band servo piston.
a. Install return springs onto servo piston.




b. Install band servo piston onto transmission case.
- Apply A.T.F. to O-ring of band servo piston and transmission case.
c. Install gasket for band servo onto transmission case.




d. Install band servo retainer onto transmission case.




4. Install rear side clutch and gear components.
a. Place transmission case in vertical position.




b. Slightly lift forward clutch drum assembly and slowly rotate it clockwise until its hub passes fully over the clutch inner race inside transmission case.




c. Check to be sure that rotation direction of forward clutch assembly is correct.




d. Install thrust washer onto front of overrun clutch hub.
- Apply petroleum jelly to the thrust washer.
- Insert pawls of thrust washer securely into holes in overrun clutch hub.




e. Install overrun clutch hub onto rear internal gear assembly.




f. Install needle bearing onto rear of overrun clutch hub.
- Apply petroleum jelly to needle bearing.




g. Check that overrun clutch hub rotates as shown while holding forward clutch hub.




h. Place transmission case into horizontal position.




i. Install rear internal gear, forward clutch hub and overrun clutch hub as a unit onto transmission case.




j. Install needle bearing onto rear internal gear.
- Apply petroleum jelly to needle bearing.




k .Install bearing race onto rear of front internal gear.
- Apply petroleum jelly to bearing race.
- Securely engage pawls of bearing race with holes in front internal gear.




l. Install front internal gear on transmission case.

Adjustment:

Adjustment




1. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
- Pay attention to its direction.




b. Install needle bearing on front of front planetary carrier.
- Apply petroleum Jelly to needle bearing.

c. Install needle bearing on rear of front planetary carrier.
- Apply petroleum jelly to bearing.
- Pay attention to its direction - Black side goes to front.




d. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum.




- Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly.




e. Install bearing races on rear of clutch pack.
- Apply petroleum jelly to bearing races.
- Securely engage pawls of bearing race with hole in clutch pack.




f. Place transmission case in vertical position.




g. Install clutch pack into transmission case.




2. Adjust total end play.

Total end play "T(1)": 0.25 - 0.55 mm (0.0098 - 0.0217 in)




a. With needle bearing installed, place J34291-1 (bridge), J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil pump. The long ends of legs should be placed firmly on machined surface of oil pump assembly and gauging cylinder should rest on top of the needle bearing. Lock gauging cylinder in place with set screw.




b. Install J34291-23 (gauging plunger) into gauging cylinder.




c. With original bearing race installed inside reverse clutch drum, place shim selecting gauge with its legs on machined surface of transmission case (no gasket) and allow gauging plunger to rest on bearing race. Lock gauging plunger in place with set screw.




d. Remove Tool and use feeler gauge to measure gap between gauging cylinder and gauging plunger. This measurement should give exact total end play.

Total end play "T(1)": 0.25 - 0.55 mm (0.0098 - 0.0217 in)

- If end play is out of specification, decrease or increase thickness of oil pump cover bearing race as necessary.

Available oil pump cover bearing race: Refer to S.D.S. Service Data and Specifications (SDS)




3. Adjust reverse clutch drum end play.

Reverse clutch drum end play "T(2)": 0.55 - 0.90 mm (0.0217 - 0.0354 in)




a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket) and allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw.



b. Install J34291-23 (gauging plunger) into gauging cylinder.




c. With original thrust washer installed on oil pump, place shim setting gauge legs onto machined surface of oil pump assembly and allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw.




d. Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch drum and play.

Reverse clutch drum end play "T(2)": 0.55 - 0.90 mm (0.0217 - 0.0354 in)

- If end play is out of specification, decrease or increase thickness of oil pump thrust washer as necessary.

Available oil pump thrust washer: Refer to S.D.S. Service Data and Specifications (SDS)

Assembly




1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case while slightly lifting front internal gear.
- Do not force output shaft against front of transmission case.




b. Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft.
- Check to be sure output shaft cannot be removed in rear direction.




c. Install needle bearing on transmission case.
- Pay attention to its direction Black side goes to rear.
- Apply petroleum jelly to needle bearing.