Part 2
ASSEMBLY
1. Install upper, inter and lower body.
a. Place oil circuit of upper body face up. Install steel balls in their proper positions.
b. Install upper separating gasket, upper inter separating gasket and upper separating plate in order shown in illustration.
- Always use new gaskets.
c. Install reamer bolts (F) from bottom of upper body. Using reamer bolts as guides, install separating plate and gaskets as a seat.
d. Install pilot filter.
e. Place inter body as shown in the illustration. Install steel balls in their proper positions.
f. Install inter body on upper body using reamer bolts (F) as guides.
- Be careful not to dislocate or drop steel balls.
g. Install steel balls and relief valve springs in their proper positions in lower body.
h. Install lower separating gasket, inner separating gasket and lower separating plate in order shown in the illustration.
i. Install bolts (E) from bottom of lower body. Using bolt as guides, install separating plate and gaskets as a set.
j. Install support plates on lower body.
k. Install lower body on inter body using reamer bolts as guides and tighten reamer bolts (F) slightly.
2. Install O-rings to solenoid valves and terminal body.
- Apply ATF to O-rings.
Bolt length, number and location:
3. Install and tighten bolts.
a. Install and tighten bolts (B) to specified torque.
Torque: 7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)
b. Install solenoid valve assembly and line pressure solenoid valve to lower body.
c. Remove reamer bolts (F) and set oil strainer on control valve assembly.
d. Reinstall reamer bolts (F) from lower body side.
e. Tighten bolts (A), (C), (D) and (F) to specified torque.
Torque: 7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)
f. Tighten bolts (E) to specified torque.
Torque: 3.4 - 4.4 Nm (0.35 - 0.45 kg-m, 30.4 - 39.1 inch lbs.)
CONTROL VALVE UPPER BODY
DISASSEMBLY
1. Remove valves at retainer plates.
- Do not use a magnetic "hand".
a. Use a screwdriver to remove retainer plates.
b. Remove retainer plates while holding spring, plugs or sleeves.
- Remove plugs slowly to prevent internal parts from jumping out.
c. Place mating surface of valve body face down, and remove internal parts.
- If a valve is hard to remove, place valve body face down and lightly tap it with a soft hammer.
- Be careful not to drop or damage valves and sleeves.
INSPECTION
Valve Spring
- Measure free length and outer diameter of each valve spring. Also check for damage or deformation.
Inspection standard: Refer to image.
- Replace valve springs if deformed or fatigued.
Control Valves
- Check sliding surfaces of valves, sleeves and plugs.
ASSEMBLY
- Lay control valve body down when installing valves. Do not stand the control valve body upright.
1. Lubricate the control valve body and all valves with ATF. Install control valves by sliding them carefully into their bores.
- Be careful not to scratch or damage valve body.
- Wrap a small screwdriver with vinyl tape and use it to insert the valves into their proper positions.
1-2 Accumulator Valve
- Install 1-2 accumulator valve. Align 1-2 accumulator retainer plate from opposite side of control valve body.
- Install return spring, 1-2 accumulator piston and plug.
2. Install retainer plates
- Install retainer plate while pushing plug or return spring.
Retainer Plate
- Install proper retainer plates.
CONTROL VALVE LOWER BODY
DISASSEMBLY
Remove valves at retainer plate.
INSPECTION
Valve Springs
- Check each valve spring for damage or deformation. Also measure free length and outer diameter.
Inspection standard: Refer to image.
- Replace valve springs if deformed or fatigued.
Control Valves
- Check sliding surfaces of control valves, sleeves and plugs for damage.
ASSEMBLY
- Install control valves.
Retainer Plate
- Install proper retainer plates.
REVERSE CLUTCH
DISASSEMBLY
1. Check operation of reverse clutch.
a. Install seal ring onto drum support of oil pump cover and install reverse clutch assembly. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring:
- D-ring might be damaged.
- Oil seal might be damaged.
- Fluid might be leaking past piston check ball.
2. Remove snap ring.
3. Remove drive plates, driven plates, retaining plate, and dish plates.
4. Set Tool on spring retainer and remove snap ring from reverse clutch drum while compressing return springs.
- Set Tool directly above springs.
- Do not expand snap ring excessively.
5. Remove spring retainer and return springs.
- Do not remove return springs from spring retainer.
6. Remove piston from reverse clutch drum by turning it.
7. Remove D-ring and oil seal from piston.
INSPECTION
Reverse Clutch Snap Ring, Spring Retainer And Return Springs
- Check for deformation, fatigue or damage.
- Replace if necessary.
- When replacing spring retainer and return springs, replace them as a set.
Reverse Clutch Drive Plates
- Check facing for burns, cracks or damage.
- Measure thickness of facing.
Thickness of drive plate:
Standard value: 2.0 Nm (0.079 inch)
Wear limit: 1.8 Nm (0.071 inch)
- If not within wear limit, replace.
Reverse Clutch Dish Plates
- Check for deformation or damage.
- Measure thickness of dish plate.
Thickness of dish plate "t": 2.8 Nm (0.110 inch)
- If deformed or fatigued, replace.
Reverse Clutch Piston
- Make sure check balls are not fixed.
- Apply compressed air to check ball oil hole opposite the return spring. Make sure that there is no air leakage.
- Apply compressed air to oil hole on return spring side to make sure air leaks past ball.