Part 7

ASSEMBLY (1)





1. Install manual shaft components.
a. Install oil seal onto manual shaft.
- Apply ATF 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 ATF to O-rings.
Accumulator piston O-rings





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





Free length of return spring: Refer to image.





c. Install accumulator pistons (A),(B),(C) and (D).
- Apply ATF to transmission case.





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





b. Install band servo piston onto transmission case.
- Apply ATF 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. Then slowly rotate it clockwise until its hub passes fully over 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
When any parts listed in the following table are replaced, total end play or reverse clutch end play must be adjusted.





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 inch) 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 "T1": 0.25 - 0.55 mm (0.0098 - 0.0217 inch)





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. The 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. Install original bearing race inside reverse clutch drum. Place shim selecting gauge with its legs on machined surface of transmission case (no gasket). 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 "T1": 0.25 - 0.55 mm (0.0098 - 0.0217 inch)

- 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 image.





3. Adjust reverse clutch drum end play.

Reverse clutch drum end play "T2": 0.55 - 0.90 mm (0.0217 - 0.0354 inch)





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