Part 2 of 2

23. Install reverse clutch assembly.
- Align teeth of reverse clutch drive plates before installing.

ADJUSTMENT 2





When any parts listed below are replaced, adjust total end play and reverse clutch end play.

TOTAL END PLAY





- Measure clearance between reverse clutch drum and needle bearing for oil pump cover.
- Select proper thickness of bearing race so that end play is within specifications.





1. Measure dimensions "K" and "L" and then calculate dimension "J".





a. Measure dimension "K".





b. Measure dimension "L".
c. Calculate dimension "J".

"J": Distance between oil pump fitting surface of transmission case and needle bearing mating surface of high clutch drum.
J = K - L





2. Measure dimension "M".
a. Place bearing race and needle bearing on oil pump assembly.





b. Measure dimension "M".

"M": Distance between transmission case fitting surface and needle bearing on oil pump cover.
"M1": Indication of gauge.





c. Measure thickness of straightedge "t".

M = M1 - t

3. Adjust total end play "T.".

T3 = J - M
Total end play "T3": 0.25 - 0.55 Nm (0.0098 - 0.0217 inch)

- Select proper thickness of bearing race so that total end play is within specifications.





Bearing races: Refer to image.

REVERSE CLUTCH END PLAY





- Measure clearance between oil pump cover and thrust washer for reverse clutch drum.
- Select proper thickness of thrust washer so that end play is within specifications.





1. Measure dimensions "0" and "P" and then calculate dimension "N".





a. Place thrust washer on reverse clutch drum.
b. Measure dimension "0".





c. Measure dimension "P".
d. Calculate dimension "N".

"N": Distance between oil pump fitting surface of transmission case and thrust washer on reverse clutch drum.
N = 0 - P





2. Measure dimensions "R" and "S" and then calculate dimension "Q".





a. Measure dimension "R".





b. Measure dimension "S".
c. Calculate dimension "Q".

"Q": Distance between transmission case fitting surface and thrust washer mating surface.
Q = R - S

3. Adjust reverse clutch end play "T4".

T4 = N - Q
Reverse clutch end play: 0.65 - 1.00 Nm (0.0256 - 0.0394 inch)

- Select proper thickness of thrust washer so that reverse clutch end play is within specifications.





Thrust washer: Refer to image.

ASSEMBLY 3





1. Remove reverse clutch assembly and install needle bearing on high clutch assembly.
- Pay attention to direction of needle bearing.

2. Install reverse clutch assembly.





3. Install anchor end pin and lock nut on transmission case.
4. Place brake band on outside of reverse clutch drum. Tighten anchor end pin just enough so that brake band is evenly fitted on reverse clutch drum.





5. Place bearing race selected in total end play adjustment step on oil pump cover.
- Apply petroleum jelly to bearing race.





6. Place thrust washer selected in reverse clutch end play step on reverse clutch drum.
- Apply petroleum jelly to thrust washer.





7. Install oil pump assembly on transmission case.





8. Tighten oil pump fixing bolts to specified torque.





9. Install O-ring to input shaft.
- Apply ATF to O-ring.





10. Adjust brake band.
a. Tighten anchor end pin to specified torque.

Anchor end pin: 3.9 - 5.9 Nm (0.4 - 0.6 kg-m, 35 - 52 inch lbs.)





b. Back off anchor end pin two and a half turns.





c. While holding anchor end pin, tighten lock nut.





11. Apply compressed air to oil holes of transmission case and check operation of brake band.

ADJUSTMENT 3
FINAL DRIVE END PLAY
- Measure clearance between differential side bearing and transmission case.
- Select proper thickness of adjusting shim so that end play is within specifications.





1. Measure dimension "T" between side bearing fitting surface of transmission case and converter housing fitting surface of transmission case.

"T1": indication of gauge





2. Measure thickness of straightedge "t".

T = T1, - t





3. Place final drive assembly on converter housing.
4. Measure dimension "U" between end of differential case and transmission case fitting surface of converter housing.





5. Measure dimension "V" between end of differential case and adjusting shim mating surface of differential side bearing.
6. Calculate final drive end play.

Final drive end play: T - U + V

7. Select proper thickness of differential side bearing adjusting shim so that final drive end play is within specifications.

Final drive end play: 0 - 0.15 Nm (0 - 0.0059 inch)

Differential side bearing adjusting shim: Refer to image.

ASSEMBLY 4





1. Install differential side bearing adjusting shim selected in final drive end play adjustment step on transmission case.





2. Install final drive assembly on transmission case.





3. Install oil tube on converter housing.





4. Install O-ring on differential oil port of transmission case.
5. Install converter housing on transmission case.
- Apply locking sealant to mating surface of converter housing.





6. Install accumulator piston.
a. Check contact surface of accumulator piston for damage.





b. Install O-rings on accumulator piston.
- Apply ATF to O-rings.

Accumulator piston O-rings: Refer to image.





c. Install accumulator pistons and return springs on transmission case.
- Apply ATF to inner surface of transmission case.





Return springs: Refer to image.





7. Install lip seals for band servo oil holes on transmission case.
- Apply petroleum jelly to lip seals.





8. Install oil filter for governor valve.
- Take care with its direction.





9. Install throttle wire to transmission case.





10. Install throttle wire to throttle lever.





11. Install control valve assembly.
a. Insert manual valve into control valve assembly.
- Apply ATF to manual valve.





b. Set manual shaft in Neutral position.
c. Install control valve assembly on transmission case while aligning manual valve with manual plate and detent valve with throttle lever.
d. Pass solenoid harness through transmission case and install terminal body on transmission case by pushing it.

Bolt length, number and location:




e. Tighten bolts (A), (B), (C) and (D).

7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)





12. Install oil pan.
a. Attach magnet to oil pan.





b. Install new oil pan gasket on transmission case.
c. Install oil pan on transmission case.
- Always replace oil pan bolts as they are self-sealing bolts.
- Tighten the four bolts in a crisscross pattern to prevent dislocation of gasket.

d. Tighten drain plug to specified torque.





13. Install governor valve.
a. Install governor valve assembly into transmission case.





b. Install O-ring to governor cap.
- Apply ATF to O-ring.





c. Install governor cap onto transmission case.





d. Install snap ring onto transmission case with a screwdriver.
- Align snap ring gap with the notch of transmission case.





14. Install inhibitor switch.
a. Set manual shaft in "P" position.
b. Temporarily install inhibitor switch on manual shaft.
c. Move selector lever to "N" position.





d. Use a 4 mm (0.157 inch) pin for this adjustment.
1. Insert the pin straight into the manual shaft adjustment hole.
2. Rotate inhibitor switch until the pin can also be inserted straight into hole in inhibitor switch.
e. Tighten inhibitor switch fixing bolts.
f. Remove pin from adjustment hole after adjusting inhibitor switch.





15. Install oil charging pipe and oil cooler tube to transmission case.





16. Install torque converter.
a. Pour ATF into torque converter.
- Approximately 1 liter (1 - 1/8 US quart, 7/8 Imp quart) of fluid is required for a new torque converter.
- When reusing old torque converter, add the same amount of fluid as was drained.





b. Install torque converter while aligning notches of torque converter with notches of oil pump.





c. Measure distance "A" to check that torque converter is in proper position.

Distance "A": 21.1 Nm (0.831 inch) or more