Part 2 of 2

DISASSEMBLY
Assembly 2





1. Apply locking sealant (Loctite #518) to transmission case as shown in illustration.





2. Set side cover on transmission case.
- Apply locking sealant to the mating surface of transmission case.





3. Tighten side cover fixing bolts to specified torque.
Tightening Torque: 3.0 - 3.4 Nm (0.31 - 0.35 kg.m, 26.9 - 30.4 inch lbs.)
- Do not mix bolts (A) and (B).
- Always replace bolts (A) as they are self-sealing bolts.





4. Remove paper rolled around bearing retainer.
5. Install thrust washer on bearing retainer.
- Apply petroleum jelly to thrust washer.





6. Install forward clutch assembly.
- Align teeth of low & reverse brake drive plates before installing.
- Make sure that bearing retainer seal rings are not spread.
- If forward clutch assembly is correctly seated, points and (2) are at almost same level.





7. Install thrust needle bearing on bearing retainer.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.





8. Install overrun clutch hub.
- Apply petroleum jelly to thrust washers.
- Align teeth of overrun clutch drive plates before installing.





9. Hold forward clutch hub and turn rear internal gear. Check overrun clutch hub for correct directions of lock and unlock.
- If not shown as illustrated, check installed direction of forward one-way clutch.





10. Install forward clutch hub and rear internal gear assembly.
- Align teeth of forward clutch drive plates before installing.
- Check that three hooks of thrust washer are correctly aligned after installing.
11. Install rear planetary carrier assembly and rear sun gear according to the following procedures.





a. Install needle bearings on rear planetary carrier.
- Apply petroleum jelly to needle bearings.
- Pay attention to direction of needle bearings.





b. Install rear sun gear on rear planetary carrier.
- Pay attention to direction of rear sun gear.





c. Install rear planetary carrier on transmission case.





12. Install thrust needle bearing on front planetary carrier, then install them together on transmission case.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.
13. Install low and reverse brake piston according to the following procedures.





a. Set arid align return springs to transmission case gutters as shown in illustration.





b. Set and align piston with retainer.





c. Install piston and retainer assembly on the transmission case.
- Align bracket to specified gutter as indicated in illustration.





d. Check that each protrusion of piston is correctly set to corresponding return spring as follows.
- Push piston and retainer assembly evenly and confirm they move smoothly.
- If they can not move smoothly, remove piston and retainer assembly and align return spring correctly as instructed in step "a".





e. Push down piston and retainer assembly and install snap ring.





14. Install low one-way clutch to front planetary carrier by turning carrier in the direction of the arrow shown.





15. Install snap ring with screwdriver.
- Forward clutch and bearing must be correctly installed for snap ring to fit into groove of transmission case.





16. Install needle bearing on transmission case.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.





17. Install bearing race, needle bearing and high clutch hub on front sun gear.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.





18. Install needle bearing and high clutch drum on high clutch hub.





19. Install needle bearing on high clutch drum.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.





20. Remove paper rolled around input shaft.
21. Install input shaft assembly in reverse clutch.
- Align teeth of reverse clutch drive plates before installing.





22. Install reverse clutch assembly on transmission case.
- Align teeth of high 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





1. Adjust total end play "T1".





a. With original bearing race installed, place Tool 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 bearing race. Lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. With needle bearing installed on high clutch drum, place Tool legs on machined surface of transmission case (with gasket). Then allow plunger to rest on needle bearing.
d. Measure gap between cylinder and 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 bearing race as necessary.
Available bearing race: Refer to Application and ID.





2. Adjust reverse clutch drum end play "T2".





a. Place Tool on machined surface of transmission case (with gasket). Then allow gauging cylinder to rest on reverse clutch drum. Lock cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. With original thrust washer installed on oil pump, place Tool legs onto machined surface of oil pump assembly. Then allow plunger to rest on thrust washer.
d. Measure gap between cylinder and plunger with feeler gauge. This measurement should give exact reverse clutch drum end play.
Reverse clutch drum end play "T2": 0.55 - 0.90 mm (0.0217 - 0.0354 inch)
- If end play is out of specification, decrease or increase thickness of thrust washer as necessary.
Available thrust washer: Refer to Application and ID.

Assembly 3





1. Install anchor end pin and lock nut on transmission case.
2. 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.





3. Place bearing race selected in total end play adjustment step on oil pump cover.
- Apply petroleum jelly to bearing race.
4. Place thrust washer selected in reverse clutch end play step on reverse clutch drum.
- Apply petroleum jelly to thrust washer.





5. Install oil pump assembly, baffle plate and gasket on transmission case.
6. Tighten oil pump fixing bolts to the specified torque.





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





8. Adjust brake band.
a. Tighten anchor end pin to the specified torque.
Anchor end pin:
Tightening Torque: 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.
Lock nut:
Tightening Torque: 31 - 36 Nm (3.2 - 3.7 kg.m, 23 - 27 ft. lbs.)





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





10. Install final drive assembly on transmission case.





11. Install oil tube on converter housing.





12. Install O-ring on differential oil port of transmission case.








13. Install converter housing on transmission case.
- Apply locking sealant (Loctite #518) to mating surface of converter housing.
14. 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 Automatic Transmission/Transaxle; Specifications.





c. Install accumulator pistons and return springs on transmission case.
- Apply ATF to inner surface of transmission case.
Return springs: Refer to Automatic Transmission/Transaxle; Specifications.





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





16. Install L & R oil tube and oil sleeve.
Tightening Torque: 5 - 7 Nm (0.5 - 0.7 kg.m, 43 - 61 inch lbs.)
17. 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.





d. Pass solenoid harness through transmission case and install terminal body on transmission case by pushing it.
e. Install stopper ring to terminal body.








f. Tighten bolts (l), (x) and (.).





18. Install oil pan.
a. Attach a 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 four bolts in a criss-cross pattern to prevent dislocation of gasket.
d. Tighten oil pan bolts and drain plug to the specified torque. Refer to Automatic Transmission/Transaxle; Service and Repair; Transaxle Overhaul; Major Overhaul.
19. Install PNP switch.





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





d. Use a 4 mm (0.16 inch) pin for this adjustment.
1. Insert the pin straight into the manual shaft adjustment hole.
2. Rotate PNP switch until the pin can also be inserted straight into hole in PNP switch.
e. Tighten PNP switch fixing bolts. Refer to Automatic Transmission/Transaxle; Service and Repair; Transaxle Overhaul; Major Overhaul.
f. Remove pin from adjustment hole after adjusting PNP switch.





20. Install oil charging pipe and oil cooler tube to transmission case..
21. Install torque converter.





a. Pour ATF into torque converter.
- Approximately 1 liter (1 - 1/8 US qt., 7/8 Imp qt.) 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: 19 mm (0.75 inch) or more