Transmission Case Section

1. Press-fit the roller bearing to the transmission case with ST.
ST 398487700 DRIFT or equivalent.





2. Using a plastic hammer, force-fit the oil seal.





3. Install the manual plate and shaft, and secure with a spring pin.

CAUTION: Be careful not to damage the oil seal lip.

NOTE: After installation, make sure of smooth movement.





4. Assemble the manual lever and parking rod to the inside shaft, and secure with a nut.
Tightening Torque: 47 +/-2 Nm (34.7 +/-1.4 ft. lbs.).





5. Install the detention spring.
Tightening Torque: 6 +/-1 Nm (4.3 +/-0.7 ft. lbs.).

NOTE: Position the spring so that its center is aligned with the center of the manual plate.





6. Install the lathe cut seal rings to the I.D./O.D. of the low and reverse piston. Then install the piston into the case with a press, ST1 and ST2.
ST1 398673600 Compressor or equivalent.
ST2 498627000 Seat or equivalent.

CAUTION:
- Be careful not to tilt the piston when installing.
- Be careful not to damage the lip seal.





7. Install the one-way clutch inner race.
a. Using a press and ST1, install the needle bearing to the inner race.
ST1 398497701 Installer or equivalent.

NOTE: Use the following ST when removing.

ST 398527700 Puller Assy or equivalent.





b. Install four seal rings.

NOTE: Apply Vaseline to the groove of the inner race and to the seal ring after installation, so that the seal ring will not expand.





c. Place the spring retainer on the inner race. Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case.
Tightening Torque: 25 +/-2 Nm (18.1 +/-1.4 ft. lbs.).

CAUTION: Be sure to tighten evenly.





8. Install the band servo sub assembly.
9. Press the O.D. servo retainer into position with ST1 and ST2, and secure with a snap ring.
ST1 498677010 Compressor or equivalent.
ST2 399703600 Puller Assy or equivalent.

CAUTION: Perform the following operations with the transmission case set vertically on wooden blocks.





10. Installation of the low & reverse brake:
a. Install dish plate, driven plates, drive plates, retaining plate, and secure with a snap ring.

NOTE:
- Pay attention to the orientation of the dish plate.
- Driven Plate: 6
- Drive Plate : 6
- Dish Plate: 1





b. Apply compressed air intermittently to check for operation.








c. Check the clearance. (Selection of retaining plate)
Standard Value: 1.1 +/-1.7 mm (0.043 +/-0.067 inch).
Allowable Limit: 2.7 mm (0.106 inch)

NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.





11. Install the thrust needle bearing to the inner race.

CAUTION: Install thrust needle bearing in the correct direction.

12. Install the forward clutch drum.
a. Install carefully while rotating the drum slowly paying special attention not to damage the seal ring.
b. Installation is complete when the drum recedes 2.5 mm (0.098 inch) from the inner race surface.





13. Assemble the overrunning clutch hub.

CAUTION: Install thrust needle bearing in the correct direction.

NOTE:
- Join the thrust needle bearing and thrust washer with Vaseline, and then install them together.
- Make sure that the splices are engaged correctly.





14. Install the one-way clutch outer race.

NOTE: Make sure the forward clutch splices are engaged correctly.





15. Assemble the rear internal gear.
a. Join the thrust needle bearing and thrust washer to the gear with Vaseline, and install the gear while rotating it.
b. Securely engage the bearing with the dog of the overrunning clutch hub.

CAUTION: Install thrust needle bearing in the correct direction.

NOTE: Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 3.5 mm (0.138 inch).





16. Install the rear planetary carrier.
Attach the thrust needle bearing to the inside of the carrier with Vaseline. Then install the carrier while rotating slowly.

CAUTION: Install thrust needle bearing in the correct direction.





17. Install the rear sun gear.

NOTE: Install the gear with the oil groove facing up.





18. Install the front planetary carrier.
Attach the thrust needle bearings to both sides of the carrier with Vaseline. Install the carrier carefully, while aligning with the splines of the forward clutch drum, and while rotating the pinion.

CAUTION: Install thrust needle bearing in the correct direction.





19. Install the front sun gear.
Attach the thrust needle bearing to the gear, and install the gear while turning slowly.

CAUTION: Install thrust needle bearing in the correct direction.





20. Install the high clutch hub.
Attach the thrust needle bearing to the hub with Vaseline and install the hub by correctly engaging the splices of the front planetary carrier.

CAUTION: Install thrust needle bearing in the correct direction.





21. Install the high clutch assembly.

NOTE: Correctly engage the high clutch hub and clutch splices.





22. Install the reverse clutch assembly.

NOTE: Engage the high clutch outer spline with the reverse clutch spline and the front sun gear with the cut-out portion of the reverse clutch drum correctly when installing.





23. Install the brake band.

CAUTION: Be careful not to damage the brake band when installing.

NOTE: Install the strut to the band servo piston stem. Then tighten it temporarily to avoid tilting the band.





24. Adjustment of total end play and reverse clutch end play.
a. Measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum "L", and the distance to the top surface of the reverse clutch drum "M"





b. Measure the distance from the oil pump housing mating surface to the top surface of the oil pump cover with needle bearing, and to the thrust surface of the reverse clutch.
c. Equation for calculation





- Total end play: C=(L+0.4)-h (Units= mm)
C: Clearance between concave portion of high clutch and end of clutch drum support
L: Length from case mating surface to concave portion of high clutch
0.4: Gasket thickness
l: Height from housing mating surface to upper surface of clutch drum support





- Reverse clutch end play: C=(M+0.4)-m (Units= mm)
C: Clearance between oil pump housing hose and end of reverse clutch
M: Distance from case mating surface to upper surface of reverse clutch
0.4: Gasket thickness
m: Height from housing mating surface to thrust-receiving area of reverse clutch





25. Install the oil pump housing assembly.
a. After completing end play adjustment, insert the bearing race in the recess of the high clutch. Attach the thrust washer and thrust needle bearing to the oil pump cover with Vaseline.
b. After correctly installing the gasket to the case mating surface, carefully install the oil pump housing assembly. Be careful to avoid hitting the drive pinion against the inside of the case.

CAUTION:
- Be careful not to damage the seal ring.
- Be sure to use a new gasket.

c. Install both parts with dowel pins aligned. Make sure no clearance exists at the mating surface.

NOTE: Any clearance suggests a damaged seal ring.





d. Secure the housing with two nuts.
Tightening Torque: 41 +/-3 Nm (30.4 +/-2.2 ft. lbs.).