Part 3 of 3
23. 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.
24. 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.
25. Adjustment of total end play and reverse clutch end play
1) 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".
2) 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.
3) Equation for calculation
Total end play: C = (L + 0.4 mm) l
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 mm) - m
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
26. Install the oil pump housing assembly.
1) 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.
2) 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.
3) Install both parts with dowel pins aligned. Make sure no clearance exists at the mating surface.
NOTE: Any clearance suggests a damaged seal ring.
4) Secure the housing with two nuts.
Tightening torque: 41 ± 3 Nm (30.4 ± 2.2 ft. lbs.)
3. Torque Converter Clutch Case And Transmission Case
1. Apply proper amount of liquid gasket (THREE BOND Part No. 1215 the entire torque converter clutch case mating surface,
NOTE: Make sure that the rubber seal and seal pipe are fitted in position.
2. Install the torque converter clutch case assembly to the transmission case assembly, and secure with six bolts and four nuts.
Tightening torque: 41 ± 3 Nm (30.4 ± 2.2 ft. lbs.)
CAUTION: When installing, be careful not to damage the torque converter clutch case bushing and oil seal.
4. Control Valve And Oil Pan
1. Install four accumulators with oil pans facing upward.
CAUTION: Be careful not to confuse the springs and installation positions.
2. Install and route the transmission harness.
CAUTION: Be careful not to damage the harness.
3. Install the control valve assembly.
1) Set the select lever in range "2".
2) Install the two brackets, ATF temperature sensor and the control valve by engaging the manual valve and manual lever, then tighten the 17 bolts.
Tightening torque: 8 ± 2 Nm (5.8 ± 0.7 ft. lbs.)
CAUTION:
- Be careful not to pinch the harness roll the gasket.
- Tighten the control valve mounting bolts evenly.
4. Install the oil strainer to the control valve. Be careful not to cut or break the 0-ring. Then tighten four bolts.
Tightening torque: 8 ± 1 Nm (5.8 ± 0.7 ft. lbs.)
5. Secure four connectors.
6. Install the oil cooler outlet pipe, and secure with two bolts.
Tightening torque: 8 ± 1 Nm (5.8 ± 0.7 ft. lbs.)
CAUTION: Fit the pipe into position. Be careful to avoid twisting.
7. Install the oil pan.
1) Attach the magnet at the specified position.
2) Apply proper amount of liquid gasket (THREE BOND Part No. 1217B) to the entire oil pan mating surface.
3) Install the oil pan to transmission case.
Tightening torque: 4.9 ± 0.5 Nm (3.6 ± 0.4 ft. lbs.)
NOTE: Tighten the bolts evenly.
5. Extension Section
NOTE: When installing new oil seal into extension case, press it with ST.
ST 498057300 INSTALLER
1. Install the filter in the extension case.
NOTE: Pay attention to the orientation of the filter.
2. Install the transfer clutch valve assembly, transfer pipe, and the stay then secure with five bolts.
Tightening torque: 8 ± 1 Nm (5.8 ± 0.7 ft. lbs.)
CAUTION:
- Be sure to tighten the going lead with one of these bolts.
- Be sure to use a new gasket.
3. Install the transfer clutch assembly to the case.
CAUTION: Be careful not to damage the seal rings.
NOTE: Insert the clutch assembly fully into position until the bearing shoulder bottoms.
6. Connection Of Each Section
1. Install oil pipe.
Tightening torque:
T1: 7.8 ± 1.0 Nm (5.8 ± 0.7 ft. lbs.)
T2: 24.5 ± 2.0 Nm (18.1 ± 1.4 ft. lbs.)
2. Install the reduction driven gear.
3. Install the parking pawl and shaft, set the select lever in the "P" range and tighten the drive pinion lock nut.
Tightening torque: 98 ± 5 Nm (72.3 ± 3.6 ft. lbs.)
NOTE: After tightening, stake the lock nut securely.
4. Install the reduction drive gear.
NOTE: Insert it fully into position until the bearing shoulder bottoms.
5. Measurement and adjustment of extension end play
1) Measure distance L from end of extension case and rear drive shaft with ST.
ST 398643600 GAUGE
L Measured value - 15 mm
2) Measure the distance 'l' from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
l = Measured value - 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE
3) Calculation equation:
T = (L + 0.4 mm) - l
T: Clearance between end of reduction drive gear and end of rear drive shaft.
L: Distance from end of extension case to end of rear drive shaft.
0.4: Gasket thickness
l: Height from end of transmission case to end of reduction drive gear.
Select suitable thrust needle bearing from among those listed in the following table to adjust clearance in the 0.05 - 0.20 mm (0.0020 - 0.0079 in) range.
6. Installation of extension case and transmission case.
1) Attach the selected thrust needle bearing to the end surface of reduction drive gear with vaseline.
2) Set the parking return spring.
3) Remove the transfer clutch from the extension case.
Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub,
NOTE: Be sure to engage the spline teeth correctly.
4) With gasket inserted between them, install the extension case to the transmission case.
CAUTION:
- Be sure to use a new gasket.
- After inserting the extension case halfway, connect the connector for duty solenoid C. Be careful not to jam the cord in the case.
- Be careful not to damage the rear drive shaft seal ring.
5) Tighten bolts to secure the case.
Tightening torque: 25 ± 2 Nm (18.1 ± 1.4 ft. lbs.)
7. Install the vehicle speed sensor 1.
Tightening torque: 7 ± 1 Nm (5.1 ± 0.7 ft. lbs.)
7. External Parts
1. Adjustment of inhibitor switch.
1. With the selector lever set to "N" adjust the inhibitor switch so that the hole of range select lever is aligned with the inhibitor switch hole with Special Service Tool(SST).
NOTE: Ensure that gauge moves properly.
(SST) 499267300 STOPPER PIN
2. With hole aligned, tighten three bolts to secure the inhibitor switch.
Tightening torque:
3.4 ± 0.5 Nm (0.35 ± 0.05 kg-m, 2.5 ± 0.4 ft. lbs.)
2. Clip the following cords and harness.
(A) Transmission harness
(B) Inhibitor switch harness
3. Install the oil cooler outlet pipe.
CAUTION: Be sure to use a new aluminum washer.
Tightening torque: 34 ± 3 Nm (3.5 ± 0.3 kg-m, 25.3 ± 2.2 ft. lbs.)
4. Install the oil cooler inlet pipe.
CAUTION: Be sure to use a new aluminum washer.
Tightening torque: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
5. Install the oil charge pipe.
CAUTION: Be careful not to damage the O-ring.
Tightening torque:
T1: 6.4 ± 0.5 Nm (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft. lbs.)
T2: 41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)
6. Adjustment of brake band
After tightening the brake band adjusting screw to 9 Nm (0.9 kg-m, 6.5 ft. lbs.) torque, back it off three turns. Then secure with a lock nut.
NOTE: When tightening the lock nut, be careful not to turn the adjusting screw,
Tightening torque: 26 ± 2 Nm (2.7 ± 0.2 kg-m, 19.5 ± 1.4 ft. lbs.)
7. Install the air breather hose.
(A) Air breather hose (Transmission case)
(B) Air breather hose (Oil pump housing)
8. Install the pitching stopper bracket.
Tightening torque: 41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)
9. Tighten the ATF and differential gear oil drain plugs.
Tightening torque:
T1: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
T2: 44 ± 3 Nm (4.5 ± 0.3 kg-m, 32.5 ± 2.2 ft. lbs.)
10. Insert the input shaft while turning lightly by hand.
CAUTION: Be careful not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
11. Install the torque converter clutch assembly.
1. Install the oil pump shaft to the torque converter clutch.
NOTE: Make sure the clip fits securely in its groove.
2. Holding the torque converter clutch assembly by hand, carefully install it to the torque converter clutch case. Be careful not to damage the bushing. Also avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover.
3. Rotate the shaft lightly by hand to engage the splines securely.
Dimension A:
3.9 - 4.1 mm (0.154 - 0.161 inch)
12. Fill ATF and differential gear oil.
NOTE: After filling oil, insert the oil level gauge into the oil inlet.
Differential gear oil capacity.
1.1 - 1.3 l (1.2 - 1.4 US qt, 1.0 - 1.1 Imp qt)
Automatic transmission fluid capacity.
2200 cc model;
7.9 - 8.2 l (8.4 - 8.7 US qt, 7.0 - 7.2 Imp qt)
2500 cc model;
9.5 - 9.8 l (10.0 - 10.3 US qt, 8.4 - 8.6 Imp qt)
Recommended fluid:
Dexron II or Dexron III type automatic transmission