Part 1
AT Main CaseREMOVAL
1. Remove the transmission assembly from the vehicle.
2. Extract the torque converter clutch assembly.
3. Remove the input shaft.
4. Lift-up the lever behind the transmission harness connector and disconnect it from stay.
5. Disconnect the inhibitor switch connector from stay.
6. Disconnect the air breather hose.
7. Remove the oil charger pipe.
8. Remove the oil cooler inlet and outlet pipes.
9. Separate the torque converter clutch case and transmission case.
10. Remove the oil pump housing.
11. Take out the high clutch, thrust needle bearing and reverse clutch assembly.
12. Take out the high clutch hub and the thrust bearing.
13. Take out the front sun gear and the thrust bearing.
14. Pull out the leaf spring without folding.
NOTE: Remove it while pressing the lower leaf spring down.
15. Remove the snap ring and thrust needle bearing.
16. Take out the retaining plate, drive plate and driven plate of 2-4 brake.
17. Take out the thrust needle bearing, planetary gear assembly and the low clutch assembly
18. Remove the 2-4 brake seal.
19. Remove the snap ring.
20. Take out the 2-4 brake return spring.
21. Remove the 2-4 brake piston and piston retainer without damaging.
22. Pull out the leaf spring without folding.
23. Remove the snap ring.
24. Take out the retaining plate, drive plate, driven plate and dish plate.
25. Turn the transmission case upside down, and then take out the socket bolts while holding the one-way clutch inner race with hand.
26. Take out the spring retainer.
27. Take out the return spring.
28. Apply compressed air.
29. Take out the low & reverse piston.
INSTALLATION
1. Install the low and reverse piston without tilting.
NOTE: Be careful not to damage the lip seal.
2. Install the return spring.
3. Install the spring retainer.
4. Install the one-way clutch inner race, spring retainer and return spring.
5. Tighten the socket head bolts evenly from the rear side of transmission case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)
6. Place the front side of transmission body upward.
7. Install thrust needle bearing.
8. Place dish plate, driven plate, and retaining plate on a surface plate in order.
9. Set the micro gauge to clutch, and read its scale.
NOTE: The value, which is read in the gauge at this time, is zero point.
10. Scale and record the weight Z of a flat board which will be put on plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 83 N (8.5 kgs, 18.7 lb).
11. Put the flat board on retaining plate.
12. Using the following formula, calculate N indicated on the push/pull gauge.
N = 83 N (8.5 kgs, 18.7 lb) - Z
N: Value indicated on push/pull gauge
83 N (8.5 kgs, 18.7 lbs.): Load applied to clutch plate
Z: Flat board weight
13. Press the center of retaining plate applying force of N with push/pull gauge, and then measure and record the height A. Make more than three measurements at even distance and take the average value.
NOTE: If three points, measure the height every 120°. If four points, measure the height every 90°.
14. Installation of the low & reverse brake: Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.
NOTE: Pay attention to the orientation of the dish plate.
15. Apply compressed air intermittently to check for operation.
16. Measure the clearance. Place the same thickness of shim on both sides to prevent the retaining plate from tilting.
17. Calculation of piston stroke
Calculate piston stroke from the recorded measurement A and B. and select the retaining plate so that the piston stroke is within the standard value. If the value from the equation exceeds the service limit, replace the drive plate with new one and adjust it to be within the standard.
T = A + C
T: Piston stroke
A: Amount of the flattened drive plate
B: Clearance between the retaining plate and the snap ring
TURBO model
Standard value: 2.7 - 3.2 mm (0.106 - 0.126 inch)
Limit value: 3.9 mm (0.154 inch)
NON-TURBO model
Standard value: 2.4 - 2.9 mm (0.094 - 0.114 inch)
Limit value: 3.6 mm (0.142 inch)
18. Install the low & reverse brake leaf spring.
19. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of 2-4 brake retainer and the hole of transmission case.
20. Install the 2-4 brake piston return spring to transmission case.
21. Position the snap ring in transmission. Using ST, press the snap ring into place.
ST 498677100 COMPRESSOR
22. Install the planetary gear and low clutch assembly to transmission case. Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.
23. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
24. Install a new 2-4 brake oil seal to transmission case.
25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
26. Check the clearance between the retaining plate and the snap ring.
NOTE:
Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.
If the clearance is above the limit, replace the drive plate with new one and adjust so that the clearance becomes the standard value.
Standard value: 0.8 - 1.2 mm (0.031 - 0.047 inch)
Allowable limit: 1.5 mm (0.059 inch)
27. Be careful not to mistake the location of the leaf spring to be inserted.
28. Install thrust needle bearing in the correct direction.
29. Install front sun gear and thrust needle bearing.
30. Install the high clutch hub. Attach the thrust needle bearing to the hub with Vaseline and install the hub by correctly engaging the splines of the front planetary carrier.
31. Install the thrust needle bearing in proper direction.
32. Install the high clutch assembly.
33. Adjust total end play.
34. Install the thrust needle bearing in proper direction.
35. Install the oil pump housing assembly.
36. Install the torque converter clutch case assembly to the transmission case assembly.
37. Insert inhibitor switch and transmission connector into stay.
38. Install air breather hose.
39. Install oil cooler pipes.
40. Install the oil charger pipe with O-ring.
41. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
42. Install the torque converter clutch assembly.
43. Install the transmission assembly to the vehicle.
DISASSEMBLY
HIGH CLUTCH, REVERSE CLUTCH
1. Remove the snap ring, and take out the retaining plate, drive plates, driven plates.
2. Remove snap ring, and take out the retaining plate, drive plates and driven plates.
3. Using ST1 and ST2, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
4. Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston.
5. Remove seal rings and lip seal from high clutch piston and reverse clutch piston.
PLANETARY GEAR, LOW CLUTCH
1. Remove snap ring from the low clutch drum.
2. Take out front planetary carrier.
3. Take out rear sun gear.
4. Take out rear planetary carrier, washer and thrust needle bearing.
5. Take out rear internal gear.
6. Remove the snap ring from the low clutch drum.
7. Compress the spring retainer, and remove the snap ring from the low clutch drum, by using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
8. Remove one-way clutch.
9. Install the one-way clutch inner race to the low clutch drum, and apply compressed air to remove the low clutch piston.
10. Remove the one-way clutch inner race.
11. Remove the one-way clutch after taking out the snap ring.
12. Remove the needle bearing after taking out the snap ring.
2-4 BRAKE
1. Separate 2-4 brake piston and piston retainer.
ONE-WAY CLUTCH INNER RACK
1. Remove seal rings.
2. Using ST, remove needle bearing.
ST 398527700 PULLER ASSY
ONE-WAY CLUTCH OUTER RACK
1. Remove the one-way clutch after taking out the snap ring.
2. Remove the needle bearing after taking out the snap ring.
ASSEMBLY
HIGH CLUTCH, REVERSE CLUTCH
NON-TURBO MODEL
1. Install seal rings and lip seal to high clutch piston and reverse clutch piston.
2. Install high clutch piston to reverse clutch piston.
3. Install reverse clutch to high clutch drum. Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation.