AT Main Case (Part 1)
AT Main CaseREMOVAL
1. Remove the transmission assembly from vehicle body.
2. Pull out the torque converter clutch assembly.
3. Remove the input shaft.
4. Lift-up the lever on the rear side of transmission harness connector, and then disconnect it from the stay.
5. Disconnect the inhibitor switch connector from the stay.
6. Disconnect the air breather hose.
7. Remove the oil charger pipe.
8. Remove the ATF cooler inlet and outlet pipes.
9. Separate the converter case from the transmission case.
10. Remove the oil pump housing.
11. Take out the high clutch and reverse clutch assembly and thrust needle bearing.
12. Take out the high clutch hub and thrust needle bearing.
13. Take out the front sun gear and thrust needle bearing.
14. Pull out the leaf spring of the 2-4 brake while taking care not to bend the spring.
NOTE: Remove it while pressing down on the lower leaf spring.
15. Remove the snap ring and thrust needle bearing.
16. Take out the retaining plate of the 2-4 brake, drive plate and driven plate.
17. Take out the thrust needle bearing, planetary gear assembly and low clutch assembly.
18. Remove the 2-4 brake seal.
19. Remove the snap ring.
20. Take out the 2-4 brake spring retainer.
21. Remove the 2-4 brake piston and 2-4 brake piston retainer while taking care not to damage them.
22. Pull out the low & reverse brake leaf spring without bending it.
23. Remove the snap ring.
24. Take out the low & reverse brake 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 by hand.
26. Remove the spring retainer.
27. Take out the return spring.
28. Apply compressed air.
29. Take out the low & reverse brake piston.
INSTALLATION
1. Install the low & reverse piston.
CAUTION: Do not let the lip seal be damaged.
2. Install the return spring.
3. Install the spring retainer.
4. Install the one-way clutch inner race.
5. Tighten the socket head bolts evenly from the rear side of transmission case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
6. Place the front side of transmission body up.
7. Install the thrust needle bearing.
8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
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 retaining plate.
NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board of its weight less than 83 N (8.5 kgf, 18.7 lb).
11. Put the flat board on retaining plate.
12. Using the following formula, read the push/pull gage, and calculate "N".
N = 83 N (8.5 kgf, 18.7 lb) - Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb) : Load applied to clutch plate
Z: Flat board weight
13. Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and take the average value.
NOTE: If measuring in three locations, measure every 120°. If in four locations, measure every 90°.
14. Installation of the low & reverse brake:
Install the dish plate, driven plate, drive plate and retaining plate, and then secure them 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.
1. Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B.
2. Piston stroke calculation
Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new one and select and adjust the retaining plate to be within the default specification values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Turbo model
Initial standard. 2.7 - 3.2 mm (0.106 - 0.126 inch)
Limit thickness: 3.9 mm (0.153 inch)
Non-turbo model
Initial standard. 2.15 - 2.65 mm (0.085 - 0.104 inch)
Limit thickness: 2.95 mm (0.116 inch)
17. Install the leaf spring of the low & reverse brake.
18. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.
19. Install 2-4 brake piston spring retainer to the transmission case.
20. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.
ST 498677100 COMPRESSOR:
21. Install the planetary gear and low clutch assembly to the transmission case.
CAUTION: Install carefully while rotating the low clutch and planetary gear assembly slowly, paying special attention not to damage the seal ring.
22. Measure the amount of drive plate compression and record that value. (Non-turbo model)
1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2. 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.
3. Scale and record the weight "Z" of a flat board which will be put on retaining plate.
NOTE:
^ Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
^ Use a flat board of its weight less than 100 N (10.2 kgf, 22.5 lb).
4. Put the flat board on retaining plate.
5. Using the following formula, read the push/ pull gage, and calculate "N".
N = 100 N (10.2 kgf, 22.5 lbs.) - Z
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 lb) : Load applied to clutch plate
Z: Flat board weight
6. Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three locations or more spaced by equal distances and take the average value.
NOTE: If measuring in three locations, measure every 120°. If measuring in four locations, measure every 90°.
23. Install the pressure rear plate, 2-4 brake drive plate, driven plate, retaining plate and snap ring.
24. Install a new 2-4 brake seal to transmission case.
25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of brake.
26. Check the piston stroke. (Non-turbo model)
1. Measure the clearance B between the retaining plate and snap ring.
2. Piston stroke calculation Calculate with A and B dimensions recorded before. If the service limits from the calculation formula are exceeded, replace the drive plate and select and adjust the retaining plate to be with in standard values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard. 1.7 - 2.1 mm (0.067 - 0.083 inch)
Limit thickness: 2.3 mm (0.091 inch)
27. Measure the clearance between the retaining plate and snap ring. (Turbo model) If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate so that the clearance is within default standard values.
Initial standard. 0.8 - 1.2 mm (0.031 - 0.047 inch)
Limit thickness: 1.5 mm (0.059 inch)
28. Install the 2-4 brake leaf spring.
CAUTION: Make sure to install in the correct position.
29. Install the thrust needle bearing in the correct direction.
30. Install the front sun gear and the thrust needle bearing.
31. Apply Vaseline, then attach the thrust needle bearing to the high clutch hub. Install the high clutch hub by correctly engaging the splines of the front planetary carrier.
32. Install the thrust needle bearing in the correct direction.
33. Install the high clutch assembly and reverse clutch assembly.
34. Adjust the total end play.
35. Install the thrust needle bearing in the correct direction.
36. Install a new gasket along with the oil pump housing assembly.
37. Install the converter case assembly to the transmission case assembly.
38. Insert the inhibitor switch and transmission connector to the stay.
39. Install the air breather hose.
40. Install the ATF cooler pipe.
41. Install the oil charger pipe along with the 0ring.
42. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
43. Install the torque converter clutch assembly.
44. Install the transmission assembly to the vehicle.