Part 1 of 2
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 lever behind the transmission harness connector and disconnect it from stay.
5) Disconnect inhibitor switch connector from stay.
6) Disconnect the air breather hose.
7) Remove the oil charge pipe.
8) Remove the oil cooler inlet and outlet pipes.
9) Separation of converter 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 leaf spring without folding.
NOTE:
Remove it while pressing down on lower leaf spring.
15) Remove snap ring and thrust needle bearing.
16) Take out 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 2-4 brake seal.
19) Remove snap ring.
20) Take out 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 snap ring.
24) Take out 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 & reverse piston without tilting.
NOTE:
Be careful not to damage the lip seal.
2) Install return spring.
3) Install spring retainer.
4) Install the one-way clutch inner race, spring retainer and return spring.
5) Tighten socket head bolts evenly from the rear side of the transmission case.
6) Place the front side of transmission body up.
7) Install 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 retaining plate, and read its scale. Make more than three measurements at even distance and take the average value.
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 8.5 kg (18.7 lbs.).
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 kgf, 18.7 lbs.) - Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 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 the dish plate, driven plate and retaining plate, and then secure them with snap ring.
NOTE:
Pay attention to the orientation of dish plate.
15) Apply compressed air intermittently to check for operation.
16) Place the same thickness of shim on both sides to prevent the plate from tilting, and then measure and record the clearance "B".
NOTE:
Do not press the shim downward with excessive force, or else the waveform of drive plates will be broken down.
17) Piston stroke calculation
Calculate with "A" and "B" dimensions which have been recorded before, and if the value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Non-turbo model
Initial standard:
2.15 - 2.65 mm (0.073 - 0.093 inch)
Limit thickness:
2.95 mm (0. 104 inch)
Turbo model
Initial standard:
2.70 - 3.20 mm (0.106 - 0.126 inch)
Limit thickness:
3.90 mm (0. 154 inch)
NOTE:
Do not make adjustment unless the drive plate is replaced.
18) Install the low & reverse brake leaf spring.
19) Install the 2-4 brake piston and 2-4 brake retainer by aligning hole of 2-4 brake retainer and hole of transmission case.
20) Install 2-4 brake piston return spring to transmission case.
21) Position snap ring in transmission. Using ST, press the snap ring into place.
ST 498677100 COMPRESSOR
22) Install planetary gear and low clutch assembly to transmission case.
CAUTION:
If installing it while rotating the low clutch and planetary gear assembly, rotate them slowly and pay attention not to damage the seal ring.
23) Selection of 2-4 brake retaining plate (Turbo model)
(1) Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
(2) Install a new 2-4 brake oil seal to transmission case.
(3) After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
(4) Check the clearance between the retaining plate and the snap ring.
NOTE:
Do not make adjustment unless the drive plate is replaced. If it exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
Initial standard:
0.8 - 1.2 mm (0.031 - 0.047 inch)
24) Selection of 2-4 brake retaining plate (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 plates.
NOTE:
^ Use a stiff flat board which does not bend against load.
^ Use a flat board of its weight less than 10.2 kg (22.5 lbs.).
(4) Put the flat board on retaining plate.
(5) Using the following formula, calculate N indicated on the push/pull gauge.
N = 100 N (10.2 kgf, 22.5 lbs.) - Z
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 lbs.): Load applied to clutch plate
Z: Flat board weight
(6) 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°.
(7) Install the pressure plate, drive plate, driven plate, retaining plate and snap ring.
(8) Install a new 2-4 brake oil seal to transmission case.
(9) After all 2-4 brake component parts have been installed, blow air intermittently and confirm the operation of brake.
(10) Measure and record the clearance "B" between the retaining plate and snap ring.
(11) Piston stroke calculation
Calculate with "A" and "B" dimensions which have been recorded before, and if the value exceeds the service limit, replace the drive plate with a new one and adjust it within the specification.
T = A + B
T: Piston stroke
A: Collapse amount of drive plate
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)
NOTE:
Do not make adjustment unless the drive plate is replaced.
25) Be careful not to mistake the location of the leaf spring to be inserted.
26) Install thrust needle bearing in the correct direction.
27) Install front sun gear and thrust needle bearing.
28) 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.
29) Install the thrust needle bearing in proper direction.
30) Install the high clutch assembly.
31) Adjust total end play.
32) Install the thrust needle bearing in proper direction.
33) Install the oil pump housing assembly.
34) Install the converter case assembly to the transmission case assembly.
35) Insert inhibitor switch and transmission connector into stay.
36) Install air breather hose.
37) Install oil cooler pipes.
38) Install the oil charge pipe with O-ring.
39) Insert the input shaft while rotating it lightly by hand, and then check the protrusion amount.
40) Install the torque converter clutch assembly.
41) Install the transmission assembly to the vehicle.