Part 1
Automatic Transmission Unit Assembly1. After applying A/T fluid to new 4 O-rings (1) and then install O-rings to 1st & reverse (No.4) brake inner piston (2) and brake reaction sleeve (3).
2. Install 1st & reverse (No.4) brake inner piston (2) to brake reaction sleeve (3).
CAUTION: Do not twist or deviate O-rings (1) during installation.
3. Install 1st & reverse (No.4) brake inner piston (1) including brake reaction sleeve (2) to transmission case.
CAUTION: Do not twist or deviate O-rings (3) during installation.
4. After applying A/T fluid to new O-ring (1) and then install O-ring to 1st & reverse (No.4) brake piston (2).
5. Install 1st & reverse (No.4) brake piston (2) to transmission case.
CAUTION: Do not twist or deviate O-ring (1) during installation.
6. Place 1st & reverse (No.4) brake return spring (1) on 1st & reverse (No.4) brake piston (2).
7. Place snap ring (1) on 1st & reverse (No.4) brake return spring and compress 1st & reverse (No.4) brake return spring (2) until the 1st & reverse (No.4) brake return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 1st & reverse (No.4) brake return spring to deform.
Special Tool (A): 09922-86010
8. Install snap ring (1).
9. Make sure 1st & reverse (No.4) brake piston and 1st & reverse (No.4) brake inner piston move smoothly when applying low pressure compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into oil hole of transmission case.
10. Using vernier calipers, measure the level difference (length A) between the upper surface of the 1st & reverse (No.4) brake piston and the hitting surface of 1st & reverse (No.4) brake flange at the both end across a diameter, and calculate the average.
NOTE:
^ 1st & reverse (No.4) brake piston must be installed tightly to the end face of transmission case.
^ Length A: 32.68 - 33.42 mm (1.287 - 1.316 inch)
11. Using vernier calipers, measure the thickness (length B) of the 1st & reverse (No.4) brake flanges, the 1st & reverse (No.4) brake plates and the 1st & reverse (No.4) brake discs altogether at the both end across a diameter, and calculate the average.
Pack Clearance 0.7 - 1.0 mm (0.028 - 0.039 inch)
^ Pack Clearance: Length A - Length B + 1.36 mm (0.0535 inch)
Length B: 30.59 - 31.62 mm (1.204 - 1.244 inch)
12. If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Available 1st & reverse (No.4) brake flange thickness
Available 1st & reverse (No.4) brake flange thickness:
13. After applying A/T fluid to thrust needle roller bearing (1), install thrust bearing race No.9 (1) to transmission case.
14. After applying A/T fluid to thrust needle roller bearing (2) and thrust needle roller bearing (1) and then install thrust needle roller bearing (2) and thrust bearing race No.9 (1) to rear planetary ring gear.
15. Install rear planetary gear assembly (1).
16. Place rear planetary flange (1) on rear planetary ring gear (2).
17. Install snap ring (1) by using flat end rod or the like.
18. Install thrust bearing race No.8 (1), thrust needle roller bearing (2), thrust bearing race No.7 (3) and planetary ring gear flange assembly (4) to intermediate shaft.
19. Install intermediate shaft (1) including planetary ring gear flange assembly (2) to transmission case.
20. Install 1st & reverse (No.4) brake flange "F", 1st & reverse (No.4) brake discs "D" and 1st & reverse (No.4) brake plates "P" in the following order.
F - D - P - D - P - D - P - D - P - D - P - D - P - D
21. Install 1st & reverse (No.4) brake flange (1) with flat side of flange facing to toward the upside.
22. Install brake plate stopper spring (1) to transmission case.
23. Install one-way No.3 clutch assembly (1) including one-way No.3 clutch inner race (2) to transmission case.
24. Install snap ring (1) by using special tool being sure not to align snap ring end gap with cut portion of transmission case.
25. Install thrust bearing race No.4 (3) to middle planetary gear assembly (1).
26. Install middle planetary gear assembly (1) including planetary sun gear (2) into intermediate shaft.
27. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to No.2 brake piston (2).
28. Install No.2 brake piston (2) to No.2 brake cylinder (3).
CAUTION: Do not twist or deviate O-ring during installation.
29. Install No.2 brake cylinder (2) including No.2 brake piston (1) to transmission case.
30. Install No.2 brake piston return spring (1) with spring side of plate facing to No.2 brake disc side.
31. Install No.2 brake discs D and No.2 brake plates "P" in the following order.
P - D - P - D - P - D
32. Install No.2 brake flange F with spring flange side of flange facing to No.2 brake disc side.
33. Compress No.2 brake piston return spring until the No.2 brake flange is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool.
CAUTION: Be careful when applying pressure, for overpressure will cause No.2 brake return spring to deform.
Special Tool
(A): 09927-66510
(B): 09913-85210
(C): 09920-13120
34. Place snap ring on No.2 brake flange being sure not to align snap ring end gap with cut portion transmission case.
35. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to No.1 brake piston (2).
36. Install No.1 brake piston (2) to No.1 brake cylinder (3).
CAUTION: Do not twist or deviate O-ring during installation.
37. Install No.1 brake cylinder (2) including No.1 brake piston (1) to transmission case.
38. Place No.1 brake piston return spring (3) on No.1 brake piston (1).
39. Compress No.1 brake piston return spring until the No.1 brake piston return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of No.1 brake piston return spring to deform.
Special Tool
(A): 09927-66530
(B): 09913-85210
(C): 09920-13120
40. Place snap ring on No.1 brake piston being sure not to align snap ring end gap with cut portion transmission case.
41. Install middle planetary ring gear (1) and front planetary ring gear flange (2) onto front planetary ring gear.
42. Install snap ring (1) by using flat end rod or the like.
43. After applying petroleum jelly to thrust needle roller bearing (1) so that thrust needle roller bearing does not fall off.
44. Install front planetary ring gear (2) and thrust needle roller bearing (1) into intermediate shaft.
45. Install thrust needle roller bearing (1) and thrust bearing race No.3 (2) onto front planetary ring gear.
46. Fit planetary carrier thrust washer No.2 (1) to front planetary gear assembly (2) with petroleum jelly so that planetary carrier thrust washer No.2 (1) does not fall off.
NOTE: Make sure projection part of planetary carrier thrust washer No.2 fit into holes of front planetary gear assembly.
47. Install front planetary gear assembly (2) and one-way No.1 clutch inner race (3) onto front planetary ring gear.
NOTE: Make sure align front planetary gear assembly trenches (4) and one-way No.1 clutch inner race holes (5).
48. Install No.1 brake discs "D", No.1 brake plates "P" and No.1 brake flange "F" in the following order.
P - D - P - D - P - D - F
49. Using vernier calipers, measure the level difference (length A) between the upper surface of the No.1 brake piston and the hitting surface of No.1 brake flange at the both end across a diameter, and calculate the average.
NOTE:
^ No.1 brake piston must be installed tightly to the end face of transmission case.
^ Length A: 15.29 - 15.77 mm (0.602 - 0.628 inch)
50. Using vernier calipers, measure the thickness (length B) of the No.1 brake flanges, the No.1 brake plates and the No.1 brake discs altogether at the both end across a diameter, and calculate the average.
Pack Clearance 0.42 - 0.72 mm (0.017 - 0.028 inch)
^ Pack Clearance: Length A - Length B Length B: 14.72 - 15.12 mm (0.58 - 0.595 inch)
51. If the pack clearance is out of specification, select another flange with suitable thickness from the list below and replace it.
Available No.1 brake flange thickness
Available No.1 brake flange thickness:
52. Install one-way No.1 clutch assembly (1) and planetary carrier thrust washer No.1 (2) to transmission case.
NOTE: Make sure projection part of planetary carrier thrust washer No.1 fit into holes of one-way No.1 clutch inner race.
53. After applying A/T fluid to new 2 O-rings (1) and then install O-rings to 2nd (No.3) brake piston (2).
54. Install 2nd (No.3) brake piston (2) to 2nd (No.3) brake cylinder (3).
CAUTION: Do not twist or deviate O-ring during installation.
55. Place 2nd (No.3) brake piston return spring (1) on 2nd (No.3) brake piston.
56. Compress 2nd (No.3) brake piston return spring (1) until the 2nd (No.3) brake piston return spring is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove by using special tool.
CAUTION: Be careful when applying pressure, for overpressure will cause plate section of 2nd (No.3) brake return spring to deform.
Special Tool (A): 09927-66540