Part 1

Before assembly, make sure again that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.

Recommended ATF: DEXRON(R) II

GENERAL NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least fifteen minutes.
3. Apply automatic transmission fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. When working with FIPG material, you must observe the following.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

ASSEMBLY

INSTALLATION POSITION AND DIRECTION OF BEARINGS AND RACES:

1. INSTALL COMPONENTS OF FIRST AND REVERSE BRAKE PISTON




a. Coat three O-rings with ATF.
b. Install the two O-rings on No.1 piston.
c. Install the O-ring on the reaction sleeve.
d. Install No.1 piston to the reaction sleeve.




e. Coat a new O-ring with ATF and install it on No. 2 piston.
f. Install No.1 piston with the reaction sleeve onto No.2 piston.




g. Align the teeth of No. 2 piston into the proper grooves.
h. Being careful not to damage the O-rings, press in No.2 and No.1 first and reverse brake pistons into the transmission case.




i. Place the piston return spring onto No.2 piston.




j. Set SST as shown, and compress the return spring with SST.

SST 09350 - 30020 (09350 - 07050)

k. Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.




2. CHECK PISTON STROKE OF FIRST AND REVERSE BRAKE
Make sure the first and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.




3. INSTALL LEAF SPRING

4. INSTALL REAR PLANETARY GEAR UNIT WITH SECOND BRAKE DRUM, FIRST AND REVERSE BRAKE PACK AND OUTPUT SHAFT




a. Install one plate.
b. Install the flange, the rounded edge facing forward.
c. Re-install the plates and discs.

Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P




d. Install the second brake drum assembly.




e. Coat the assembled bearing and race with petroleum jelly and install it onto the case.





HINT: Assembled bearing and race diameter




f. Align the teeth of the second brake drum, flange, discs and plates as shown in the figure.




g. Align the splines of the transmission case and the assembled rear planetary gear, second brake drum, first and reverse brake pack and output shaft, indicated by A.




h. Hold the output shaft with wooden blocks or equivalents.




i. Using SST, install the snap ring.

SST 09350 - 30020 (09350 - 07060)

5. CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE




Using a feeler gauge, measure the clearance between the plate and second brake drum as shown in the figure.

Clearance: 0.50 - 1.02 mm (0.0197 - 0.0402 in.)

If the values are nonstandard, select another flange.





HINT: There are six different thicknesses for the flange.




6. INSTALL SECOND BRAKE PISTON SLEEVE




7. INSTALL NEW BRAKE DRUM GASKET




8. INSTALL N0.1 ONE-WAY CLUTCH

9. INSTALL FLANGE. PLATES AND DISCS OF SECOND BRAKE




a. Install the plate with the rounded edge side of the plate facing the discs.

Plate thickness: 2.5 mm (0.098 in.)

b. Install the plates and discs.

Install in order: P = Plate D = Disc
D-P-D-P-D-P-D

c. Install the flange with the rounded edge of the flange facing the disc.




d. Install the snap ring.




10. CHECK PACK CLEARANCE OF SECOND BRAKE
Using a feeler gauge, measure the clearance between the snap ring and flange as shown in the figure.

Clearance: 0.50 - 1.76 mm (0.0197 - 0.0693 in.)

If the values are nonstandard, check for an improper installation.




11. INSTALL PLANETARY SUN GEAR
While turning the planetary sun gear clockwise, install it into No.1 one-way clutch.

HINT: Confirm the thrust washer is installed correctly.

12. INSTALL FRONT PLANETARY GEAR




a. Coat the bearing and race with petroleum jelly and install them onto the front planetary gear.





HINT: Bearing and race diameter




b. Install the front planetary gear to the sun gear.




c. Using SST, install the snap ring.

SST 09350 - 30020 (09350 - 07070)

d. Remove the wooden blocks or equivalents under the output shaft.




e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.





HINT: Race diameter

13. INSTALL SECOND COAST BRAKE BAND




a. Install the second coast brake band to the case.




b. Install the pin through the brake band.




c. Install the E-ring to the pin.

14. INSTALL FRONT PLANETARY RING GEAR TO FORWARD AND DIRECT CLUTCH




a. Coat the bearing and race with petroleum jelly and install them onto the forward clutch.





HINT: Bearing and race diameter




b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.





HINT: Race diameter




c. Align the flukes of the discs in the forward clutch.




d. Align the splines of the front planetary ring gear with the flukes of the discs and install the front planetary ring gear to the forward clutch.

15. INSTALL ASSEMBLED DIRECT CLUTCH, FORWARD CLUTCH AND FRONT PLANETARY RING GEAR INTO CASE




a. Coat the bearing and race with petroleum jelly and install them onto the ring gear.





HINT: Bearing and race diameter




b. Install the assembled direct clutch, forward clutch and front planetary ring gear into the transmission case.




c. Using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum as shown in the figure.

Height: 5.3 - 7.3 mm (0.209 - 0.287 in.)

If the values are nonstandard, check for an improper installation.




d. Coat the assembled bearing and race with petroleum jelly and install it onto the forward clutch.





HINT: Assembled bearing and race diameter




16. INSTALL SECOND COAST BRAKE COVER. PISTON ASSEMBLY AND SPRING
a. Coat two new O-rings with ATF and install them to the cover.
b. Install the spring, piston assembly and cover to the case.
c. Using SST, install the snap ring.

SST 09350 - 30020 (09350 - 07060)

17. CHECK PISTON ROD STROKE OF SECOND COAST BRAKE




a. Place a mark on the second coast brake piston rod as shown in the figure.




b. Using SST, measure the stroke applying the compressed air (392 - 785 kPa, 4 - 8 kgf/sq.cm, 57 - 114 psi) as shown in the figure.

SST 09240 - 00020

Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

If it is still more than standard value, replace the brakeband with a new one.

18. INSTALL OVERDRIVE SUPPORT ASSEMBLY




a. Coat the race with petroleum jelly and install it onto the overdrive support assembly.





HINT: Race diameter




b. Using two bolts of SST, aim the bolt and oil holes of the overdrive support toward the valve body side, and align them with the bolt holes of the transmission case and insert.

SST 09350 - 30020 (09350 - 07020)

c. Temporarily tighten the two bolts.




d. Using SST, Install the snap ring as shown in the figure.

SST 09350 - 30020 (09350 - 07060)

HINT: Install the snap ring open end toward the valve body as shown in the illustration.




e. Torque the two bolts.

Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)




19. CHECK OUTPUT SHAFT
a. Using a dial indicator, measure the end play of the output shaft with hand.

End play: 0.27 - 0.86 mm (0.0106 - 0.0339 in.)

If the values are nonstandard, check for an improper installation.

b. Check to see that output shaft rotates smoothly.

20. INSTALL FLANGES, PLATES AND DISCS OF OVERDRIVE BRAKE




a. Install the 4.0 mm (0.1 57 in.) thick flange (flat ring) with the rounded edge side of the flange facing the discs.

b. Install the plates and discs.

Install in order: P = Plate D = Disc
D-P-D-P-D

c. Install the flange (stepped ring) with the flat side of the flange facing the disc.




d. Install the snap ring.