Part 2

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE




a. Place SST and a dial indicator onto the overdrive brake piston as shown in the figure.

SST 09350 - 30020 (09350 - 06120)




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

Piston stroke: 1.32 - 1.62 mm (0.0520 - 0.0638 in.)

If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again.

If the piston stroke is nonstandard, select another flange.




HINT: There are seven different thickness for the flange.

22. INSTALL OVERDRIVE PLANETARY GEAR UNIT WITH OVERDRIVE DIRECT CLUTCH AND ONE-WAY CLUTCH




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




HINT: Assembled bearing and race diameter




b. Install the overdrive planetary ring gear.




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





HINT: Bearing and race diameter




d. Coat the race with petroleum jelly and install it onto the planetary gear.





HINT: Race diameter




e. Install the overdrive planetary gear with the overdrive direct clutch and one-way clutch.




f. Place SST on the transmission case.

SST 09350 - 36010 (09350 - 06090)

g. Using calipers, measure distance between the tops of SST and the clutch drum.

Standard distance: 15.5 - 16.5 mm (0.610 - 0.650 in.)

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




h. Coat the assembled bearing and race with petroleum jelly and install it onto the O/D direct clutch.





HINT: Assembled bearing and race diameter

23. INSTALL OIL PUMP INTO CASE




a. Coat the race with petroleum jelly and install it onto the oil pump.





HINT: Race diameter

b. Coat a new O-ring with ATF and install it around the pump body.




c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the O/D direct clutch drum.

NOTE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.

e. Install the seven bolts.

Torque: 22 N.m (220 kgf.cm, 16 ft.lbf)




24. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.




25. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil hole indicated in the figure.

HINT: When inspecting the O/D direct clutch, check with the C0 accumulator piston hole closed.

If there is no noise, disassemble and check the installation condition of the parts.

1. O/D direct clutch
2. Direct clutch
3. Forward clutch
4. O/D brake
5. Second coast brake
6. Second brake
7. First and reverse brake




26. INSTALL SPEED SENSOR ROTOR AND KEY
a. Install the key on the output shaft.
b. Align the groove of the sensor rotor with the key, install the sensor rotor.
c. Using snap ring pliers, install the snap ring.




27. INSTALL TRANSFER CASE
a. Clean contacting surface of any residual packing material using gasoline alcohol.
b. Apply seal packing to the case as shown in the figure.

Seal packing: Part No. 08826 - 00090, THREE BOND 1281 or equivalent




c. Install the case and torque the seven bolts.

Torque: 34 N.m (345 kgf.cm, 25 ft.lbf)

HINT: Each bolt length mm, in.) is indicated in the figure.

28. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEALS




a. Using SST, drive in two new oil seals.

SST 09350 - 30020 (09350 - 07110)

b. Coat the oil seal lip with MP grease.




c. Install a new spacer to the manual valve lever.
d. Install the manual valve lever shaft to the transmission case through the manual valve lever.




e. Using a hammer, drive in a new spring pin.




f. Match the manual valve lever indentation with the spacer hole and caulk them with the punch.
g. Make sure the shaft rotates smoothly.

29. INSTALL PARKING LOCK PAWL AND ROD




a. Install the E-ring to the shaft.
b. Install the parking lock pawl, shaft and spring.




c. Connect the parking lock rod to the manual valve lever.




d. Place the parking lock pawl bracket onto the transmission case and torque the three bolts.

Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)




e. Shift the manual valve lever to the P position, and confirm the planetary ring gear is correctly locked up by the lock pawl.

30. INSTALL ACCUMULATOR SPRINGS AND PISTONS







a. Coat new O-rings with ATF and install them to the pistons.
b. Install the four springs and pistons to the bore as shown in the figure.






HINT: The pistons are marked in relief with either C-0, B-0, C-2, B-2 to differentiate between them.




31. INSTALL CHECK BALL BODY AND SPRING




32. INSTALL THROTTLE CABLE
a. Coat a new O-ring with ATF and install it to the cable.
b. Install the cable to the case.

33. INSTALL VALVE BODY




a. Align the groove of the manual valve to the pin of the lever.
b. Connect the throttle cable to the cam.
c. Confirm the springs into the accumulator pistons are installed correctly.




d. Install the sixteen bolts.

HINT: Each bolt length (mm, in.) is indicated in the figure.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

34. INSTALL TRANSMISSION SOLENOID WIRING




a. Coat a new O-ring with ATF and install it to the grommet.
b. Insert the solenoid wiring to the case and install the stopper plate.




c. Connect the connectors to No.1, No. 2 and lock-up solenoids.




35. INSTALL OIL TUBE
Using a plastic hammer, install the tube into position shown in the figure.

NOTE: Be careful not to bend or damage the tube.

36. INSTALL OIL STRAINER AND GASKETS




a. Install two new gaskets to the oil strainer case.




b. Install the oil strainer case and torque the five bolts.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

HINT: Each bolt length (mm, in.) is indicated in the figure.




c. Install a new gasket to the oil strainer case.
d. Install the oil strainer and torque the eleven bolts.

Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf)

37. INSTALL OIL PAN




a. Install the six magnets as shown in the figure.




b. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.
c. Apply seal packing to the oil pan as shown in the figure.

Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent




d. Install and torque the nineteen bolts.

Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)

38. INSTALL TRANSFER AND PROPELLER SHAFT UPPER DUST COVER TO TRANSMISSION WITH NEW GASKET




a. Shift the two shift fork shafts to the high-four position.




b. Apply MP grease to the adaptor oil seal.
c. Place a new gasket to the transfer adaptor.
d. Install the transfer to the transmission.

HINT: Take care not to damage the oil seal by the input gear spline when installing the transfer.




e. Install and torque the bolts with the propeller shaft upper dust cover.

Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)

f. Install the dust cover bolt to the bracket.

Torque: 23 N.m (230 kgf.cm. 17 ft.lbf)




39. INSTALL ENGINE REAR MOUNTING

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




40. INSTALL DYNAMIC DAMPER

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)




41. INSTALL BREATHER HOSE
Connect the breather hose for transfer upper cover and transmission control retainer as shown.

Hose depth: 13 mm (0.51 in.)




42. INSTALL TRANSMISSION HOUSING
Install and torque the six bolts.

Torque: 14 mm bolt 34 N.m (345 kgf.cm. 25 ft.lbf)
17 mm bolt 57 N.m (580 kgf.cm, 42 ft.lbf)




43. INSTALL SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the speed sensor.
b. Install the speed sensor and stopper plate.




44. INSTALL UNIONS
a. Coat new O-rings with ATF and install them to each union.
b. Install the front union as shown in the figure.

Torque: 29 N.m (300 kgf.cm. 22 ft.lbf)

45. INSTALL FLUID TEMPERATURE SENSOR




a. Coat new O-ring with ATF and install it to the sensor.
b. Install and torque the fluid temperature sensor.




c. Install the rear union as shown in the figure.

Torque: 29 N.m (300 kgf.cm. 22 ft.lbf)

46. INSTALL NEUTRAL START SWITCH




a. Install the neutral start switch onto the manual valve lever shaft and temporarily tighten the adjusting bolt.
b. Install the grommet and a new lock washer. Install and torque the nut.

Torque: 6.9 N.m (70 kgf.cm. 61 in.lbf)




c. Using the control shaft lever, fully turn the manual lever shaft back and return two notches. It is now in neutral.




d. Align the neutral basic line and the switch groove, and tighten the adjusting bolt.

Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

HINT: Bend at least two of the lock washer tabs.




47. INSTALL TRANSMISSION CONTROL SHAFT LEVER

Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)