Part 1

TRANSMISSION INSTALLATION






1. Install components of first and reverse brake piston.
a. Coat the 3 new O-rings with ATF.
b. Install the 2 O-rings on the No.1 piston.
c. Install the O-ring on the reaction sleeve.
d. Install the No.1 piston to the reaction sleeve.





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





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





j. Set Special Service Tool (SST) 09350-30020 (09350-07050) as shown, and compress the return spring with SST.
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 the flange, the rounded edge facing forward.
b. Reinstall the plates and discs.
- Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P-D-P
c. Install the second brake drum assembly.








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





e. Align the teeth of the second brake drum, flange, discs and plates.





f. 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.
g. Hold the output shaft with wooden blocks or equivalents.




h. Using SST 09350 - 30020 (09350 - 07060), install the snap ring.





5. Check pack clearance of first and reverse brake.
Using a feeler gauge, measure the clearance between the plate and second brake drum.
Clearance: 0.60 - 1.12 mm (0.0236 - 0.0441 in.)





If the values are non-standard, select another flange.

HINT: There are 6 different thicknesses for the flange.






6. Install second brake piston sleeve.





7. Install new brake drum gasket.





8. Install no.1 one-way clutch.





9. Install flange, plates and discs of second brake.
a. Install the 1.8 mm (0.071 in.) thick plate with the rounded edge side of the plate facing the disc.
b. Install the plates and discs.
- Plate thickness: 2.5 mm (0.098 in.)
- Install in order: P = Plate D = Disc
D-P-D-P-D-P-D-P-D-P





c. Using a screwdriver, install the snap ring.





10. Check pack clearance of second brake.
Using a feeler gauge, measure the clearance between the snap ring and flange.
Clearance: 0.62 - 1.98 mm (0.0244 - 0.0780 in.)
If the values are non-standard, check for an improper installation.





11. Install planetary sun gear.
While turning the planetary sun gear clockwise, install it into the 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.





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





c. Using SST 09350-30020(09350-07070), install the snap ring.
d. Remove the wooden blocks or equivalent under the output shaft.








e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear. Use the correct 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. Using needle-nose pliers, install the E-ring to the Din.








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. Use the correct race diameter.








b. Coat the race with petroleum jelly and install it onto the front planetary ring gear. Use the correct 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. Use the correct 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.
Height: 5.3 - 7.3 mm (0.209 - 0.287 in.)
If the values are non-standard, check for an improper installation.








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





16. Install second coast brake cover, piston assembly and spring.
a. Coat the 2 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 09350-30020(09350-07060), install the snap ring.





17. Check piston rod stroke of second coast brake.
a. Place a mark on the second coast brake piston rod.





b. Using SST 09240 - 00020, measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf-cm2, 57 - 114 psi).
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)
If it is still more than standard value, replace the brake band with a new one.





18. Install overdrive support assembly.





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





b. Using 2 bolts of SST 09350 - 30020 (09350 - 07020), 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.
c. Temporarily tighten the 2 bolts.





d. Using SST 09350 - 30020 (09350 - 07060), install the snap ring.

HINT: Install the snap ring open end toward the valve body.






e. Torque the 2 bolts.
Torque: 25 N.m (260 kgf-cm, 19 ft.lbs)





19. Check output shaft.
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 non-standard, 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 (0.157 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-P-D
c. Install the flange (stepped ring) with the flat side of the flange facing the disc.





d. Using a screwdriver, install the snap ring.





21. Check piston stroke of overdrive brake.
a. Place SST 09350 - 30020 (09350 - 06120) and a dial indicator onto the overdrive brake piston.








b. Measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf-cm2, 57 - 114 psi).
Piston stroke: 1.40 - 1.70 mm (0.0551 - 0.0669 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 7 different thicknesses for the flange.