Part 1

TRANSMISSION INSTALLATION






1. Install transmission case.
Install the transmission case in the overhaul attachment.





2. Install bearing and race.
a. Coat the assembled bearing and race with petroleum jelly.
b. Install it onto the case. Assembled bearing and race diameter
Bearing and race: mm (in.)
- Inside: 39.2 (1.543)
- Outside: 57.7 (2.272)





3. Install leaf spring.





4. Install rear planetary gear with first and reverse brake pack and output shaft.
a. Install the flange, the rounded edge facing upward.
b. Install the 6 plates and 6 discs.
Install in order: P = Plate D = Disc





c. Align the teeth on the flange, discs and plates.





d. face the snap ring upward (front side) and install the second brake drum to the planetary gear.

NOTICE: Face the oil hole in the drum towards the lower aide of the transmission case (the side the valve body is installed).






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





f. Install the assembled output shaft.





9. Rest the output shaft on wooden blocks.





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. Flange thickness






6. Install second brake piston sleeve.





7. Install new brake drum gasket.
a. Coat the gasket with ATF.
b. Install a new brake drum gasket.





8. Install No.1 one-way clutch.
a. Install the No.1 thrust washer onto the second brake.





b. Install the 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 5 plates and 5 discs.
Install in order: P = Plate D = Disc
- D-P-D-P-D-P-D-P-D-P
c. Install the flange with the rounded edge of the flange facing the disc.





d. Using a screwdriver, install 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.
Bearing and race diameter: mm (in.)
- Bearing
Inside: 35.5 (1.398)
Outside: 47.7 (1.878)
- Race
Inside: 33.7 (1.327)
Outside: 47.6 (1.874)





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





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





e. Coat the bearing race with petroleum jelly and install it onto the front planetary gear.
Race diameter: mm (in.)
- Race
Inside: 34.3 (1.350)
Outside: 47.8 (1.882)





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





b. Install the E-ring to the pin.
c. Install the pin through the brake band.





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.
Bearing and race diameter: mm (in.)
- Bearing
Inside: 26.0 (1.024)
Outside: 46.7 (1.839)
- Race
Inside: 26.0 (1.024)
Outside: 48.9 (1.925)





b. Coat the race with-petroleum jelly and install it onto the front planetary ring gear.
Race diameter: mm (in.)
- Race
Inside: 26.8 (1.055)
Outside: 47.0 (1.850)





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.
Coat the bearing and race with petroleum jelly and install them onto the ring gear.
Bearing and race diameter: mm (in.)
- Bearing
Inside: 32.6 (1.283)
Outside: 47.7 (1.878)
- Race
Inside: 30.6 (1.205)
Outside: 53.6 (2.110)





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 illustration.
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.
Assembled bearing and race diameter
Bearing and race diameter: mm (in.)
- Bearing and Race
Inside: 33.7 (1.327)
Outside: 47.6 (1.874)





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, 57 - 114 psi).
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)
If the stroke is more than specified, replace the piston rod.
Piston rod length:
- 71.4 mm (2.811 in.)
- 72.9 mm (2.870 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 bearing and race with petroleum jelly and install it onto the overdrive support assembly.
Bearing and race diameter: mm (in.)
- Bearing
Inside: 33.6 (1.323)
Outside: 50.3 (1.980)
- Race
Inside: 36.8 (1.449)
Outside: 50.9 (2.004)






b. Confirm the thrust washer is installed correctly.

HINT: Make sure that the lug shape matches the hole on the O/D support.






c. 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.
d. Temporarily tighten the 2 bolts.





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

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






f. Torque the 2 bolts.
Torque: 25 N.m (19 ft. lbs.)





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 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.
Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the discs.
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, 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 non-standard, select another flange.






HINT: There are 7 different thicknesses for the flange.






22. Install overdrive planetary gear unit with overdrive direct clutch and one- way clutch.
a. Coat the race with petroleum jelly and install them onto the overdrive support.
Race Diameter: mm (in.)
- Race:
Inside: 37.1 (1.461)
Outside: 59.0 (2.323)





b. Install the overdrive planetary ring gear.





c. Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.
Bearing and race diameter: mm (in.)
- Bearing
Inside: 26.0 (1.024)
Outside: 46.8 (1.843)
- Race
Inside: 24.2 (0.953)
Outside: 47.8 (1.882)





d. Coat the race with petroleum jelly and install it onto the planetary gear.
Race Diameter: mm (in.)
- Race:
Inside: 27.1 (1.067)
Outside: 41.8 (1.646)





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





f. Coat the assembled bearing and race with petroleum jelly and install it onto the overdrive direct clutch.
Bearing and race diameter: mm (in.)
- Bearing and race:
Inside: 28.9 (1.138)
Outside: 50.2 (1.976)





23. Install oil pump into case.
a. Coat the race with petroleum jelly and install it onto the oil pump.
Race Diameter: mm (in.)
- Race:
Inside: 28.1 (1.106)
Outside: 47.3 (1.862)
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.

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





e. Install the 7 bolts.
Torque: 22 N.m (16 ft. lbs.)





24. Check input shaft rotation.
Make sure the input shaft rotates smoothly.