Part 1
COMPONENT PARTS INSTALLATIONDisassembly, inspection and assembly of each component group have been indicated in the preceding chapter. 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 Automatic Transmission Fluid: DEXRON (R) II
General Installation 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 and affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least 15 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 places.
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.
Bearing And Race Diameters
Basic Subassembly Reassembly
1. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEALS
a. Using Special Service Tools (SST), drive in 2 new oil seals as far as they will go.
SST 09350-20015 (09361-30010)
b. Coat the oil seal lips with MP grease.
c. Assemble 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. Drive in the pin to the shaft.
f. Match the spacer hole to the lever calking hollow and calk the spacer to the lever.
g. Make sure the manual valve lever shaft turns smoothly.
2. INSTALL COMPONENTS OF NO.3 BRAKE PISTON
a. Coat 5 new O-rings to the inner piston, reaction sleeve and outer piston.
NOTICE: The thinner O-ring goes on the outside of the reaction sleeve.
c. Assemble the inner piston, reaction sleeve and outer piston.
d. Stand the transmission case up.
e. Being careful not to damage the O-rings, press in the assembled pistons into the transmission case with hand.
f. Place the piston return spring onto the outer piston.
g. Set SST as shown, and compress the return springs with SST.
SST 09350-20015 (09369-20040)
h. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring seat claw.
3. CHECK NO.3 BRAKE PISTONS MOVING
Make sure the No.3 brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
4. INSTALL RACE
Coat the race with petroleum jelly and install it onto the transmission case.
Race diameter
5. INSTALL BRAKE APPLY TUBE
Install the tube, aligning its locking tab with the cutout of the case.
HINT: Make sure that the lips of the tube end are completely inserted into the outer piston.
6. INSTALL REAR PLANETARY GEAR UNIT AND OUTPUT SHAFT
a. Coat the 2 bearings with petroleum jelly and install them onto the rear planetary gear unit.
Bearings diameter
b. Install the rear planetary gear unit to the transmission case.
7. INSTALL PRESSURE PLATE, DISCS AND PLATES
a. Install the pressure plate, the flat surface facing forward.
b. Install the 5 discs and 4 plates.
Install in order: P = Plate D = Disc
D - P - D - P - D - P - D - P - D
8. CHECK PACK CLEARANCE OF NO.3 BRAKE
Using calipers, measure the clearance between the disc and transmission case.
Clearance: 0.61 - 2.64 mm (0.0240 - 0.1039 inch)
If the values are non-standard, check for an improper installation.
9. INSTALL FRONT PLANETARY GEAR UNIT
a. Remove the one-way clutch inner race from the planetary gear unit.
b. Install the front planetary gear unit.
HINT: Mesh the splines of the planetary gear with the flukes of the discs by rotating and pushing the planetary gear.
c. Position the notched tooth of the inner race toward the valve body side of the case. Push it into place.
HINT: The inner race is correctly installed if the snap ring groove is fully visible.
d. Using a screwdriver, install the snap ring.
10. INSTALL CENTER SUPPORT
a. Aim the bolt and oil holes of the center support toward the valve body side, and align them with the bolt and oil holes of the transmission case and insert.
b. Install the 2 bolts with the wave washers, and tighten the bolts.
HINT: First tighten the accumulator piston side.
Torque: 25 Nm (260 kgf.cm, 19 ft. lbs.)
11. INSTALL REAR CLUTCH
a. Coat the race with petroleum jelly and install it onto the rear clutch.
Race diameter
b. Install the rear clutch.
HINT:
- Mesh the splines of the rear clutch with the flukes of the disc by rotating and pushing the rear clutch.
- If the rear clutch is fully meshed with the center support, the splined center of the clutch will be flush with the end of the sun gear shaft.
12. INSTALL FRONT CLUTCH
a. Coat the bearings and race with petroleum jelly and install them onto the front clutch.
Bearing and race diameter
b. Install the front clutch.
HINT: Mesh the splines of the front clutch with the flukes of the discs by rotating and pushing the front clutch.
13. MEASURE INSTALLATION DISTANCE OF FRONT CLUTCH
a. Place SST on the transmission case.
SST 09350-20015 (09370-12010)
b. Using calipers, measure the distance between the tops of SST and the clutch drum. If the distance corresponds to that during disassembly, the front clutch is installed correctly.
14. INSTALL OVERDRIVE (O/D) CASE
a. Finger tighten the 2 SSTs on the transmission case.
SST 09350-20015 (09362-30011)
HINT: Remove the SST after installation of the oil pump.
b. Coat the races with petroleum jelly and install them onto the O/D case.
Races diameter
c. Insert the O/D case gently through the 2 guide bolts (SST) with cutout portion of the case facing the valve body side.
15. INSTALL O/D PLANETARY GEAR UNIT WITH O/D DIRECT CLUTCH AND ONE-WAY CLUTCH
a. Coat the thrust washer with petroleum jelly and install it onto the O/D planetary gear.
b. Coat the race with petroleum jelly and install it onto the O/D planetary gear.
Race diameter
c. Install the O/D planetary gear with the O/D direct clutch and one-way clutch.
HINT: Mesh the splines of the O/D planetary gear with the flukes of the discs by rotating and pushing the O/D planetary gear.
16. MEASURE INSTALLATION DISTANCE OF O/D DIRECT CLUTCH
a. Place SST on the overdrive case.
SST 09350-20015 (09370-12010)
b. Using calipers, measure distance between the tops of SST and the clutch drum. If the distance corresponds to that during disassembly, the overdrive direct clutch is installed correctly.
17. INSTALL TRANSMISSION HOUSING
a. Coat a new O-ring with ATF and install it around the overdrive case.
b. Install the transmission housing and 6 bolts.
c. Tighten the bolts.
Torque:
10 mm bolt 34 Nm (345 kgf.cm, 25 ft. lbs.)
12 mm bolt 57 Nm (580 kgf.cm, 42 ft. lbs.)
18. INSTALL OIL PUMP
a. Coat the assembled bearing and race with petroleum jelly and install it onto the oil pump.
Assembled bearing and race diameter
b. Coat a new O-ring with ATF and install it around the pump body.
c. Install the oil pump gently through the 2 guide bolts (SST).
d. Apply sealant to the bolt heads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Finger tighten the 5 bolts.
f. Using a screwdriver, remove the 2 SST.
g. Finger tighten the 2 bolts.
Torque: 21 Nm (215 kgf.cm, 16 ft. lbs.)
19. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.