Part 1

4-SPEED GEAR UNIT INSTALLATION



1. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and pawl.

2. INSTALL MANUAL VALVE SHAFT
a. Coat the oil seal lip with the Multipurpose (MP) grease.





b. Install the manual valve shaft oil seal to the case.





c. Assembly a new collar to the manual valve lever.





d. Install the manual valve shaft to the transmission case through the manual lever.
e. Install the parking lock rod.





f. Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface.





g. Match the collar hole to the lever calking hollow and calk the collar to the lever.





h. Install the retaining spring.





3. INSTALL PARKING LOCK PAWL BRACKET

Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P position.

5. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE





a. Coat the new O-rings with Automatic Transmission Fluid (ATF).
b. Install the two O-rings on the piston.





c. Push the piston into the bore of the case, facing the spring seat upward.

6. INSTALL PISTON RETURN SPRING
a. Place the return spring and snap ring on the piston.





b. Place Special Service Tool (SST), and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)





c. Install snap ring. Visually check to make sure it is fully seated and centered by the three lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the spring retainer claw.
d. Remove the SST.





7. INSTALL SNAP RING TO TRANSAXLE CASE
8. INSTALL OVERDRIVE UNIT





a. Install the overdrive brake apply gasket and overdrive clutch apply gasket.





b. Install the overdrive brake drum to the case.
c. Install the new case gasket to the case.





d. Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 inch).





e. Place the new gasket onto the transaxle case.
f. Install the overdrive assembly with overdrive case to the transaxle case.





g. Coat the threads of 23 mm (0.91 inch) bolts with sealer.

Sealer: Part No. 08833-00070, THREE BOND 1324 or equivalent

h. Install and tighten the thirteen bolts.

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





9. CHECK INTERMEDIATE SHAFT END PLAY
a. Make sure that the intermediate shaft as thrust play in axial direction.

Thrust play: 0.47-1.50 mm (0.0185-0.0591 inch)

If the thrust play is not within specification, check the installation of intermediate shaft.
b. Make sure that the intermediate shaft turns smoothly.

10. INSTALL REAR PLANETARY GEAR





a. Install the rear planetary ring gear.
b. Place the bearing onto the ring gear.

Bearing outer diameter: 38.7 mm (1.524 inch)
Bearing inner diameter: 22.6 mm (0.890 inch)





c. Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear.





d. Install the rear planetary gear.

11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE





a. Install the seven plates and seven discs.
Install in order:
P=Plate D=Disc
P-D-P-D-P-D-P-D-P-D-P-D-P-D

b. Install the flange, facing the flat end downward.





c. Install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.

12. CHECK FIRST AND REVERSE BRAKE





a. Check the operation of the first and reverse brake piston.
Apply compressed air into the case passage and confirm that the piston moves.





b. Using a filler gauge, check that pack clearance of the first and reverse brake.

Clearance: 0.85-2.05 mm (0.033-0.081 inch)

13. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE





a. Place the No.2 one-way clutch with the shiny side of flange upward.





b. Install the one-way clutch while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If can not turn the planetary gear clockwise, check the installation of the one-way clutch.





c. Install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.

d. Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear.





14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO.1 ONE-WAY CLUTCH





a. Coat the thrust washer with petroleum jelly and install it on the No.1 one-way clutch.





b. Place the No.1 one-way clutch onto the rear planetary gear.

16. INSTALL SECOND BRAKE



a. Install the flange, facing the flat end upward.
b. Install the three discs and plates.
Install in order:
P=Plate D=Disc
D-P-D-P-D-P





c. Place the piston return spring into the case.





d. Place the second brake drum into the case.

HINT: Align the groove of the drum with the bolt.





e. Place the snap ring into the case so that end gap is installed into the groove.
f. While compressing the piston return spring over the drum with hammer handles, install the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of cutouts.





17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the second brake drum.





18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and confirm that the piston moves.

19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM



a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.





b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.





20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

HINT: After installing the oil seal ring, check that it moves smoothly.

21. INSTALL FRONT PLANETARY GEAR





a. Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear.

Bearing outer diameter: 45.5 mm (1.791 inch)
Bearing inner diameter: 30.1 mm (1.185 inch)





b. Install the planetary gear onto the sun gear.





22. INSTALL FRONT PLANETARY RING GEAR





23. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.

24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH



a. Coat the bearing with petroleum jelly and install it onto rear side of the forward clutch.

Bearing outer diameter: 47.6 mm (1.874 inch)
Bearing inner diameter: 31.4 mm (1.236 inch)





b. Coat the bearing with petroleum jelly and install it onto front side of the forward clutch.






HINT: There are two different-thick bearings for adjustment of the input shaft thrust play.





c. Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.





d. Mesh the hub of the forward clutch flukes of the direct clutch discs.

HINT: Be careful that the bearing and thrust washer do not get out of place.





e. Install the direct clutch and forward clutch into the case.

HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.





f. Check the distance between the direct clutch drum and the sun gear input drum.

Distance: Approx. 3 mm (0.12 inch)

25. INSTALL OIL PUMP INTO CASE





a. Coat a now O-ring with ATF and install it to the oil pump.





b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

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

Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)





26. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.

Thrust play: 0.25-0.90 mm (0.0098-0.0354 inch)

HINT: There are two different-thick bearings for end of stator shaft. If the thrust play is in excess of standard, select one of them.

Bearing thickness:
3.60 mm (0.1417 inch)
4.19 mm (0.1650 inch)

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

28. INSTALL SECOND COAST BRAKE PISTON



a. Coat the new O-rings with ATF and install it to the cover.
b. Install the outer spring with the piston.
c. Place the cover into the bore.





d. Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351 -32050)
e. Check that the front end of the piston rod contacts the center of the second brake band depression.
29. CHECK SECOND COAST BRAKE PISTON STROKE





a. Apply a small amount of paint to the piston rod at the point it meets the case, as shown in the illustration.





b. Using SST, measure the piston stroke applying and releasing the compressed air (392-785 kPa, 4-8 kgf/cm2 , 57-114 psi), as shown.
SST 09240-00020

Piston stroke: 2.0-3.5 mm (0.079-0.138 inch)

If the stroke is more than specified, replace the piston rod with a longer one.

Piston rod length:
9.52 mm (3.748 inch)
96.3 mm (3.791 inch)

If the still more than standard value, replace the brake band with a new one.