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REASSEMBLY

NOTICE:
- The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
Recommended ATF: D-II or DEXRON III (DEXRON II)
- All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
- Dry all parts with compressed air-never use shop rags.
- When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.
- The recommended ATF or kerosene should be used for cleaning.
- After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.
- When disassembling a valve body, be sure to match each valve together with the corresponding spring.
- New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.
- All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
- All gaskets and rubber O-rings should be replaced.
- Do not apply adhesive cements to gaskets and similar parts.
- Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
- If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.
- Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts in place.
- When working with FIPG material, you must observe the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.





BEARING AND RACE INSTALLATION POSITION AND DIRECTION





1. INSTALL TRANSMISSION CASE
Install the transmission case in the overhaul attachment.
2. INSTALL NO. 1 AND NO. 2 1ST & REVERSE BRAKE PISTON





a. Coat 3 new O-rings with ATF.
b. Install the 2 O-rings on the No. 1 1st & reverse brake piston.
c. Install the O-rings on the reaction sleeve.
d. Install the No. 1 1st & reverse brake piston to the reaction sleeve.





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





g. Align the teeth of the No. 2 1st & reverse brake piston into the proper grooves.
h. Being careful not to damage the O-rings, and press the No. 2 and No. 1 1st & reverse brake pistons into the transmission case.





i. Place the piston return spring onto the No. 2 1st & reverse brake piston.





j. Set SST as shown, and compress the return spring with SST.
SST 09350-30020 (09350-07050)

NOTICE: Stop compressing when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.

k. Using a screwdriver, install the snap ring. Make sure the end gap of the snap ring is not aligned with the spring retainer claw.





3. CHECK PISTON STROKE OF 1ST & REVERSE BRAKE
Make sure the 1st & reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.





4. INSTALL BEARING AND RACE
a. Coat the assembled bearing & race with petroleum jelly.
b. Install it onto the case.





Assembled bearing & race diameter





5. INSTALL LEAF SPRING
6. INSTALL REAR PLANETARY GEAR, 1ST & REVERSE BRAKE PACK AND OUTPUT SHAFT
a. Install the flange with the rounded edge facing upward.





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





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





d. Face the snap ring upward (front side) and install the 2nd brake drum to the planetary gear.

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





e. Align the splines of the transmission case with assembled rear planetary gear, 1st & reverse brake with output shaft, indicated by A.





f. Install the assembled output shaft.





g. Rest the output shaft on wooden blocks.





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





7. CHECK PACK CLEARANCE OF 1ST & REVERSE BRAKE
Using a feeler gauge, measure the clearance between the plate and 2nd brake drum.
Clearance: 0.60 - 1.12 mm (0.0236 - 0.0441 inch)
If the clearance is non-standard, select another flange.

HINT: There are 6 different thicknesses for the flange.





Flange thickness





8. INSTALL 2ND BRAKE PISTON SLEEVE





9. INSTALL NEW BRAKE DRUM GASKET
a. Coat a new gasket with ATF.
b. Install the brake drum gasket.
10. INSTALL NO. 1 ONE-WAY CLUTCH





a. Install the No. 1 thrust washer onto the 2nd brake.





b. Install the No. 1 one-way clutch.
11. INSTALL 2ND BRAKE PACK





a. Install the 1.8 mm (0.071 inch) thick plate with the rounded edge side of the plate facing the disc.
b. Install the plates and 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 the snap ring.





12. CHECK PACK CLEARANCE OF 2ND BRAKE
Using a feeler gauge, measure the clearance between the snap ring and flange.
Clearance: 0.62 - 1.98 mm (0.0244 - 0.0780 inch)
If the clearance is non-standard, check for an improper installation.





13. 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.

14. 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





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





c. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
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.





Race diameter

15. INSTALL 2ND COAST BRAKE BAND





a. Install the 2nd coast brake band to the case.





b. Install the E-ring to the pin.
c. Install the pin through the brake band.
16. INSTALL DIRECT CLUTCH TO FORWARD CLUTCH





a. Install the assembled bearing & race and thrust washer to the forward clutch.





b. Install the direct clutch to the forward clutch.
17. 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





b. Coat the race with petroleum jelly and install it onto the front planetary ring gear.





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.
18. 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.





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, as shown in the illustration.
Height: 5.3 - 7.3 mm (0.209 - 0.287 inch)
If the distance is non-standard, check for an improper installation.





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





Assembled bearing & race diameter

19. INSTALL 2ND COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING





a. Coat 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, install the snap ring.
SST 09350-30020 (09350-07060)
20. CHECK PISTON ROD STROKE OF 2ND COAST BRAKE





a. Place a mark on the 2nd coast brake piston rod.





b. Using SST, measure the stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
SST 09240-00020
Piston rod stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)
If the stroke is more than the specified, replace the piston rod.
Piston rod length: 71.4 mm (2.811 inch) 72.9 mm (2.870 inch)
If it is still more than the standard value, replace the brake band with a new one.