Transmission Assembly

Assembling





^ Install O-ring into planet carrier.

Note:
If you replace planet carrier adjust.





^ Insert axial needle bearing with washers and planet carrier in input gear.
1 Input gear is installed in transmission housing.
2 Axial needle bearing washer. Insert smooth side into input gear.
3 Axial needle bearing
4 Axial needle bearing washer
5 Install planet carrier with O-ring installed





^ Place washer and axial needle bearing on the "small sun gear" in the planet carrier.
^ Center washer and axial needle bearing in small sun gear.
^ Install adjustment washer for -B1-.
^ Insert inner and outer -B1- plates.
^ Insert pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates. Replacement parts must comply with transmission code letters.





^ Insert dished washer with rounded side facing toward free wheel.

Note:
Adjust -B1- when you replace

^ Transmission housing
^ Free wheel
^ Piston for reverse gear brake -B1-
^ or plates





^ Preload free wheel rollers with assembly ring 3267 and insert free wheel.





^ Install circlip for free wheel -b- and circlip for supporting tube -a-.
^ Insert circlip gaps over free wheel retaining wedge -arrow-
^ Install Transmission Vehicle Speed Sensor -G38-.
^ Check measurement of -B1-.





^ Insert components into transmission housing, starting with the large sun wheel down to small input shaft.
1 Large sun wheel
2 Needle bearing washer (collar faces large sun wheel)
3 Axial needle bearing
4 Large input shaft
5 Axial needle bearing
6 Needle bearing
7 Small input shaft





^ Install small drive shaft bolt -1- with washer -2- and shim -3-.
Tightening torque 30 Nm (22 ft. lbs.).

Note:
^ Insert shim -3- onto small input shaft shoulder -arrow-.
^ Shim, determining thickness refer to Planet carrier adjusting.

^ Check measurement of planet carrier.





^ Snap in axial needle bearing with thrust washer to 3rd and 4th gear clutch -K3-.
1 Axial needle bearing with thrust washer
2 3rd and 4th gear clutch -K3-





^ Be sure piston rings are correctly seated on -K3-.
^ Be sure that the ends of the piston rings are hooked together.





^ Insert 1st to 3rd gear clutches -K1- with 3rd and 4th gear clutch -K3-.





^ Insert shims -arrow- in -K1-.

Note:
^ Measure shim again when replacing -K1-, -K2- or ATF pump refer to Clutch play between -K1- and -K2-, adjusting.
^ 1 or 2 shims can be installed.





^ Insert reverse gear clutch -K2-.
^ Insert supporting tube for -K2- plate set -arrow- so that support tube groove engages in free wheel wedge.





^ Install -B2- plates as follows:
^ First insert a 3 mm thick outer plate.
^ Insert three spring caps in outer plate.
^ Insert compression springs -arrows-
^ Insert all, except last outer plate
^ Insert three spring caps on compression springs.
^ Insert last outer plate -3 mm thick-.
Determine shim.





^ Install shim -a-.
^ Insert retaining ring -b- onto shim. Smooth side must face shim.

Note:
^ Adjust 2nd and 4th gear brakes -B2- when replacing:
^ Transmission housing
^ Supporting tube
^ ATF pump
^ Retaining ring
^ For plates.

Replacement parts for these components must comply with transmission code letters.
^ Install ATF pump seal.
^ Install O-ring on ATF pump.





^ Install ATF pump.
^ Tighten bolts evenly crosswise.

Note:
Be sure that O-ring is not damaged. Tightening torque: 8 Nm (71 inch lbs.).

^ Then turn bolts 90° further.
Turning further can be done in several stages.
^ Check measurement of clutch play.





^ Insert sealing plugs with O-rings -arrow-.
Installation position: Lug engages in oil channel.
^ Install valve body with conductor strip.
^ Install oil pan.





^ Install cover -arrow- with gasket and spacer bushings.

Note:
Tightening torque: 8 Nm (71 inch lbs.)





^ Install ATF overflow pipe -1- and sealing plug -2- with new seal and tighten hand tight.
^ Install torque converter.
^ Transmission, installing.
^ Fill with 3 L (3.16 qt) of ATF.
^ Check ATF level and top-up.