Component Parts Installation (Part 1)

INSTALLATION OF COMPONENT PARTS
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 ATF: DEXRON(R) II

GENERAL NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could case fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least fifteen 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 place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, sure to use new gaskets and 0-rings.
7. Dry all parts with compressed air never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.

1. INSTALL BEARING TO TRANSAXLE HOUSING




a. Using SST and a press, press the bearing into the transaxle housing.

SST 09350 - 32014 (09351 - 32140)




b. Install the bearing stopper with a bolt.




2. INSTALL NEW GASKET AND OIL TUBE APPLY COVER
Install the new gasket and oil tube apply cover, and tighten the three bolts.

3. INSTALL OIL TUBES




a. Using a plastic hammer, install the three (A241E) or tour (A241L, A243L) oil tubes.

NOTE: Be careful not to bend or damage the tubes.




b. Install the four tube clamps.




4. INSTALL BEARING TO TRANSMISSION CASE
Using SST and a press, press the bearing into the transmission case.

SST 09350 - 32014 (09351 - 32090)




5. INSTALL B(4) ACCUMULATOR PISTON AND SPRING
6. INSTALL OIL GALLERY COVER AND GASKET




a. Clean the threads of the screws and case with white gasoline.
b. Install the new gasket and oil gallery cover in place.
c. Install and tighten the three bolts.




d. Apply seal packing or equivalent to the six screws.

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

e. Using a torx wrench, install and tighten the three screws.

7. INSTALL MANUAL VALVE SHAFT AND LEVER




a. Install the parking lock rod to the manual valve lever.
b. Slide in the shaft and install the washer, new spacer and manual lever.




c. Install the retaining spring.

HINT: Make sure there is a washer between the retaining spring and case.




8. INSTALL PIN
a. Using a punch and hammer, drive in the pin.
b. Position the spacer and stake it.




9. INSTALL CAM GUIDE BRACKET
Install the cam guide bracket and then insert the parking lock rod into the guide bracket.




10. INSTALL PARKING LOCK SLEEVE
Install the parking lock sleeve protruding portion up ward.




11. PLACE STOPPER PLATE
Place the stopper plate on the protruding portion of lock sleeve.




12. INSTALL GUIDE SLEEVE AND SPRING
13. INSTALL PARKING LOCK PAWL, PAWL SHAFT AND SHAFT CLAMP




a. Install the parking lock pawl.




b. Insert the parking lock pawl shaft and install the shaft clamp.

14. INSTALL FIRST AND REVERSE BRAKE PISTON




a. Install the two new 0-rings to the piston.
b. Coat the O-rings with ATF.




c. Place the piston into the bore of the case, facing the spring seats upward.
d. Using SST, press in the piston.

SST 09350 - 32014 (09351 - 32040)

HINT: Be careful not to damage the O-rings.

e. Remove SST.

15. INSTALL PISTON RETURN SPRING AND SNAP RING




a. Install the piston return spring assembly and snap ring in place.
b. Set SST, and tighten the bolt gradually to compress the springs.

SST 09350 - 32014 (09351 - 32040)

NOTE: Avoid bending the spring retainer by overtightening the bolt.




c. Using snap ring pliers, install the snap ring.

HINT: 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 SST.
SST 09350-32014 (09351-32040)

16. INSTALL UNDERDRIVE BRAKE PISTON




a. Coat the O-rings with ATF.
b. Install the two new O-rings to the piston.




c. Place the piston into the case with the cup side up, being careful not to damage the O-rings.




17. INSTALL RETURN SPRING
18. INSTALL PLATES, DISCS AND FLANGE




a. Install in order: D=Disc P=Plate F=Flange
P - D - P - D - P - D - F

HINT: Install the flange with the flat end facing downward.




b. Place SST on the flange, and compress the flange with a press.

SST 09350 - 32014 (09351 - 32070)

c. Install the snap ring.

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




19. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES
Using compressed air, confirm that the underdrive brake piston moves smoothly.




20. INSTALL OIL SEAL RINGS TO TRANSMISSION CASE
Install the two oil seals to the transmission case.




21. INSTALL UNDERDRIVE ONE-WAY CLUTCH




22. INSTALL ANTI-RATTLE CLIP
In the place shown in the figure (the space between the one-way clutch outer race and case), push the anti-rattle clip in until you hear the "click".




23. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Align the flukes of discs in the underdrive brake
b. Install the clutch assembly.
c. Turn the clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.




24. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the inner race.

Height: 17.3 - 18.2 mm (0.681 - 0.717 in.)

25. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH




a. Set a dial indicator (long type pick or SST) as shown.

SST 09350 - 32014 (09351 - 32190)




b. Applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 11 4 psi, 392 - 785 kPa), measure the underdrive clutch piston stroke.

Piston stroke:
A241E, A243L 1.21 - 1.55 mm (0.0476 - 0.0610 in.)
A241L 1.47-1.89 mm (0.0579 - 0.0744 in.)

If the piston stroke is less than limit, parts may have been misassembled. Check them.

If the piston stroke is nonstandard, select another flange.

HINT: There are two different flange thicknesses.

Flange thickness:
A2411 2.04 mm (0.0803 in.)
2.40 mm (0.0945 in.)

A241E, A243L 2.30 mm (0.0906 in.)
2.50 mm (0.0984 in.)
2.70 mm (0.1063 in.)




26. INSTALL BEARING WITH RACE
Install the thrust bearing with race, with the bearing facing upward.

Bearing: Outer diameter 45.2 mm (1.780 in.)
Inner diameter 31.0 mm (1.220 in.)




27. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.




28. INSTALL COUNTER SHAFT ASSEMBLY
a. Align the flukes of the discs in the underdrive clutch.
b. Install the counter shaft assembly.




29. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.

Height: 33.3 - 35.5 mm (1.311 - 1.398 in.)




30. INSTALL THRUST NEEDLE BEARING

Bearing: Outer diameter 57.7 mm (2.272 in.)
Inner diameter 41.0 mm (1.614 in.)




31. INSTALL COUNTER DRIVEN GEAR
Using SST and press, press in the driven gear.

SST 09350 - 32014 (09351 - 32100, 09351 - 32140)




32. TIGHTEN NEW LOCK NUT
a. Using SST to hold the driven gear, tighten a new lock nut.

SST 09330 - 00021 and 09350 - 32014 (09351 - 32032)

Torque: 1,600 kg-cm (116 ft-lb, 157 N.m)

b. Remove SST.




33. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.

End play: 0.23 - 0.89 mm (0.0091 - 0.0350 in.)




34. STAKE LOCK NUT
Using a punch and hammer, stake the lock nut.




35. INSTALL SNAP RING TO TRANSMISSION CASE
Using snap ring pliers, install the snap ring to the transmission case.