Component Parts Installation (Part 2)

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.




36. INSTALL INTERMEDIATE SHAFT
37. INSTALL TRANSAXLE REAR COVER




a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or transmission case.
b. Apply seal packing to the rear cover as shown.

Seal packing: Part No.08833-00090. THREE BOND
1131, LOCTITE 518 or equivalent




c. Install and tighten the thirteen bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)

HINT: Each bolt length (mm) is indicated in the figure.







38. INSTALL NEW APPLY GASKETS
Install the two (A241E) or three (A241L, A243L) new apply gaskets.

HINT: The oil seal may be inserted with either end up or down.

39. INSTALL GOVERNOR DRIVEN GEAR




a. Install the thrust washer.




b. Install the governor driven gear.




40. CHECK INTERMEDIATE SHAFT
Make sure that the intermediate shaft turns smoothly.

41. INSTALL DISCS. PLATES AND FLANGE




a. Install the inner flange, facing the flat end upward.




b. Install in order: D=Disc P=Plate
D - P - D - P - D - P - D - P - D - P - D




c. Install the outer flange, the flat end facing downward.




42. INSTALL SNAP RING

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




43. CONFIRM THAT FIRST AND REVERSE BRAKE PISTON MOVES
Using compressed air, confirm that the first and reverse brake piston moves smoothly.

44. INSTALL REAR PLANETARY RING GEAR TO CASE







a. Coat the races and bearing with petroleum jelly, and install them onto the ring gear as shown.




b. Using a screwdriver, align the flukes of the discs.
c. Install the rear planetary ring gear into the case.

45. INSTALL REAR PLANETARY GEAR




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

HINT: Make sure that the different lug shapes match the openings on the gear.




b. Align the spline of the planetary gear with the flukes of the discs and install the planetary gear into the first and reverse brake discs.




c. Check that part A of the rear planetary gear is below the upper surface of the flange.

46. INSTALL NO.2 ONE-WAY CLUTCH




a. Place the one-way clutch into the case, the shiny side facing upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.

SST 09350 - 32014 (09351 - 32050)

c. Check that the planetary gear turns freely clockwise and locks counterclockwise.




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




47. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of the cutouts.

48. INSTALL SECOND BRAKE INTO CASE




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




49. INSTALL SECOND BRAKE PISTON RETURN SPRING
Install each of the springs over the protrusions in the case.




50. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the band guide so that its tip touches the case.




51. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.




52. INSTALL SNAP RING
a. Place the snap ring into the case so that the end gap is installed into the groove.
b. While compressing the piston return springs over the drum with hammer handles, install the snap ring.

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




53. INSTALL SECOND BRAKE DRUM GASKET
Drive in a new drum gasket until it makes contact with the second brake drum.




54. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.

55. INSTALL SECOND BRAKE HUB AND NO.1 ONE-WAY CLUTCH




a. Using a screwdriver, align the flukes of the discs in the second brake.




b. Align the spline of the hub with the flukes of the discs and install the hub to the second brake discs.




56. CHECK SECOND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the second brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)

57. 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.

58. INSTALL FRONT PLANETARY GEAR







a. Coat the race and bearing with petroleum jelly and install them onto the planetary gear.




b. Install the planetary gear.

59. INSTALL FRONT PLANETARY RING GEAR







a. Coat the races and bearing with petroleum jelly and install them onto the planetary ring gear.
b. Install the ring gear.






HINT: If the planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.







c. Coat the races and bearing with petroleum jelly and install them onto the tip of ring gear flange as shown.




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

61. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH







a. Coat the race and bearing with petroleum jelly, and install them onto the forward clutch drum.




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




c. Using a screwdriver, align the flukes of discs in the direct clutch.




d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

HINT: If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surfaces of the forward clutch.




e. Place the direct clutch and forward clutch into the case.
f. While rotating the forward clutch to mesh the front planetary ring gear and discs, install them.




g. Check the distance between A and B as shown in the illustration.

Distance: Approx. 3 mm (0.118 in.)




62. INSTALL DIFFERENTIAL
63. INSTALL TRANSAXLE HOUSING




a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.
b. Apply seal packing to the transaxle housing as shown.

Seal packing: Part No.08833-00090, THREE BOND 1131, LOCTITE 518 or equivalent.




c. Apply sealant to the bolt threads.

Sealant: Part No.08833-00080, Adhesive 1344. THREE BOND 1344, LOCTITE 242 or equivalent

d. Install and tighten the bolts.

Torque: 300 kg-cm (22 ft-lb, 29 N.m)

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

64. CHECK PRELOAD OF DIFFERENTIAL SIDE BEARING
65. INSTALL OIL PUMP INTO CASE




a. Coat the race with petroleum jelly and install it onto the stator shaft.

Race: Outer diameter 43.0 mm (1.693 in.)
Inner diameter 30.5 mm (1.201 in.)




b. Coat the new O-ring with ATF, and install it to pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

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


e. Install and tighten the six bolts.

Torque: 250 kg-cm (18 ft-lb, 25 N.m)




66. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play in axial direction.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)

If the play is not as specified, select and replace the race for the end of the stator shaft.

HINT: There are two different thicknesses of races. If necessary, select one of them.

Race thickness: 0.8 mm (0.031 in.)
1.4 mm (0.055 in.)




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

68. INSTALL SECOND COAST BRAKE PISTON




a. Install the two new O-rings to the cover.

HINT: Coat the O-rings with ATF before installing.




b. Install the spring, piston and cover into the bore.




c. Using SST, install the snap ring while pressing the cover.

SST 09350 - 31014 (09351 - 32050)

d. Check that the front end of the piston rod contacts the center of the second brake band depression.

69. MEASURE PISTON STROKE OF SECOND COAST BRAKE




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 (4-8 kg/sq.cm, 57-11 4 psi, 392-785 kPa) as shown.

SST 09240 - 00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

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

70. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Coat the new O-rings with ATF, and install them to the pistons.




b. Install the pistons and springs to the case.




A241E




A241L




A243L




c. Place the cover with a new gasket and gradually tighten the bolts a little a time in sequence.

HINT: Each bolt length (mm) is indicated in the figure.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)