Part 2

22. INSTALL FLANGES, PLATES AND DISCS OF OVERDRIVE BRAKE

a. Install the 4.0 mm (0.157 in.) thick flange (flat ring) with the rounded edge side of the flange facing the disc.
b. Install the plates and discs.

Install in order: P = Plate D = Disc
7M-GE: D-P-D-P-D-P-D
7M-GTE: D-P-D-P-D-P-D-P-D

c. Install the flange (stepped ring) with the flat side of the flange facing the disc.

d. Install the snap ring.

23. CHECK PISTON STROKE OF OVERDRIVE BRAKE

a. Place SST and a dial indicator onto the overdrive brake piston as shown in the figure.
SST 09350-30020 (09350-06120)

b. Measure the stroke applying and releasing the corn- pressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown in the figure.

Piston stroke:
7M-GE: 1.40 - 1.70 mm (0.0551 - 0.0669 in.)
7M-GTE: 1.75 - 2.05 mm (0.0689 - 0.0807 in.)

If the piston stroke is less than the limit, parts may have been assembled incorrectly, check and reassemble again. If the piston stroke is nonstandard, select another flange.

HINT: There are seven different thicknesses for the flange.

24. REMOVE FLANGES, PLATES AND DISCS OF OVERDRIVE BRAKE

a. Remove the snap ring.

b. Remove the flanges, plates and discs.

25. INSTALL OVERDRIVE GEAR UNIT WITH OVERDRIVE DIRECT CLUTCH AND ONE-WAY CLUTCH

a. Coat the bearing and race with petroleum jelly and install them onto the overdrive support.

HINT: Bearing and race diameter

b. Install the overdrive planetary ring gear.

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

HINT: Bearing and race diameter

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

HINT: Race diameter

e. Install the over drive planetary gear with the overdrive direct clutch and one-way clutch.

f. Coat the assembled bearing and race with petroleum jelly and install it onto the O/D direct clutch.

HINT: Assembled bearing and race diameter

26. INSTALL FLANGES, PLATES AND DISCS OF OVERDRIVE BRAKE

d. Install the snap ring.

27. INSTALL OIL PUMP INTO CASE

a. Coat the race with petroleum jelly and install it onto the oil pump.

HINT: Race diameter

b. Coat the new O-ring with ATF and install it around the 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 into the O/D 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 the seven bolts.

Torque: 220 kg-cm (16 ft-lb, 22 N.m)

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

29. INSTALL THROTTLE CABLE
a. Coat a new O-ring with ATF and install it to the cable.
b. Install the cable to the case.

30. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil hole indicated in the figure.
1. O/D direct clutch
2. Direct clutch
3. Forward clutch
4. O/D brake
5. Second coast brake
6. Second brake
7. First and reverse brake

HINT: When inspecting the O/D direct clutch, check with the C0 accumulator piston hole closed.

If there is no noise disassemble and check the installation condition of the parts.

31. INSTALL ACCUMULATOR SPRINGS, PISTONS AND PINS

a. Coat new O-rings with ATF and install them to the pistons.
b. Install the four springs and four accumulator pistons to the bore as shown in the figure.

HINT: The pistons are marked in relief with either C(0), B(0), C(2) or B(2) to the discriminate between them.

c. Install the two springs to the C(0) accumulator piston.

32. INSTALL CHECK BALL BODY AND SPRING

33. INSTALL VALVE BODY

a. Align the groove of the manual valve to the pin of the lever.

b. Connect the throttle cable to the cam.
c. Confirm the springs into the accumulator pistons are installed correctly.

d. Install the seventeen bolts.

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

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

34. INSTALL SOLENOID WIRING

a. Coat a new O-ring with ATF and install it to the grommet.
b. Insert the solenoid wiring to the case and install the stopper plate.

c. Connect the connectors to No.1, No.2 and lock-up solenoid.

35. INSTALL OIL TUBES
Using a plastic hammer, install the two tubes into positions shown in the figure.

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

36. INSTALL OIL STRAINER AND GASKETS

a. Install two new gaskets to the oil strainer.

b. Install and torque the three bolts.

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

c. Clamp the solenoid wire.

37. INSTALL MAGNETS IN PAN
Install the four magnets in the indentations of the oil pan as shown in the figure.

38. INSTALL OIL PAN

a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.
b. Apply seal packing to the oil pan as shown in the figure.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

c. Install and torque the nineteen bolts.

Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)

39. INSTALL SENSOR ROTOR AND KEY

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

b. Install the key on the output shaft.
c. Align the groove of the sensor rotor with the key, install the sensor rotor.

40. INSTALL SPEEDOMETER DRIVE GEAR AND BALL

a. Install the lock ball on the output shaft.
b. Align the groove of the drive gear with the ball, install the drive gear.

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

41. INSTALL EXTENSION HOUSING AND NEW GASKET
Install the extension housing with a new gasket to the case.
Install and torque the six bolts.

HINT: The two lower bolts are shorter.

Torque: 370 kg-cm (27 ft-lb, 36 N.m)

42. INSTALL TRANSMISSION HOUSING
Install and torque the six bolts.

Torque:
10 mm Bolt 345 kg-cm (25 ft-lb, 34 N.m)
12 mm Bolt 580 kg-cm (42 ft-lb, 57 N.m)

43. INSTALL SPEED SENSOR
a. Coat a new O-ring with ATF and install it to the speed sensor.
b. Install the speed sensor. Install and torque the bolt.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

c. Connect the connector.

44. INSTALL SPEEDOMETER DRIVEN GEAR
a. Coat a new O-ring with ATF and install it to the speedometer driven gear.
b. Install the speedometer driven gear. Install and torque the bolt.

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

45. INSTALL UNIONS

a. Coat new two O-rings with ATF and install them to each union.
b. Install the front union.

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

c. Install the rear union as shown in the figure.

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

46. INSTALL NEUTRAL START SWITCH

a. Using the control shaft lever, fully turn the manual lever shaft back and return two notches. it is now in neutral.
b. Insert the neutral start switch onto the manual valve lever shaft and temporarily tighten the adjusting bolt.

c. Install the grommet and a new lock washer. Install and torque the nut.

Torque: 70 kg-cm (61 in.-lb, 6.9 N.m)

d. Align the neutral standard line and the switch groove, and tighten the adjusting bolt.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)

e. Bend the tabs of the lock washer.

HINT: Bend at least two of the lock washer tabs.

47. INSTALL CONTROL SHAFT LEVER

Torque: 160 kg-cm (12 ft-lb, 16 N.m)

48. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON INNER CABLE

HINT: New cable does not have a cable stopper staked.

a. Bend the cable so there is a radius of about 200 mm (7.78 in.).
b. Pull the inner cable lightly until a slight resistance is felt, and hold it.
c. Stake the stopper, 0.8 - 1.5 mm (0.031 - 0.059 in.) from the end of outer cable.

49. INSTALL WIRE HARNESS CLAMP AND THROTTLE CABLE CLAMP