Automatic Transmission Unit Reassembly

Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.

Coat 2 new O-rings with the ATF, and install them to the brake piston No.4.

Install the brake piston No.4 to the reaction sleeve.

NOTICE:

Do not damage the O-rings.

With the brake piston No.4 underneath (the rear side), install the brake reaction sleeve and the brake piston No.4 to the transmission case.

NOTICE:

Do not damage the O-rings.

Coat a new O-ring with ATF.

Install the O-ring on the 1st and reverse brake piston.

With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

NOTICE:

Do not damage the O-ring.

Place the brake return spring onto the brake piston.

Place SST on the brake return spring, and compress the return spring.

SST

09350-30020(09350-07050)

Using SST, install the snap ring.

SST

09350-30020(09350-07070)

Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

Install the thrust needle roller bearing.

Thrust needle roller bearing diameter:

	Inside	Outside
Thrust needle roller bearing	40.6 mm (1.598 in)	58.0 mm (2.284 in.)

Install the thrust needle roller bearing.

Coat the thrust bearing race No.9 and thrust bearing race No.7 with petroleum jelly, and install it onto the rear planetary gear.

Bearing and race diameter:

	Inside	Outside
Bearing	20.8 mm (0.819 in)	38.5 mm (1.516 in.)
Race No.7	19.0 mm (0.748 in)	35.0 mm (1.378 in.)
Race No.9	43.3 mm (1.705 in)	56.7 mm (2.232 in.)

Install the rear planetary gear assembly.

Make sure that the 1st and reverse brake piston moves smoothly while applying compressed air intermittently into the transmission case.

Using vernier calipers, measure the level difference (length A) between the upper surface of the brake apply tube and the hitting surface of the brake flange No.4 at both ends across the 1st and reverse brake piston diameter, and calculate the average.

NOTICE:

The 1st and reverse brake piston must be securely installed to the end face of the transmission case.

HINT:

Length A = 23.32 to 24.18 mm (0.9181 to 0.952 in.)

Using vernier calipers, measure the combined thickness (length B) of the brake flanges, the 4 brake plates No.4 and the 5 brake discs No.4 at both ends across the diameter, and calculate the average.

HINT:

Length B = 23.64 to 26.00 mm (0.9303 to 1.0236 in.)

Pack Clearance = Length A - Length B - 0.18 mm (0.0071 in.) + 1.8 mm (0.071 in.)

Pack Clearance:

0.5 to 0.8 mm (0.0197 to 0.0315 in.)

If the pack clearance is outside the standard, select and install a brake flange that brings the pack clearance to be within the standard.

HINT:

There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Thickness H:

NO.	Thickness H	NO.	Thickness H
0	0 mm (0 in.)	8	0.8 mm (0.03150 in.)
2	0.2 mm (0.00787 in.)	10	1.0 mm (0.03937 in.)
4	0.4 mm (0.01575 in.)	12	1.2 mm (0.04724 in.)
6	0.6 mm (0.02362 in.)	14	1.4 mm (0.05512 in.)

Install the 4 plates, the 5 discs and the 2 flanges.

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P - D - P - D - F

Install the brake plate stopper spring.

Install the thrust bearing race No.8, the thrust needle roller bearing, the thrust bearing race No.7 and the planetary ring gear flange to the intermediate shaft.

Bearing and race diameter:

	Inside	Outside
Thrust bearing race No.7	29.6 mm (1.165 in.)	44.9 mm (1.768 in.)
Thrust needle roller bearing	27.8 mm (1.095 in.)	43.85 mm (1.726 in.)
Thrust bearing race No.8	27.8 mm (1.095 in.)	43.7 mm (1.721 in.)

Install the 1 way No.3 clutch assembly and the 1 way clutch inner race to the intermediate shaft.

Install the intermediate shaft with the 1 way No.3 to clutch assembly the case.

Using SST, install the snap ring.

SST

09350-30020(09350-07050,09350-07060)

Install the center planetary gear assembly and the planetary sun gear to the case.

Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

Race diameter:

	Inside	Outside
Race	55.2 mm (2.173 in.)	71.2 mm (2.803 in.)

Coat 2 new O-rings with ATF, and install them to the brake piston No.2.

Being careful not to damage the O-rings, press the brake piston No.2 into the brake cylinder No.2.

Install the brake piston No.2 to the case.

HINT:

Install the brake cylinder No.2 so that the projection protrudes from the upside of the transmission case.

Check that the oil pressure apply hole of the brake cylinder No.2 aligns with the oil pressure apply hole of the transmission case.

Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.

Install in order:

P = Plate, D = Disc, F = Flange

F -D - P - D - P - D - P - D - F

Using SST and a press, install the brake No.2 spring snap ring.

SST

09351-40010(09351-04010,09351-04020,09351-04040,09351-04050)

Inspect the piston stroke of the brake piston No.2.

1. Make sure that the brake piston No.2 moves smoothly while applying compressed air intermittently into the transmission case.
   





2. Using SST and a dial indicator, measure the moving distance (distance A) of the clutch disc at both ends across the diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
   

   SST

   09350-30020(09350-06120)
   

   Pack Clearance:

   0.6 to 0.9 mm (0.024 to 0.035 in.)
   

3. If the piston stroke is outside the standard, select and install a brake flange that brings the piston stroke within the standard.
   

   HINT:

   There are 8 types of flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

   Flange thickness:

   No.	Thickness
   0	2.0 mm (0.079 in.)
   1	2.1 mm (0.083 in.)
   2	2.2 mm (0.087 in.)
   3	2.3 mm (0.091 in.)
   4	2.4 mm (0.094 in.)
   5	2.5 mm (0.098 in.)
   6	2.6 mm (0.102 in.)
   7	2.7 mm (0.106 in.)

Coat 2 new O-rings with ATF, and install them on the brake piston No.1.

Be careful not to damage the O-rings. Press the brake piston No.1 into the brake cylinder No.1.

Install the brake piston return spring and the brake piston No.1 with the brake cylinder No.1 to the transmission case.

HINT:

Install the brake cylinder No.1 so that the projection protrudes from the upside of the transmission case.

Check that the oil pressure apply hole of the brake cylinder No.2 aligns with the oil pressure apply hole of the transmission case.

Using SST and a press, install the brake piston return spring snap ring.

SST

09351-40010(09351-04010,09351-04030,09351-04040,09351-04050)

Install the thrust needle roller bearing to the front planetary ring gear flange.

Thrust needle roller bearing diameter:

	Inside	Outside
Thrust needle roller bearing	58.5 mm (2.303 in.)	73.5 mm (2.894 in.)

Install the front planetary ring gear flange to the center planetary ring gear.

Using a screwdriver, install the snap ring.

Install the center planetary ring gear to the front planetary ring gear.

Using a screwdriver, install the snap ring.

NOTICE:

Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.

Install the front planetary ring gear to the case.

Install the thrust needle roller bearing and the thrust washer.

Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

Thrust needle roller bearing and race diameter:

	Inside	Outside
Bearing	38.6 mm (1.520 in.)	53.1 mm (2.091 in.)
Race	34.9 mm (1.374 in.)	50.8 mm (2.0 in.)

Install the front planetary gear assembly and the 1 way clutch inner race to the case.

Inspect the piston stroke of brake piston No.1.

1. Make sure the brake piston No.1 moves smoothly while applying compressed air intermittently into the transmission case.
   





2. Using vernier calipers, measure the level difference (length A) between the upper surface of the brake piston No.1 and the hitting surface of the brake flange No.1 at both ends across the brake piston No.1 diameter.
   

3. Using vernier calipers, measure the thickness (length B) of the brake flange, the 3 brake plates No.1 and the 3 brake discs No.1 altogether at both ends across the diameter, and calculate the average.
   

   HINT:

   Length A = 15.27 to 15.92 mm (0.60118 to 0.62677 in.)

   Length B = 14.50 to 15.54 mm (0.57087 to 0.691181 in.)

   Piston stroke = Length A - Length B

   Piston stroke:

   0.42 to 0.72 mm (0.017 to 0.028 in.)
   

   If the piston stroke is outside the specification, parts may have been assembled incorrectly, so check and reassemble again.
   If the piston stroke not still outside the specification range, select another flange that brings the piston stroke within the specification.
   

   HINT:

   There are 4 different thicknesses for the flange.

   Flange thickness:

   No.	Thickness
   0	2.0 mm (0.079 in.)
   1	2.2 mm (0.087 in.)
   2	2.4 mm (0.094 in.)
   3	2.6 mm (0.102 in.)

Install the 3 plates, the 3 discs and the flange.

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P

Install the 2nd brake cylinder to the case.

Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.

Install the 1 way clutch assembly and the thrust washer to the case.

Using SST, install the snap ring.

SST

09350-30020(09350-07060)

Install the flange, the 4 discs and the 4 plates to the case.

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P - D - P

Using a screwdriver, install the snap ring.

SST

09350-30020(09350-07060)

Install the 1 way No.2 clutch assembly and washer No.2 to the clutch drum and input shaft.

Hold the reverse clutch hub and turn the 1 way No.2 clutch assembly.

Check that the 1 way No.2 clutch assembly turns freely clockwise and locks counterclockwise.
If there is a problem with the 1 way clutch, replace it.

Install the 2 thrust needle roller bearings and thrust washer.

Coat the race and washer with petroleum jelly and install it onto the clutch drum and input shaft assembly.

Thrust needle roller bearing and diameter:

	Inside	Outside
Thrust needle roller bearing A	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
Bearing Race	37.0 mm (1.457 in.)	51.2 mm (2.016 in.)
Thrust needle roller bearing B	33.5 mm (1.319 in.)	48.0 mm (1.890 in.)

Install the clutch drum and input shaft onto the transmission case.

Install the thrust bearing race No.1 to the front oil pump.

Coat a new O-ring with ATF, and install it around the oil pump assembly.

Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.

Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

Install the 9 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Using SST and a hammer, drive in 2 new oil seals.

SST

09350-30020(09350-07110)

Coat the oil seal lips with MP grease.

Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

HINT:

When inspecting the O/D direct clutch, check with the C3 accumulator piston hole closed.

If there is no sound, disassemble and check the parts installation condition.

1. Clutch No.2 (C2)
   

2. Clutch No.4 (C4)
   

3. Clutch No.3 (C3)
   

4. Clutch No.1 (C1)
   

5. Brake No.3 (B3)
   

6. Brake No.1 (B1)
   

7. Brake No.2 (B2)
   

8. Brake No.4 (B4)
   

Install a new spacer to the manual valve lever.

Install the manual valve lever shaft to the transmission case through the manual valve lever.

Using a hammer, drive in a new spring pin.

Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.

Make sure that the shaft rotates smoothly.

Install the E-ring to the shaft.

Install the parking lock pawl, the shaft and the spring.

Connect the parking lock rod to the manual valve lever.

Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.

Torque:

7.3 N*m{74 kgf*cm, 65 in.*lbf}

Shift the manual valve lever to the P position, and confirm the planetary gear is correctly locked up by the lock pawl.

Install the 2 springs and the accumulator valve to the hole.

B-1 accumulator spring:

Inner spring:

Free length	Outer diameter	Color
44.98 mm (1.7709 in.)	11.30 mm (0.445 in.)	Natural

Outer spring:

Free length	Outer diameter	Color
46.36 mm (1.8252 in.)	17.10 mm (0.6732 in.)	Natural

Coat new O-rings with ATF, and install them to the piston.

Install the 2 springs and the accumulator piston to the hole.

C-3 accumulator spring:

Inner spring:

Free length	Outer diameter	Color
44.0 mm (1.732 in.)	14.0 mm (0.551 in.)	Yellow

Outer spring:

Free length	Outer diameter	Color
76.65 mm (3.0178 in.)	20.10 mm (0.7913 in.)	White

Coat 2 new O-rings with ATF, and install them to the piston.

Install the spring and the accumulator piston to the hole.

Accumulator spring:

Free length	Outer diameter	Color
64.5 mm (2.539 in.)	19.5 mm (0.768 in.)	Orange

Coat 2 new O-rings with ATF, and install them to the piston.

Install the spring and the accumulator piston to the hole.

Accumulator spring:

Free length	Outer diameter	Color
65.07 mm (2.5618 in.)	16.2 mm (0.6378 in.)	Pink

Install the check ball body and the spring.

Install the 3 brake drum gaskets.

Install the 3 transaxle case gaskets.

Align the groove of the manual valve lever with the pin of the manual valve.

Install the 19 bolts.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

HINT:

Each bolt length is indicated below.

Bolt length:

Bolt A:

25 mm (0.98 in.)

Bolt B:

36 mm (1.42 in.)

Bolt C:

45 mm (1.77 in.)

Bolt D:

50 mm (1.97 in.)

Install the detent spring and the detent spring cover with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new O-ring to the transmission wire.

Install the transmission wire harness.

Install the bolt.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Connect the 9 solenoid connectors.

Install the ATF temperature sensor.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the clamp and the 2 bolts.

Torque:

Bolt A:

6.4 N*m{65 kgf*cm, 57 in.*lbf}

Bolt B:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Coat a new O-ring with ATF, and install them to the valve body oil strainer assembly.

Install the oil strainer with the 4 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the 3 transmission oil cleaner magnets.

Install a new gasket on the oil pan.

Install and tighten the 20 bolts.

Torque:

4.4 N*m{45 kgf*cm, 39 in.*lbf}

Install a new gasket and the drain plug.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install a new gasket and the over flow plug.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Using SST and a hammer, install a new oil seal until it fits with the extension housing.

SST

09325-40010

Using SST and a press, install a new extension housing dust deflector.

SST

09950-60020(09951-01030)

Install the transmission case adapter radial ball bearing to the extension housing.

Using snap ring pliers, install a new snap ring.

Install the thrust needle roller bearing and the 2 bearing races.

Using a snap ring expander, install the snap ring.

Using a feeler gauge, measure the clearance between the snap ring and the race.

Clearance:

0.02 to 0.12 mm (0.0008 to 0.0047 in.)

HINT:

There are 12 different thicknesses for the race.

Flange thickness:

NO.	Thickness	NO.	Thickness
1	3.80 mm (0.1496 in.)	7	4.10 mm (0.1614 in.)
2	3.85 mm (0.1516 in.)	8	4.15 mm (0.1634 in.)
3	3.90 mm (0.1535 in.)	9	4.20 mm (0.1653 in.)
4	3.95 mm (0.1555 in.)	10	4.25 mm (0.1673 in.)
5	4.00 mm (0.1575 in.)	11	4.30 mm (0.1693 in.)
6	4.05 mm (0.1594 in.)	12	4.35 mm (0.1713 in.)

Clean the threads of the bolts and the case with white gasoline.

Apply FIPG to the extension housing as shown in the illustration.

FIPG:

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

Install the extension housing with 6 new bolts.

Torque:

34 N*m{345 kgf*cm, 25 ft.*lbf}

HINT:

Each bolt length is indicated below.

Bolt length:

Bolt A:

45 mm (1.772 mm)

Bolt B:

35 mm (1.378 mm)

Clean the threads of the bolts and the case with white gasoline.

Install the transmission housing with the 10 bolts.

Torque:

A {14 mm (0.551 in.) bolt}:

34 N*m{347 kgf*cm, 25 ft.*lbf}

B {17 mm (0.669 in.)bolt}:

57 N*m{581 kgf*cm, 42 ft.*lbf}

Install the breather tube.

Install the 2 bolts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.

Install the 2 transmission revolution sensors.

Install the 2 bolts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Coat new O-rings with ATF, and install them to the transmission oil cooler.

Install the transmission oil cooler with the 3 bolts.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf}

Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.

Install a new lock washer. Install and tighten the nut.

Torque:

6.9 N*m{70 kgf*cm, 61 in.*lbf}

Using the control shaft lever, move the manual lever shaft back all the way and then forward 2 notches. It is now in neutral.

Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Using a screwdriver, bend the tabs of the lock washer.

HINT:

Bend at least 2 lock washer tabs.

Install the control shaft lever RH, washer and the nut.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

Install the transaxle case cover upper with the 2 bolts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}