Automatic Transmission

ASSEMBLY





1. Insert the parking lock gear (5).
2. Install the multi-disc holding clutch B2 (4) in the transmission housing (6).
3. Screw in the bolts (7). Tighten the bolts to 16 Nm (141 inch lbs.).





Note: During the measurement the snap ring (7) must contact the upper bearing surface of the groove in the outer multi-disc carrier (8).

Note: Pay attention to the sequence of discs. Place new friction multi-discs in ATF fluid for one hour before installing.

4. Insert and measure the spring washer (4) and multi-disc holding clutch pack B3 (2, 6).
a. Put the multi-discs for multi-disc holding clutch B3 together in the sequence shown in the illustration and insert individually.
b. Using a feeler gauge, determine the play "L" at three points between the snap-ring (7) and outer multi-disc (1). B3 clutch clearance should be 1.0-1.4 mm (0.0390.055 inch). Adjust the clearance as necessary.
c. Adjust with snap-ring (7), if necessary. Snap-rings are available in thicknesses of 3.2 mm (0.126 inch), 3.5 mm (0.138 inch), 3.8 mm (0.150 inch), 4.1 mm (0.162 inch), 4.4 mm (0.173 inch), and 4.7 mm (0.185 inch).
5. Place the intermediate plate (3) on the converter housing (2) and align.

Note: The intermediate plate can generally be used several times. The plate must not be coated with sealant





6. Check that the driving clutch K1 feed hole (1) in the inner hub of multi-disc holding clutch B1 is free before installing multi-disc holding clutch B1.





7. Install the multi-disc holding clutch B1 (5) onto the converter housing (2) and intermediate plate (3). Installed position of clutch B1 (5) in relation to converter housing (2) is specified by a plain dowel pin (arrow) in clutch B1 (5).
8. Install the bolts to multi-disc holding clutch B1 (5) to the converter housing (2).
9. Securely tighten the multi-disc holding clutch B1 (5) on the converter housing (2) to 10 Nm (88.5 inch lbs.).





10. Install a new torque converter hub seal (1) into the oil pump using Special Tool 8902A.
11. Install a new oil pump outer O-ring seal (2) onto the oil pump.
12. Install the oil pump (6) and securely tighten. Tighten the oil pump bolts to 20 Nm (177 inch lbs.).





13. Using grease, insert the teflon rings (7) in the groove so that the joint remains together.
14. Install the driving clutch K1 (1) onto multi-disc holding clutch B1.
15. Install the drive shaft with driving clutch K2 (6) and front planetary gear set (1).
16. Install the front washer (5) and the thrust needle bearing (4).
17. Install the output shaft with the center and rear planetary gear set and driving clutch K3 (3).
18. Using grease, install both the teflon rings (7) in the groove at the rear of the output shaft so that the joint stays together.
19. Mount the transmission housing on the torque converter housing.
20. Screw in the bolts through the transmission housing into the torque converter housing. Tighten the bolts to 20 Nm (177 inch lbs.).
21. Measure the end-play between the parking lock gear and the grooved ball bearing in order to select the proper geartrain end-play shim.





a. Place Special Tool 6311 (1) on the transmission housing. Using a depth gauge, measure from the gauge bar (1) to the parking lock gear (2).





b. Using a depth gauge, measure from the Special Tool 6311 (1) to the contact surface of the output shaft bearing (2) in the transmission housing.
c. Subtract the first figure from the second figure to determine the current end-play of the transmission. Select a shim such that the end-play will be 0.3-0.5 mm (0.012-0.020 inch). Shims are available in thicknesses of 0.2 mm (0.008 inch), 0.3 mm (0.012 inch), 0.4 mm (0.016 inch), and 0.5 mm (0.020 inch).
d. Install the selected end-play shim.
22. Screw in the bolts through the converter housing into the transmission housing. Tighten the bolts to 20 Nm (177 inch lbs.)
23. Install the output shaft bearing in the rear transmission housing.





a. Using Special Tool 9287 (1), install the output shaft bearing (2) into the transmission housing (3). The closed side of the plastic cage must point towards the parking lock gear.





b. Install the retaining ring (1). Ensure that the retaining ring (1) is seated correctly in the groove.
c. Check that there is no play between the bearing (2) and the retaining ring (1) using a feeler gauge.
d. There must be no play between the retaining ring (1) and the bearing (2). If the ring cannot be installed, a thinner ring must be used. If there is play between the ring (1) and the bearing (2), a thicker ring must be installed. Retaining rings are available in thicknesses of 2.0 mm (0.079 inch), 2.1 mm (0.083 inch), and 2.2 mm (0.087 inch).
24. Rotate the transmission so that the bellhousing is pointed upward and ensuring that the output shaft is allowed to move freely.





25. Measure the input shaft end-play.

Note: If the end-play is incorrect, the transmission is incorrectly assembled, or the geartrain end-play shim is incorrect. The geartrain end-play shim is selective.

a. Attach Special Tool 8266-18 (2) to Special Tool 8266-8 (1).
b. Attach Special Tool C-3339 (3) to Special Tool 8266-8 (1).
c. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Special Tool 8266-18 (2) to secure it to the input shaft.
d. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
e. Move the input shaft in and out and record reading. End play should be 0.3-0.5 mm (0.012-0.020 inch). Adjust as necessary.
26. Install the output shaft washer onto the output shaft.





27. Install a new transmission rear seal into the transmission case (2) with Special Tool 8902A (1).
28. Install the propeller shaft flange onto the output shaft.
29. Place the transmission in the PARK position before attempting to tighten the output shaft nut.
30. Install a new output shaft nut. Tighten the output shaft nut to 120 Nm (88.5 ft. lbs.).
31. Stake the output shaft nut to the output shaft as follows.





a. Place the Special Tool 9078 (2) Special Tool C-4171 onto the output shaft.
b. Rotate the Special Tool 9078 (2) until the alignment pin (3) engages the output shaft notch (4).





c. Press downward on the staking tool (1) until the staking pin (3) contacts the output shaft nut flange (2).
d. Strike Special Tool C-4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft.





32. Install the electrohydraulic unit (2). Tighten the bolts to 8 Nm (71 inch lbs.).
33. Install the oil filter (4).
34. Install the oil pan (5). Tighten the bolts to 8 Nm (71 inch lbs.).
35. Install the guide bushing (12).





36. Install the torque converter (1).