Part 2

TRANSMISSION ASSEMBLY (Continue)


Assembly






46. Install input clutch assembly (with front carrier assembly and rear internal gear) (1) to transmission case.

CAUTION:
Check that the needle bearing (2) is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.





47. Install 1st one-way clutch (1) to front brake hub (with under drive carrier) (2).
48. Check operation of 1st one-way clutch.
a. Hold 1st one-way clutch.
b. Check front brake hub for correct locking and unlocking directions.

Black Arrow :Unlocked
White Arrow :Locked

CAUTION:
If not shown in figure, check installation direction of 1st one-way clutch.





49. Install under drive carrier (with 1st one-way clutch) (1) to transmission case.





50. Install snap ring (1) to transmission case.

CAUTION:
Be careful not to damage snap ring.





51. Install front brake retaining plate (thin) (1), front brake drive plates (2), front brake driven plate (3), and front brake retaining plate (thick) (4) to transmission case.

Arrow :Front


CAUTION:
Check order of plates.





52. Install needle bearing (1) to under drive carrier assembly.

CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





53. Install under drive sun gear (1) to under drive carrier assembly.





54. Adjustment of total end play "T".
- Measure clearance between bearing race (1) and oil pump cover (2).
- Select proper thickness of bearing race so that end play is within specifications.





a. Measure dimensions "K" and "L", and calculate dimension "J".

1 : Transmission case
2 : Under drive sun gear
A : Straightedge

"J" : Distance between the oil pump fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
J = K - L






i. Measure dimension "K" between the converter housing fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.

CAUTION:
Never change the straight edge installation position before the completion of "L" measurement.





ii. Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
iii. Measure dimension "K" and "L" in at least three places, and take the average.
iv. Calculate dimension "J".

J = K - L





b. Measure dimensions "M1" and "M2", and calculate dimension "M".

1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge

"M" : Distance between the transmission case fitting surface of oil pump and the needle bearing on oil pump.

M = M1- M2





i. Place bearing race (1) and needle bearing (2) on oil pump assembly (3).





ii. Measure dimension "M1" between the transmission case fitting surface of oil pump and the end of oil pump.

1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge


CAUTION:
Measure dimension "M1" in at least three places, and take the average.





iii. Measure dimension "M2" between the needle bearing on oil pump and the end of oil pump.

1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge


CAUTION:
Measure dimension "M2" in at least three places, and take the average.
iv. Calculate dimension "M".

M = M1- M2





c. Adjust total end play "T".

1 : Bearing race
2 : Oil pump assembly

T = J - M
Total end play "T" : Total End Play "Total End Play".


- Select proper thickness of bearing race so that total end play is within specifications.

Bearing races : Total End Play "Total End Play".





55. Adjustment of front brake clearance "C".
- Measure clearance between front brake piston (1) and front brake retaining plate (2).
- Select proper thickness of front brake retaining plat so that clearance is within specifications.





a. Measure dimensions "O" and "P", and calculate dimension "N".

1 : Transmission case
2 : Front brake retaining plate
A : Straightedge

"N" : Distance between the oil pump fitting surface of transmission case and the front brake retaining plate.
N = O - P





i. Measure dimension "O" between the converter housing fitting surface of transmission case and the front brake retaining plate.

1 : Transmission case
2 : Front brake retaining plate
A : Straightedge


CAUTION:
Never change the straight edge installation position before the completion of "P" measurement.





ii. Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.

1 : Transmission case
A : Straightedge

iii. Measure dimension "O" and "P" in at least three places, and take the average.
iv. Calculate dimension "N".

N = O - P





b. Measure dimensions "Q1" and "Q2", and calculate dimension "Q".

1 : Front brake piston
2 : Oil pump assembly
A : Straightedge

"Q" : Distance between the transmission case fitting surface of oil pump and the front brake piston.
Q = Q1- Q2






i. Measure dimension "Q1" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.

1 : Front brake piston
2 : Oil pump assembly
A : Straightedge


CAUTION:
Measure dimension "M2" in at least three places, and take the average.





ii. Measure dimension "Q2" of the straightedge.

1 : Front brake piston
2 : Oil pump assembly
A : Straightedge

iii. Calculate dimension "Q".

Q = Q1- Q2






c. Adjust front brake clearance "C".

1 : Front brake piston
2 : Front brake retaining plate

C = N - Q
Front brake clearance "C" : Front Brake Clearance "Front Brake Clearance".

- Select proper thickness of retaining plate so that front brake clearance is within specifications.

Retaining plate : Front Brake Clearance "Front Brake Clearance".





56. Remove under drive sun gear (1) from under drive carrier assembly.





57. Install needle bearing (1) to under drive sun gear.

CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





58. Install O-ring (1) to oil pump assembly.





59. Install seal ring (1) to oil pump assembly.





60. Install bearing race (1) to oil pump assembly.





61. Install under drive sun gear (with needle bearing) (1) to oil pump assembly (2).





62. Install oil pump assembly (with under drive sun gear) to transmission case.

CAUTION:
Apply ATF to oil pump bearing.





63. Apply recommended sealant to oil pump assembly as shown in the figure.

Sealing Point: Genuine RTV silicone sealant or equivalent. Refer to Recommended Chemical Products And Sealants.

CAUTION:
Completely remove all moisture, oil and old sealant, etc. from the oil pump mounting bolts and oil pump mounting bolt mounting surfaces.





64. Tighten oil pump bolts (Arrow) to the specified torque.





65. Install O-ring to input clutch assembly.





66. Install converter housing to transmission case, and tighten converter housing bolts (Arrow) to the specified torque.





67. Connect TCM connector (A) to joint connector.





68. Install joint connector (1) to the control valve & TCM.

CAUTION:
Apply ATF to O-ring of joint connector.





69. Install the control valve & TCM (1) to transmission case.

CAUTION:





- Make sure that input speed sensor securely installs input speed sensor holes (A).
- Hang down output speed sensor harness toward outside so as not to disturb installation of the control valve & TCM.
- Adjust A/T assembly harness connector of the control valve & TCM to terminal hole of transmission case.





- Assemble it so that manual valve cutout is engaged with manual plate projection.





70. Install bolts and clip (1) to the control valve & TCM. Tighten bolt (E) to the specified torque before tightening the other than bolts.

Arrow :Front











71. Connect output speed sensor connector (A).
72. Engage output speed sensor harness with terminal clips (Arrow).





73. Pull down joint connector (1).

CAUTION:
Be careful not to damage connector.





74. Install snap ring (1) to joint connector (2).





75. Install magnets (1) in oil pan.
76. Install oil pan gasket to transmission case.

CAUTION:
- Never reuse oil pan gasket.
- Install it in the direction to align hole positions.
- Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.





77. Install oil pan (2) and clips (1) to transmission case.

White Arrow :Front
Black Arrow :Oil pan mounting bolt

CAUTION:
- Be careful not to pinch harnesses.
- Completely remove all moisture, oil and old gasket, etc. from oil pan mounting surface.





78. Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure after temporarily tightening them. Tighten oil pan mounting bolts to the specified torque.

Arrow :Front


CAUTION:
Never reuse oil pan mounting bolts.
79. Install drain plug to oil pan. Tighten drain plug to the specified torque.

CAUTION:
Never reuse drain plug gasket.





80. Pour ATF into torque converter.
- Approximately 2 liter (2-1/8 US qt, 1-3/4 Imp qt) of ATF is required for a new torque converter.
- When reusing old torque converter, add the same amount of ATF as was drained.





81. Install torque converter while aligning notches of torque converter with notches of oil pump.

CAUTION:
Install torque converter while rotating it.





82. Measure dimension "A" to make sure that torque converter is in proper position.

B : Scale
C : Straightedge

Dimension "A" : Torque Converter "Torque Converter".