Part 4

OVERHAUL





75. INSTALL THRUST NEEDLE ROLLER BEARING NO.1.
a. Install the 2 races and bearing onto the rear planetary ring gear.





Bearing and race diameter: mm (in.)

76. INSTALL OUTPUT SHAFT ASSY





a. Install the thrust washer to the output shaft with center & rear planetary gear.





b. Install the output shaft with center & rear planetary gear.
77. INSTALL 2ND BRAKE DISC SET





a. Install the spring to the case.
b. Install the flange, clutch plate, 5 plates and 6 discs from the case.
Install in order: P = Plate, D = Disc
Flange - D - P - D - P - D - P - D - P - D - P - D - Flange





Flange thickness: mm (in.)





78. INSTALL FRONT PLANETARY SUN GEAR SUB-ASSY
a. Install the front & center planetary sun gear from the case.
79. INSTALL FRONT PLANETARY GEAR ASSY





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





b. Install the front planetary gear and 2 washers from the case.





80. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSY
a. Lay the transmission case.





81. INSTALL BRAKE DRUM SUB-ASSY NO. 1 NO.2
a. Install the multiple disc brake to the case.
82. INSTALL 1 WAY CLUTCH ASSY





a. Install the No.1 one-way clutch to the multiple disc brake.





b. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)





83. INSTALL BRAKE DRUM GASKET NO.2
a. Coat new gasket with ATF
b. Install the brake drum gasket No. 2.





84. INSTALL BRAKE DRUM GASKET
a. Coat new gasket with ATF
b. Install the brake drum gasket.
85. INSTALL SUN GEAR INPUT DRUM SUB-ASSY





a. Install the thrust washer.





b. Install the sun gear input drum.





c. Coat the bearing, 2 races with petroleum jelly and install them onto the sun gear input drum.





Bearing and race diameter: mm (in.)

86. INSTALL 2ND COAST BRAKE BAND ASSY





a. Install the 2nd coast brake band to the transmission case.





b. Install the E-ring to the pin.
c. Install the pin through the brake band.





d. Using a needle nose plier, install the E-ring to the pin.
87. INSTALL INPUT SHAFT ASSY





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





Assembled bearing & race and diameter: mm (in.)





b. Install the assembled bearing & race and thrust washer to the input shaft assy.





Assembled bearing & race diameter: mm (in.)

88. INSTALL DIRECT CLUTCH ASSY





a. Install the direct clutch assy and forward clutch hub to the input shaft assy.





b. Insert the direct clutch assy with input shaft assy to the case.





c. With the case set upright, using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum.
Height: 4.1 - 6.0 mm (0.16 - 1.236 inch)
If the height is non-standard, check for improper installation.
89. INSTALL 2ND COAST BRAKE PISTON





a. Coat 2 new O-rings with ATF and install them to the cover.
b. Install the spring, piston assembly and cover to the case.





c. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)
90. INSPECT PISTON STROKE OF 2ND COAST BRAKE





a. Place a mark on the 2nd coast brake piston rod.





b. Using SST, measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).
SST 09240-00020
Piston rod stroke: 2.0 - 3.0 mm (0.079 - 0.118 inch)
If the stroke is more than the specified, replace the piston rod with a longer one.





Piston rod length: mm (in.)

If it is still more than standard value, replace the brake band with a new one.
91. INSTALL OVERDRIVE SUPPORT SUB-ASSY





a. Coat the assembled bearing & race and race with ATF and install them onto the O/D support sub-assy.





Assembled bearing & race and race diameter: mm (in.)





b. Coat the thrust washer with petroleum jelly and install it onto the O/D support sub-assy.

HINT: Make sure that the lug shapes match the holes on the O/D support sub-assy.





c. Using 2 bolts of SST, face the bolt and oil holes of the O/D support sub-assy toward the valve body side, align them with the bolt holes of the transmission case and install the bolts.
SST 09350-30020 (09350-07020)





d. Install the 2 bolts.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)





e. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)





92. INSPECT OUTPUT SHAFT ASSY
a. Using a dial indicator, measure the end play of the output shaft with hand.
End play: 1.63 - 2.89 mm (0.064 - 0.114 inch)
If the values are non-standard, check for improper installation.
b. Check to see that output shaft rotates smoothly.
93. INSTALL OVERDRIVE BRAKE CLUTCH DISC





a. Install the O/D brake pack (1 flange, 4 discs and 4 plates).
Install in order: P = Plate, D = Disc
P - D - P - D - P - D - P - D
b. Install the flange (stepped ring) with the flat side of the flange facing the disc.
c. Install the spring to the case.





d. Using a screwdriver, install the snap ring.

NOTICE: Be sure the end gap of the snap ring is not aligned with cutout portion of the brake drum.

94. INSPECT OVERDRIVE BRAKE PISTON





a. Place SST and a dial indicator onto the O/D brake piston.
SST 09350-30020 (09350-06120)





b. Measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).
Piston Stroke: 1.40 - 1.70 mm (0.055 - 0.067 inch)
If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
If the piston stroke is non-standard, select another flange.

HINT: There are 7 different thickness for the flange.





Flange thickness: mm (in.)

95. INSTALL OVERDRIVE PLANETARY RING GEAR





a. Coat the race with petroleum jelly and install it onto the O/D planetary ring gear.





Race diameter: mm (in.)





b. Install the O/D planetary ring gear.





96. INSTALL OVERDRIVE PLANETARY GEAR THRUST NEEDLEROLLER BEARING
a. Install the bearing and race onto the O/D planetary ring gear.





Bearing and race diameter: mm (in.)

97. INSTALL OVERDRIVE PLANETARY GEAR ASSY





a. Coat the race with petroleum jelly and install it onto the O/D planetary gear.





Race diameter: mm (in.)





b. Install the O/D planetary gear with the O/D direct clutch & O/D one-way clutch.





98. INSTALL OVERDRIVE PLANETARY GEAR THRUST NEEDLE ROLLER BEARING
a. Install the assembled bearing & race onto the O/D direct clutch.





Assembled bearing & race diameter: mm (in.)

99. INSTALL OIL PUMP ASSY





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





Race diameter: mm (in.)

b. Coat a 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 overdrive direct clutch drum.

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





e. Install the 7 bolts.
Torque: 21 Nm (215 kgf-cm, 16 ft. lbs.)