Part 1

AUTOMATIC TRANSMISSION UNIT

COMPONENTS:

REASSEMBLY (STEPS 1 - 31)

1. BEARING POSITION

2. INSTALL BRAKE PISTON NO. 4
a. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
b. Coat 2 new O-rings with the ATF, and install them to the brake piston No. 4.
c. Install the brake piston No. 4 to the reaction sleeve.

NOTICE: Be careful not to damage the O-rings.

3. INSTALL BRAKE REACTION SLEEVE
a. 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: Be careful not to damage the O-rings.

4. INSTALL 1ST AND REVERSE BRAKE PISTON
a. Coat a new O-ring with ATF.
b. Install the O-ring on the 1st and reverse brake piston.
c. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

NOTICE: Be careful not to damage the O-ring.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Place the brake return spring onto the brake piston.

b. Place SST on the brake return spring, and compress the return spring.
SST 09350-30020 (09350-07050)
c. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)

6. INSTALL BRAKE APPLY TUBE
a. Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

7. INSTALL REAR PLANETARY GEAR ASSEMBLY

a. Install the thrust needle roller bearing. Thrust needle roller bearing diameter

b. Install the thrust needle roller bearing.
c. 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
d. Install the rear planetary gear assembly

8. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

9. INSTALL BRAKE DISC NO. 4
a. 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

10. INSTALL BRAKE PLATE STOPPER SPRING
a. Install the brake plate stopper spring.

11. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. 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:

12. INSTALL 1 WAY NO. 3 CLUTCH ASSEMBLY
a. Install the 1 way No. 3 clutch assembly and the 1 way clutch inner race to the intermediate shaft.

13. INSTALL INTERMEDIATE SHAFT

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

b. Using SST, install the snap ring.
SST 09350-30020 (09350-07050, 09350-07060)

14. INSTALL CENTER PLANETARY GEAR ASSEMBLY
a. Install the center planetary gear assembly and the planetary sun gear to the case.
b. Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

Race Diameter:

15. INSTALL BRAKE PISTON NO. 2

a. Coat 2 new O-rings with ATF, and install them to the brake piston No. 2.
b. Being careful not to damage the O-rings, press the brake piston No. 2 into the brake cylinder No. 2.
c. 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.

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

16. INSTALL BRAKE DISC NO. 2

a. 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

b. Using SST and a press, install the brake No. 2 spring snap ring.
SST 09351-40010 (09351-04010, 09351-04020, 09351-04040, 09351-04050)

17. INSPECT PISTON STROKE OF BRAKE PISTON NO. 2

18. INSTALL BRAKE PISTON NO. 1
a. Coat 2 new O-rings with ATF, and install them on the brake piston No. 1.
b. Be careful not to damage the O-rings. Press the brake piston No. 1 into the brake cylinder No. 1.

19. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

a. 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.

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

20. INSTALL BRAKE PISTON RETURN SPRING SNAP RING
a. Using SST and a press, install the brake piston return spring snap ring.
SST 09351-40010 (09351-04010, 09351-04030, 09351-04040, 09351-04050)

21. INSTALL CENTER PLANETARY RING GEAR
a. Install the thrust needle roller bearing to the front planetary ring gear flange.

Thrust Needle Roller Bearing Diameter:

b. Install the front planetary ring gear flange to the center planetary ring gear.
c. Using a screwdriver, install the snap ring.

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

22. INSTALL FRONT PLANETARY RING GEAR
a. Install the front planetary ring gear to the case.

23. INSTALL FRONT PLANETARY GEAR ASSEMBLY

a. Install the thrust needle roller bearing and the thrust washer.
b. Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

Thrust Needle Roller Bearing and Race Diameter:

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

24. INSPECT PISTON STROKE OF BRAKE PISTON

25. INSTALL BRAKE DISC NO. 1
a. 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

26. INSTALL 2ND BRAKE CYLINDER

a. Install the 2nd brake cylinder to the case.

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

27. INSTALL 1 WAY CLUTCH ASSEMBLY
a. Install the 1 way clutch assembly and the thrust washer to the case.

28. INSTALL 2ND BRAKE PISTON HOLE SNAP RING
a. Using SST, install the snap ring.
SST 09350-30020 (09350-07060)

29. INSTALL 2ND BRAKE DISC SET
a. 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

30. INSTALL BRAKE NO. 3 SNAP RING
a. Using a screwdriver, install the snap ring.
SST 09350-30020 (09350-07060)

31. INSTALL 1 WAY NO. 2 CLUTCH ASSEMBLY
a. Install the 1 way No. 2 clutch assembly and washer No. 2 to the clutch drum and input shaft.