Part 2

AUTOMATIC TRANSMISSION UNIT

COMPONENTS:

REASSEMBLY (STEPS 32 - 62)
32. INSPECT 1 WAY NO. 2 CLUTCH ASSEMBLY
33. INSTALL CLUTCH DRUM AND INPUT SHAFT

a. Install the 2 thrust needle roller bearings and thrust washer.
b. 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:

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

34. INSTALL OIL PUMP ASSEMBLY

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

b. Coat a new O-ring with ATF, and install it around the oil pump assembly
c. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly 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.

e. Install the 9 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

35. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
a. Using SST, drive in 2 new oil seals.
SST 09350-30020 (09350-07110)
b. Coat the oil seal lips with MP grease.

36. INSPECT INDIVIDUAL PISTON OPERATION
37. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

a. Install a new spacer to the manual valve lever.
b. Install the manual valve lever shaft to the transmission case through the manual valve lever.

c. Using a hammer, drive in a new spring pin.

d. Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.
e. Make sure that the shaft rotates smoothly.

38. INSTALL PARKING LOCK PAWL SHAFT
a. Install the E-ring to the shaft.
b. Install the parking lock pawl, the shaft and the spring.

39. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
a. Connect the parking lock rod to the manual valve lever.

40. INSTALL PARKING LOCK PAWL BRACKET

a. Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.
Torque: 7.3 Nm (74 kgf-cm, 65 inch lbs.)

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

41. INSTALL B-1 ACCUMULATOR VALVE

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

B-1 Accumulator Spring Inner Spring:

B-1 Accumulator Spring Outer Spring:

42. INSTALL C-3 ACCUMULATOR PISTON

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

C-3 Accumulator Spring Inner Spring:

C-3 Accumulator Spring Outer Spring:

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

43. INSTALL B-3 ACCUMULATOR PISTON

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

b. Install the spring and the accumulator piston to the hole.

Accumulator Spring:

44. INSTALL C-2 ACCUMULATOR PISTON

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

b. Install the spring and the accumulator piston to the hole.

Accumulator Spring:

45. INSTALL CHECK BALL BODY
a. Install the check ball body and the spring.

46. INSTALL BRAKE DRUM GASKET
a. Install the 3 brake drum gaskets.

47. INSTALL TRANSAXLE CASE GASKET
a. Install the 3 transaxle case gaskets.

48. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

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

b. Install the 19 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 25 mm (0.98 inch)
Bolt B: 36 mm (1.42 inch)
Bolt C: 45 mm (1.77 inch)
Bolt D: 50 mm (1.97 inch)

c. Install the detent spring and the detent spring cover with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

49. INSTALL TRANSMISSION WIRE

a. Install a new O-ring to the transmission wire.
b. Install the transmission wire harness.
c. Install the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

d. Connect the 9 solenoid connectors.
e. Install the ATF temperature sensor.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
f. Install the clamp and the 2 bolts.
Torque:
Bolt A 6.4 Nm (65 kgf-cm, 57 inch lbs.)
Bolt B 10 Nm (102 kgf-cm, 7 ft. lbs.)

50. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
a. Coat a new O-ring with ATF, and install them to the valve body oil strainer assembly.
b. Install the oil strainer with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

51. INSTALL TRANSMISSION OIL CLEANER MAGNET
a. Install the 3 transmission oil cleaner magnets.

52. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
a. Install a new gasket on the oil pan.

b. Install and tighten the 20 bolts.
Torque: 4.4 Nm (45 kgf-cm, 39 inch lbs.)
c. Install a new gasket and the drain plug.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
d. Install a new gasket and the over flow plug.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)

53. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL
a. Using SST and a hammer, install a new oil seal until it fits with the extension housing.
SST 09325-40010

54. INSTALL EXTENSION HOUSING DUST DEFLECTOR
a. Using SST and a press, install a new extension housing dust deflector.
SST 09950-60020 (09951-01030)

55. INSTALL EXTENSION (ATM) HOUSING SUB-ASSEMBLY

a. Install the transmission case adapter radial ball bearing to the extension housing.
b. Using a snap ring pliers, install a new snap ring.

c. Install the thrust needle roller bearing and the 2 bearing races.
d. Using a snap ring expander, install the snap ring.

e. 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 inch)
If the clearance is outside the standard, select another race that brings the clearance within the standard.

HINT: There are 12 different thicknesses for the race.

Flange Thickness:

f. Clean the threads of the bolts and the case with solvent.

g. Apply FIPG to the extension housing as shown in the illustration.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

h. Install the extension housing with 6 new bolts.
Torque: 34 Nm (345 kgf-cm, 25 ft. lbs.)

HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 45 mm (1.772 mm)
Bolt B: 35 mm (1.378 mm)

56. INSTALL AUTOMATIC TRANSMISSION HOUSING
a. Clean the threads of the bolts and the case with solvent.
b. Install the transmission housing with the 10 bolts.
Torque:
A (14 mm (0.551 inch) bolt) 34 Nm (347 kgf-cm, 25 ft. lbs.)
B (17 mm (0.669 inch) bolt) 57 Nm (581 kgf-cm, 42 ft. lbs.)

57. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE
a. Install the breather tube.
b. Install the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

58. INSTALL TRANSMISSION REVOLUTION SENSOR
a. Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.
b. Install the 2 transmission revolution sensors.
c. Install the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

59. INSTALL TRANSMISSION OIL COOLER
a. Coat new O-rings with ATF, and install them to the transmission oil cooler.
b. Install the transmission oil cooler with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)

60. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

a. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.
b. Install a new lock washer. Install and tighten the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)

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

d. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

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

HINT: Bend at least 2 of the lock washer tabs.

61. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH
a. Install the control shaft lever RH, washer and the nut.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

62. INSTALL TRANSAXLE CASE COVER UPPER
a. Install the transaxle case cover upper with the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)