Part 1

AUTOMATIC TRANSMISSION UNIT

REASSEMBLY

1. BEARING POSITION
2. INSTALL NO.4 BRAKE PISTON

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 No.4 brake piston.
c) Install the No.4 brake piston to the reaction sleeve.

NOTICE: Be careful not to damage the 4 O-rings.

3. INSTALL BRAKE REACTION SLEEVE

a) With the No.4 brake piston underneath (the rear side), install the brake reaction sleeve with the No.4 brake piston 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.

d) Place the brake return spring onto the brake piston.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

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

c) Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

NOTICE: Engage the 1st and reverse brake piston claw with the protrusion of the brake apply tube.

6. INSTALL REAR PLANETARY GEAR ASSEMBLY

a) Install the No.9 thrust bearing race.

Race Diameter:

b) Install the 2 thrust needle roller bearings.

c) Install the rear planetary gear assembly.

7. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE
8. INSTALL NO.4 BRAKE DISC

a) Install the sleeve, 4 plates, the 4 discs and the flange.
Install in order: P = Plate, D = Disc, F = Flange, S = Sleeve
F-D-P-D-P-D-P-D-P-S

9. INSTALL BRAKE PLATE STOPPER SPRING

a) Install the brake plate stopper spring.

10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

a) Install the No.8 thrust bearing race, the thrust needle roller bearing, the No.7 thrust bearing race and the planetary ring gear flange to the intermediate shaft.

Bearing and Race Diameter:

11. INSTALL NO.3 ONE WAY CLUTCH ASSEMBLY

a) Install the No.3 one way clutch assembly and the one way clutch inner race to the intermediate shaft.

12. INSTALL INTERMEDIATE SHAFT

a) Install the intermediate shaft with the No.3 one way clutch assembly to the transmission case.

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

13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

a) Install the center planetary gear assembly and the planetary sun gear to the transmission case.
b) Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear.

14. INSTALL NO.2 BRAKE PISTON

a) Coat 2 new O-rings with ATF, and install them to the No.2 brake piston.
b) Press the No.2 brake piston into the No.2 brake cylinder.

NOTICE: Be careful not to damage the 2 O-rings.

c) Install the No.2 brake cylinder to the transmission case.

HINT: Install the No.2 brake cylinder so that the projection protrudes from the upside of the transmission case.

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

15. INSTALL NO.2 BRAKE DISC

a) Install the 2 flanges, the 2 plates, 3 discs and brake piston return spring.
Install in order: P = Plate, D = Disc, F = Flange
F-D-P-D-P-D-F

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

16. INSPECT PISTON STROKE OF NO.2 BRAKE PISTON
17. INSTALL NO.1 BRAKE PISTON

a) Coat 2 new O-rings with ATF, and install them on the No.1 brake piston.
b) Press the No.1 brake piston into the No.1 brake cylinder.

NOTICE: Be careful not to damage the 2 O-rings.

18. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

a) Install the brake piston return spring and the No.1 brake piston with the No.1 brake cylinder to the transmission case.

HINT: Install the No.1 brake cylinder so that the projection protrudes from the upside of the transmission case.

b) Check that the oil pressure apply hole of the No.1 brake cylinder aligns with the oil pressure apply hole of the transmission case.

19. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

a) Using SST, a screwdriver and a press, install the brake piston return spring snap ring.
SST 09351-40010 (09351-04010, 09351-04030, 09351-04040, 09351-04050)

20. 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 center planetary ring gear and the front planetary ring gear flange on the front planetary ring gear.

c) Using a screwdriver, install the snap ring.

NOTICE: Install the snap ring to the ring gear so that both ends of the snap ring come to the center of a protrusion on the ring gear.

21. INSTALL FRONT PLANETARY RING GEAR

a) Install the front planetary ring gear to the transmission case.

22. 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.

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

23. INSPECT PISTON STROKE OF NO.1 BRAKE PISTON
24. INSTALL NO.1 BRAKE DISC

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

25. INSTALL 2ND BRAKE PISTON

a) Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
b) Press the 2nd brake piston into the 2nd brake cylinder.

NOTICE: Be careful not to damage the 2 O-rings.

c) Place the brake piston return spring on the 2nd brake piston.

d) Using SST, a screwdriver and a press, install the snap ring.
SST 09351-40010 (09351-04060, 09351-04070)

NOTICE: Be sure that the end gap of the snap ring is not aligned with the spring retainer claw.

26. INSTALL 2ND BRAKE CYLINDER

a) Install the 2nd brake cylinder to the transmission 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 ONE WAY CLUTCH ASSEMBLY

a) Install the one way clutch assembly and the thrust washer to the transmission case.

28. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

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