Part 3

18. Install the rear sun gear.

NOTE: Install the gear with the oil groove facing up.

19. Install the front planetary carrier. Attach the thrust needle bearings to both sides of the carrier with vaseline. Install the carrier carefully, while aligning with the splines of the forward clutch drum, and while rotating the pinion.

CAUTION: Install thrust needle bearing in the correct direction.

20. Install the front sun gear. Attach the thrust needle bearing to the gear, and install the gear while turning slowly.

CAUTION: Install thrust needle bearing in the correct direction.

21. Install the high clutch hub. Attach the thrust needle bearing to the hub with vaseline and install the hub by correctly engaging the splines of the front planetary carrier.

CAUTION: Install thrust needle bearing in the correct direction.

22. Install the high clutch assembly.

NOTE: Correctly engage the high clutch hub and clutch splines.

23. Install the reverse clutch assembly.

NOTE: Engage the high clutch outer spline with the reverse clutch spline and the front sun gear with the cut-out portion of the reverse clutch drum correctly when installing.

24. Install the brake band.

CAUTION: Be careful not to damage the brake band when installing.

NOTE: Install the strut to the band servo piston stem. Then tighten it temporarily to avoid tilting the band.

25. Adjustment of total end play and reverse clutch end play

1. Measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum "L", and the distance to the top surface of the reverse clutch drum "M".

2. Measure the distance from the oil pump housing mating surface to the top surface of the oil pump cover with needle bearing, and to the thrust surface of the reverse clutch.

3. Equation for calculation

- Total end play Select suitable bearing race from among those listed in this table so that clearance C is in the 0.25 - 0.55 mm (0.0098 - 0.0217 inch) range.
C = (L + 0.4 mm) - l

- Reverse clutch end play Select suitable thrust washer from among those listed in this table so that clearance C is in the 0.55 - 0.90 mm (0.0217 - 0.0354 inch) range.
C = (M + 0.4 mm) - m

26. Install the oil pump housing assembly.
1. After completing end play adjustment, insert the bearing race in the recess of the high clutch. Attach the thrust washer and thrust needle bearing to the oil pump cover with vaseline.

2. After correctly installing the gasket to the case mating surface, carefully install the oil pump housing assembly. Be careful to avoid hitting the drive pinion against the inside of the case.

CAUTION:
- Be careful not to damage the seal ring.
- Be sure to use a new gasket.

3. Install both parts with dowel pins aligned. Make sure no clearance exists at the mating surface.

NOTE:
Any clearance suggests a damaged seal ring.

4. Secure the housing with two nuts.

Tightening torque:
41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)

3. Torque Converter Clutch Case And Transmission Case

1. Apply proper amount of liquid gasket (THREE BOND Part No. 1215) to the entire torque converter clutch case mating surface.

NOTE: Make sure that the rubber seal and seal pipe are fitted in position.

2. Install the torque converter clutch case assembly to the transmission case assembly, and secure with six bolts and four nuts.

CAUTION: When installing, be careful not to damage the torque converter clutch case bushing and oil seal.

Tightening torque.
41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)

4. Control Valve and Oil Pan

1. Install four accumulators with oil pans facing upward.

CAUTION: Be careful not to confuse the springs and installation positions.

2. Install and route the transmission harness.

CAUTION: Be careful not to damage the harness.

3. Install the control valve assembly.
1. Set the select lever in range "2".

2. Install the two brackets, ATF temperature sensor and the control valve by engaging the manual valve and manual lever, then tighten the 17 bolts.

CAUTION:
- Be careful not to pinch the harness roll the gasket.
- Tighten the control valve mounting bolts evenly.

Tightening torque.
8 ± 1 Nm (0.8 ± 0.l kg-m, 5.8 ± 0.7 ft. lbs.)

4. Install the oil strainer to the control valve. Be careful not to cut or break the 0-ring. Then tighten four bolts.

Tightening torque:
8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)

5. Secure four connectors.

6. Install the oil cooler outlet pipe, and secure with two bolts.

CAUTION:
Fit the pipe into position. Be careful to avoid twisting.

Tightening torque.
8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)

7. Install the oil pan.

1. Attach the magnet at the specified position.

2. Apply proper amount of liquid gasket (THREE BOND Part No. 1217B) to the entire oil pan mating surface.

3. Install the oil pan to the transmission case assembly, and secure with 20 bolts.

NOTE: Tighten the bolts evenly.

Tightening torque:
4.9 ± 0.5 Nm (0.50 ± 0.05 kg-m, 3.6 ± 0.4 ft. lbs.)

5. Extension Section

NOTE: When installing new oil seal into extension case, press it with SST.

SST 498057300 INSTALLER

Extension Section
1. Install the filter in the extension case.

NOTE: Pay attention to the orientation of the filter.

2. Install the transfer clutch valve assembly, transfer pipe, and the stay then secure with five bolts.

CAUTION:
- Be sure to tighten the going lead with one of these bolts.
- Be sure to use a new gasket.

Tightening torque:
8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)

3. Install the transfer clutch assembly to the case.

CAUTION: Be careful not to damage the seal rings.

NOTE: Insert the clutch assembly fully into position until the bearing shoulder bottoms.

6. Connection of Each Section (FWD)
1. Install vehicle speed sensor 1 on transmission case.

Tightening torque.,
7 ± 1 Nm (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)

2. Install oil pipe.

Tightening torque:
7.8 ± 1.0 Nm (0.80 ± 0.10 kg-m, 5.8 ± 0.7 ft. lbs.)

3. Install the reduction driven gear.

4. Install the parking pawl and shaft, set the select lever in the "P" range and tighten the drive pinion lock nut.

NOTE: After tightening, stake the lock nut securely.

Tightening torque:
98 ± 5 Nm (10.0 ± 0.5 kg-m, 72.3 ± 3.6 ft. lbs.)

5. Install the reduction drive gear assembly.

NOTE: Insert it fully into position until the bearing shoulder bottoms.

6. Measurement and adjustment of extension end play

1. Measure distance L from end of rear case to point at bearing location with SST.
SST 398643600 GAUGE
L = Measured value - 15 mm

2. Measure distance l from end of transmission case to end of bearing.
l = Measured value - 50 mm
SST1 398643600 GAUGE
SST2 499577000 GAUGE

3. Calculation equation:
T = (L + 0.4 mm) - l
T : Clearance between end of reduction drive gear and end of bearing
L : Distance from end of case to point at bearing location
0.4: Gasket thickness
l : Height from end of case to end of bearing

4. Tighten bolts.

Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

Connection of each Section (AWD)
1. Install oil pipe.

Tightening torque:
7.8 ± 1.0 Nm (0.8 ± 0.10 kg-m, 5.8 ± 0.7 ft. lbs.)

2. Install the reduction driven gear.

3. Install the parking pawl and shaft, set the select lever in the "P" range and tighten the drive pinion lock nut.

NOTE: After tightening, stake the lock nut securely.

Tightening torque.
98 ± 5 Nm (10.0 ± 0.5 kg-m, 72.3 ± 3.6 ft. lbs.)

4. Install the reduction drive gear assembly.

NOTE: Insert it fully into position until the bearing shoulder bottoms.

5. Measurement and adjustment of extension end play

1. Measure distance L from end of extension case and rear drive shaft with SST.
SST 398643600 GAUGE
L = Measured value - 15 mm

2. Measure the distance "l" from the transmission case mating surface to the reduction drive gear end surface with SST1 and SST2.
l = Measured value - 50 mm
SST1 398643600 GAUGE
SST2 499577000 GAUGE

3. Calculation equation:
T = (L + 0.4 mm) - l
T : Clearance between end of reduction drive gear and end of rear drive shaft
L : Distance from end of extension case to end of rear drive shaft
0.4: Gasket thickness
l : Height from end of transmission case to end of reduction drive gear

Select suitable thrust needle bearing from among those listed in the following table to adjust clearance in the 0.05 - 0.20 mm (0.0020 - 0.0079 inch) range.
Select from one to five shims so that clearance is within specifications.

6. Installation of extension case and transmission case
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with vaseline.
2. Set the parking return spring.
3. Remove the transfer clutch from the extension case.
Set the needle bearing on the reduction drive shaft and then install transfer clutch to the transfer clutch hub.

NOTE: Be sure to engage the spline teeth correctly.

4. With gasket inserted between them, install the extension case to the transmission case.

CAUTION:
- Be sure to use a new gasket.
- After inserting the extension case halfway, connect the connector for duty solenoid C. Be careful not to jam the cord in the case.
- Be careful not to damage the rear drive shaft seal ring.

5. Tighten bolts to secure the case.

Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

7. Install the vehicle speed sensor 1

Tightening torque:
7 ± 1 Nm (0.7 ± 0.l kg-m, 5.1 ± 0.7 ft. lbs.)

External Parts
1. Adjustment of inhibitor switch

1. With the selector lever set to "N" adjust the inhibitor switch so that the hole of range select lever is aligned with the inhibitor switch hole with SST.

NOTE: Ensure that gauge moves properly.

SST1 499267300 STOPPER PIN

2. With hole aligned, tighten three bolts to secure the inhibitor switch.

Tightening torque:
3.4 ± 0.5 Nm (0.35 ± 0.05 kg-m, 2.5 ± 0.4 ft. lbs.

2. Clip the following cords and harness.
3. Install the oil cooler outlet pipe.

Tightening torque.
34 ± 3 Nm (3.5 ± 0.3 kg-m, 25.3 ± 2.2 ft. lbs.)

4. Install the oil cooler inlet pipe.

CAUTION: Be sure to use a new aluminum washer.

Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

5. Install the oil charge pipe.

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

Tightening torque:
Upper
41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)
Lower
6.4 ± 0.5 Nm (0.65 ± 0.O5 kg-m, 4.7 ± 0.4 ft. lbs.)

6. Adjustment of brake band
After tightening the brake band adjusting screw with SST to 9 Nm (0.9 kg-m, 6.5 ft. lbs.) torque, back it off three turns. Then secure with a lock nut.

NOTE: When tightening the lock nut, be careful not to turn the adjusting screw.

Tightening torque:
26 ± 2 Nm (2.7 ± 0.2 kg-m, 19.5 ± 1.4 ft. lbs.)

7. Install the air breather hose.

8. Install the pitching stopper bracket.

Tightening torque.
41 ±3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)

9. Tighten the drain plugs.

Tightening torque:
Diff.
44 ± 3 Nm (4.5 ± 0.3 kg-m, 32.5 ± 2.2 ft. lbs.)
ATF
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

10. Insert the input shaft while turning lightly by hand.

CAUTION: Be careful not to damage the bushing.

Normal protrusion A:
50 - 55 mm (1.97 - 2.17 inch)

11. Install the torque converter clutch assembly.
1. Install the oil pump shaft to the torque converter clutch.

NOTE: Make sure the clip fits securely in its groove.

2. Holding the torque converter clutch assembly by hand, carefully install it to the torque converter clutch case. Be careful not to damage the bushing. Also avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover.

3. Rotate the shaft lightly by hand to engage the splines securely.

Dimension A:
3.9 - 4.1 mm (0. 154 - 0.l6l inch)

12. Fill ATF and differential gear oil.

NOTE: After filling oil, insert the oil level gauge into the oil inlet.

Differential gear oil capacity:
1.1 - 1.3 l (1.2 - 1.4 US qt, 1.0 - 1.1 Imp qt)
Automatic transmission fluid capacity:
2200 cc:
7.9 - 8.2 l (8.4 - 8.7 US qt, 7.O - 7.2 Imp qt)
2500 cc:
9.5 - 9.8 l (10.0 - 10.3 US qt, 8.4 - 8.6 Imp qt)
Recommended fluid:
Dexron II or Dexron III type automatic transmission