Part 2 of 2

21. Install leaf spring of 2-4 brake.

NOTE: Be careful not to mistake the location of the leaf spring to be inserted.





22. Install thrust needle bearing.

CAUTION: Install thrust needle bearing in the correct direction.





23. Install front sun gear and thrust needle bearing.

CAUTION: Install thrust needle bearing in the correct direction.





24. Install the high clutch hub and thrust needle bearing.
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.





25. Install the high clutch assembly.

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

26. Adjustment of total end play:





1. Using ST, measure the distance from the transmission case mating surface to the recessed portion of the high clutch drum "L".
ST 398643600 GAUGE





2. Using ST, measure the distance from the oil pump housing mating surface to the top surface of the oil pump cover with thrust needle bearing.
ST 398643600 GAUGE











3. Calculation of 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 + G) - l

27. 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 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:
T: 41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)

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.)

Control Valve And Oil Pan





1. Install and route the transmission harness.

CAUTION: Be careful not to damage the harness.

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





2. Temporarily tighten the valve body on the transmission case.

CAUTION: Be sure to engage the manual valve with the manual plate during installation.

3. Tighten the valve body to the specified torque.
Tightening torque: 8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)





3. Connect all connectors.
4. 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. Install torque converter turbine speed sensor and vehicle speed sensor 2 (front).
Tightening torque: 7 ± 1 Nm (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)

Extension Section

NOTE: When installing new oil seal into extension case, press it with Service Tool ST.

ST 498057300 INSTALLER





1. Install the transfer pipe to extension case.





2. 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.

Connection Of Each Section





1. Install the parking pawl, shaft and return spring.





2. Install inlet filter to transmission case.





3. Install transfer valve plate, valve body and duty solenoid C (transfer) to transmission case.

CAUTION:
^ Be sure to install transfer seal lip to transfer control valve body.
^ If transfer seal lip is damaged, replace seal with new one.

Tightening torque: 8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)
4. Connect connector to duty solenoid C (transfer).





5. Install the reduction drive gear assembly.

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





6. Using a plastic hammer, install reduction driven gear assembly, and tighten drive pinion lock nut.

NOTE:
^ Be sure to use a new lock nut and a washer.
^ Set the select lever in the "P" range.
^ After tightening, stake the lock nut securely.

Tightening torque: 98 ± 5 Nm (10.0 ± 0.5 kg-m, 72.3 ± 3.6 ft. lbs.)
7. Measurement and adjustment of extension end play.





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





2. Measure the distance "f" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
l = Measured value - 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE





3. Calculation equation:

NOTE: Add 0.05 mm (0.0020 inch) and 0.20 mm (0.0079 inch) thick shims to area "T". Calculate formula 2 to determine "H". The calculated "H" refers to the shim thickness range. Select shims of suitable thicknesses within the calculated "H" range.

T = (L ± G) - e - H
T : Shim clearance
L : Distance from end of extension case to end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 inch)
l : Height from end of transmission case to end of reduction drive gear
H : Thrust needle bearing thickness 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
8. Installation of extension case and transmission case
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

CAUTION: Install thrust needle bearing in the correct direction.

2. Install the extension case to the transmission case.

CAUTION: Be sure to use a new gasket.





3. Tighten bolts to secure the case.

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





9. Install the vehicle speed sensor 1 (rear).
Tightening torque: 7 ± 1 Nm (0. 7 ± 0.1 kg-m, 5.1 ± 0. 7 ft. lbs.)

External Parts





1. Using Service Tool ST, install ATF filter to transmission case.
Calculate ATF filter torque specifications using the following formula.
T2 = L2/(L1 + L2) x T1
T1: 14 ± 2 Nm (1.4 ± 0.2 kg-m, 10.1 ± 1.4 ft. lbs.)
[Required torque setting]
T2: Tightening torque
L1: ST length 0.078 m (3.07 inch)
L2: Torque wrench length

CAUTION: Align ST with torque wrench while tightening ATF filter.

ST 498545400 OIL FILTER WRENCH
2. Adjustment of inhibitor switch





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

NOTE: Ensure that gauge moves properly.

ST 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.)





3. Install air breather hose.





4. Insert inhibitor switch and transmission connector into stay.
5. Install the oil cooler outlet pipe.

CAUTION: Be sure to use a new aluminum washer.

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





6. Install the oil cooler inlet pipe.

CAUTION: Be sure to use a new aluminum washer.

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





7. Install the oil charge pipe.

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

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





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: 2.7 - 2.9 mm (0.106 - 0.114 inch)