Part 2

INSTALLATION OF 3-SPEED GEAR UNIT




1. INSTALL GOVERNOR PRESSURE ADAPTOR
a. Install the governor pressure adaptor into the case.
b. Align the hole of adaptor with the hole of the case and install the torsion spring.
c. Check that the adaptor does not slide or the spring fall out when pulled by hand.




2. INSTALL MANUAL VALVE SHAFT
a. Install the manual valve shaft oil seal to the case.




b. Assemble a new collar to the manual valve lever.
c. Install the manual valve shaft to the transmission case through the manual valve lever.




d. Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface.




e. Match the collar hole to the lever calking hollow and calk the collar to the lever.




f. Install the retaining spring.




g. Make sure that the lever moves smoothly.




3. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and pawl.




4. INSTALL PARKING LOCK ROD




5. INSTALL PARKING LOCK PAWL BRACKET

Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)




6. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P range.




7. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE
a. Coat the new O-rings with ATF.
b. Install the two O-rings on the piston.




c. Push the piston into the bore of the case, facing the spring seat upward.




8. INSTALL PISTON RETURN SPRING
a. Place the return spring and snap ring on the piston.
b. Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)




c. Install snap ring. Visually check to make sure it is fully seated and centered by the three lugs on the spring retainer.

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

d. Remove SST.

9. INSTALL INTERMEDIATE SHAFT AND TRANSAXLE REAR COVER




a. Install the intermediate shaft to the case.




b. Install the new gasket and rear cover.

Torque: 250 kg-cm (18 ft-lb, 25 N.m)




10. CHECK INTERMEDIATE SHAFT END PLAY

a. Make sure that the intermediate shaft has thrust play in axial direction.

Thrust play: 0.49 - 1.51 mm (0.0193 - 0.0594 in.)

If the thrust play is not within specification, check the installation of intermediate shaft.

b. Make sure that the intermediate shaft turns smoothly.




11. INSTALL FIRST AND REVERSE BRAKE IN CASE
a. Install the inner flange, facing the fiat end toward the oil pump side.
b. Install the discs and plates.

Install in order: P=Plate D=Disc

Flange-D-P-D-P-D-P-D-P-D-Flange

c. Install the outer flange, facing the flat end toward the piston side.




12. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of cutouts.




13. CHECK OPERATION OF FIRST AND REVERSE BRAKE
Apply compressed air into the oil passage with the case and be sure that the piston moves.




14. INSTALL RING GEAR INTO CASE

a. Coat the races and bearing with petroleum jelly and install them onto the ring gear.




Bearing and races:




b. Install the ring gear into the case.

15. INSTALL REAR PLANETARY GEAR INTO CASE




a. Align the flukes of the discs in the first and reverse brake.




b. Coat the thrust washer with petroleum jelly. Align the tab of the washer with the hollow of the carrier.
c. Align the spline of the planetary carrier with either of the flukes of the discs, and install the planetary gear into the first and reverse brake discs.




16. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD

a. Place the one-way clutch with the shiny side upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)




c. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.




17. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise.




18. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of the cutouts.




19. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the two band guides so that its tip touches the case.




20. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, facing the flat end toward the oil pump side.
b. Install the discs and plates.

Install in order: P=Plate D=Disc
Flange - D - P - P - D - P - P




21. INSTALL PISTON RETURN SPRING
Each spring end is installed onto the protrusion with the case.




22. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.




23. INSTALL SNAP RING
a. Place the snap ring into the case so that the end gap is installed into the groove.
b. While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
c. Be sure the end gap of the snap ring is not aligned with one of the cutouts.




24. INSTALL SECOND BRAKE DRUM GASKET
Install a new gasket until it makes contact with the second brake drum.




25. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case, and be sure that the piston moves.




26. INSTALL NO.1 ONE-WAY CLUTCH AND SECOND BRAKE HUB
a. Align the flukes of the discs in the 2nd brake.
b. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.




c. Check the distance between the surfaces of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)




27. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.

28. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR







a. Coat the races and bearing with petroleum jelly, and install them onto the ring gear.







b. Coat the race and bearing with petroleum jelly, and install them onto the planetary gear.




c. Install the planetary gear onto the ring gear.

29. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR




a. If the planetary gear and other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.




b. Coat the race with petroleum jelly and install it onto the tip of ring gear flange.

Race: Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)




30. INSTALL INTERMEDIATE SHAFT OIL SEAL RING