Part 2

23. CHECK PISTON STROKE OF OVERDRIVE BRAKE





a) Place SST and a dial indicator onto the overdrive brake piston.
SST 09350-30020 (09350-06120)





b) Measure the stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kg-cm2 or 57 - 114 psi).

Piston Stroke: 1.75 - 2.05 mm (0.0690 - 0.0807 inch)

If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.
If the piston stroke is non-standard, select another flange.

HINT: There are 7 different flange thicknesses.

Flange Thickness:

24. INSTALL OVERDRIVE PLANETARY GEAR UNIT WITH OVERDRIVE DIRECT CLUTCH AND ONE-WAY CLUTCH



a) Coat the race with petroleum jelly and install it onto the overdrive planetary ring gear.

Race Diameter:

b) Install the overdrive planetary ring gear.




c) Coat the bearing and race with petroleum jelly and install them onto the planetary ring gear.

Bearing And Race Diameter:

d) Coat the race with petroleum jelly and install it onto the planetary gear.

Race Diameter:

e) Install the overdrive planetary gear with the overdrive direct clutch and one-way clutch.




f) Coat the assembled bearing and race with petroleum jelly and install them onto the overdrive direct clutch.

Assembled Bearing And Race Diameter:

25. INSTALL OIL PUMP INTO CASE




a) Coat the race with petroleum jelly and install it onto the oil pump.

Race Diameter:

b) Coat a new 0-ring with ATF and install it around the pump body.
c) Place the oil pump through the input shaft, and align the bolt holes of the pump body 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.

NOTICE: Do not push on the oil pump strongly, or the oil seal ring will stick to the direct clutch drum.





e) Install the 7 bolts.

Torque: 21 Nm (215 kg-cm, 16 ft. lbs.)





26. CHECK INPUT SHAFT ROTATION
Make sure the input shaft rotates smoothly.

27. INDIVIDUAL PISTON OPERATION INSPECTION
Check for the sound of operation while applying compressed air into the oil holes indicated in the illustration.





HINT: When inspecting the O/D direct clutch, check with the C. accumulator piston hole closed.

If there is no noise, disassemble and check the installation condition of the parts.
(1) Direct clutch
(2) Forward clutch
(3) O/D brake
(4) Second coast brake
(5) Second brake
(6) First and reverse brake

28. INSTALL MANUAL VALVE LEVER, SHAFT AND OIL SEAL





a) Using SST, drive in a new oil seal.
SST 09350 - 30020 (09350 - 07110)
b) Coat the oil seal lip with MP grease.





c) Install a new spacer to the manual valve lever.
d) Install the manual valve lever shaft to the transmission case through the manual valve lever.





e) Using a hammer, drive in a new spring pin.





f) Match the manual valve lever indentation with the spacer hole and caulk them together with the punch.
g) Make sure the shaft rotates smoothly.

29. INSTALL PARKING LOCK PAWL AND ROD





a) Install the E-ring to the shaft.
b) Install the parking lock pawl, shaft and spring.





c) Connect the parking lock rod to the manual valve lever.





d) Place the parking lock pawl bracket onto the transmission case and torque the 3 bolts.

Torque: 7 Nm (75 kg-cm, 65 inch lbs.)





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





30. INSTALL ACCUMULATOR SPRINGS AND PISTONS
a) Coat new 0-rings with ATF and install them to the pistons.
b) Install the 6 springs and 4 accumulator pistons to the bore.

HINT: The pistons are marked in relief with either Co, Bo, C2 or B2 to discriminate between them.

Accumulator Springs:

31. INSTALL SPRING AND CHECK BALL BODY
32. INSTALL VALVE BODY





a) Align the groove of the manual valve to the pin of the lover.





b) Install the 20 bolts.

Torque: 10 Nm (100 kg-cm, 7 ft. lbs.)

HINT: Each bolt length (mm, inch) is indicated in the illustration.

33. INSTALL SOLENOID WIRING
a) Coat a new 0-ring with ATF and install it to the solenoid wire.





b) Install the solenoid wiring to the case and install the stopper plate.

Torque: 5.4 Nm (65 kg-cm, 48 inch lbs.)





c) Connect the 5 solenoid connectors.





d) Install the clamp with 2 bolts.





34. INSTALL OIL STRAINER AND GASKETS Install the oil strainer and torque the 3 bolts.

Torque: 10 Nm (100 kg-cm, 7 ft. lbs.)

35. INSTALL OIL PAN





a) Install the 3 magnets in the oil pan, as shown.
b) Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.





c) Apply seal packing to the oil pan.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent





d) Install and torque the 19 bolts.

Torque: 17 Nm (75 kg-cm, 65 inch lbs.)





36. INSTALL SPEEDOMETER DRIVE GEAR
37. INSTALL EXTENSION HOUSING
a) Clean the threads of the bolts and case with white gasoline.





b) Apply seal packing to the extension housing.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
c) Apply seal packing or equivalent to the 6 bolts.
Seal packing: Part No.08833-00070, THREE BOND 1324 or equivalent





d) Install and torque the 6 bolts.

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 35 mm (1.378 inch)
Bolt B: 45 mm (1.772 inch)

Torque: 34 Nm (345 kg-cm, 25 ft. lbs.)

38. INSTALL TRANSMISSION OUTPUT FLANGE





a) Install a new oil seal to the output flange.
b) Install the output flange and 2 washers.





c) Using SST, install a new nut.
SST 09060-20100

Torque: 123 Nm (1,250 kg-cm, 90 ft. lbs.)

HINT: Shift the manual valve lever to the P position.





d) Using a hammer and chisel, stake the nut.

39. REMOVE TRANSMISSION CASE FROM OVERHAUL ATTACHMENT
40. INSTALL TRANSMISSION HOUSING
a) Clean the threads of the bolts and case with white gasoline.
b) Apply seal packing or equivalent to the 6 bolts.
Seal packing: Part No.08833-00070, THREE BOND 1324 or equivalent





c) Install and torque the 6 bolts.

Torque:
14 mm bolt: 34 Nm (345 kg-cm, 25 ft. lbs.)
17 mm bolt: 57 Nm (580 kg-cm, 42 ft. lbs.)

41. INSTALL O/D DIRECT CLUTCH SPEED SENSOR
a) Coat a new 0-ring with ATF and install it to the speed sensor.
b) Install the speed sensor.





c) Install and torque the bolts.

Torque: 5.4 Nm (55 kg-cm, 48 inch lbs.)

42. INSTALL NO.2 VEHICLE SPEED SENSOR
a) Coat a new 0-ring with ATF and install it to the speed sensor.
b) Install the speed sensor.





c) Install and torque the bolts.

Torque: 5.4 Nm (55 kg-cm, 48 inch lbs.)

43. INSTALL NO.1 VEHICLE SPEED SENSOR
a) Coat a new 0-ring with ATF and install it to the No. 1 vehicle speed sensor.
b) Install the No.1 vehicle speed sensor.





c) Install and torque the bolt.

Torque: 16 Nm (160 kg-cm, 12 ft. lbs.)

44. INSTALL UNIONS
a) Coat 2 new 0-rings with ATF and install them to each union.





b) Install each union.

Torque: 29 Nm (300 kg-cm, 22 ft. lbs.)

45. INSTALL OIL TEMPERATURE SENSOR
a) Coat a new 0-ring with ATF and install it to the oil temperature sensor.





b) Install the oil temperature sensor.

Torque: 29 Nm (300 kg-cm, 22 ft. lbs.)

46. INSTALL PARK/NEUTRAL POSITION SWITCH





a) Using the control shaft lever, fully turn the manual lever shaft back and return 2 notches. It is now in neutral.
b) Insert the park / neutral position switch onto the manual valve lever shaft and temporarily tighten the adjusting bolt.





c) Install the grommet and a new lock washer. Install and torque the nut.

Torque: 7 Nm (70 kg-cm, 61 inch lbs.)

d) Clean the threads of the adjusting bolt and case with white gasoline.
e) Apply seal packing or equivalent to the adjusting bolt.
Seal packing: Part No.08833-00070, THREE BOND 1324 or equivalent





f) Align the neutral basic line and the switch groove, and tighten the adjusting bolt.

Torque: 13 Nm (130 kg-cm, 9 ft. lbs.)





g) Using a screwdriver, bend the tabs of the lock washer.

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





47. INSTALL CONTROL SHAFT LEVER

Torque: 16 Nm (160 kg-cm, 12 ft. lbs.)