Automatic Transmission Unit: Reassembly

Fig 1: Checking Bearing Position

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Bearing diameter 

1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.
2. Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.
3. Install the No. 4 brake piston to the reaction sleeve.
   Fig 2: Identifying No. 4 Brake Piston O-Rings

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1. Coat a new O-ring with ATF, and install it to the reaction sleeve.
2. With the No. 1 brake piston underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case.
   NOTE: Be careful not to damage the O-rings.
   Fig 3: Identifying Brake Reaction Sleeve

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1. Coat a new O-ring with ATF.
2. Install the O-ring on the 1st and reverse brake piston.
3. With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.
   NOTE: Be careful not to damage the O-ring.
   Fig 4: Identifying 1ST And Reverse Brake Piston

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4. Place the piston return spring onto the No. 4 brake piston.
   Fig 5: Locating Piston Return Spring

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1. Place SST on the spring retainer, and compress the return spring.

   SST 09350-30020 (09350-07050) 

2. Using SST, install the snap ring.

   SST 09350-30020 (09350-07070) 

   Fig 6: Installing Snap Ring

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1. Install the thrust needle roller bearing.

   Standard thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	45.9 mm (1.807 in.)	64.0 mm (2.520 in.)

   Fig 7: Identifying Thrust Needle Roller Bearing

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2. Install the thrust needle roller bearing.
3. Coat the No. 9 thrust bearing race with petroleum jelly, and install it onto the rear planetary ring gear.

   Standard bearing and race diameter 

   BEARING AND RACE SPECIFICATION
   
   

   Item	Inside	Outside
   Bearing	21.5 mm (0.847 in.)	40.8 mm (1.606 in.)
   Race	48.5 mm (1.909 in.)	62.7 mm (2.469 in.)

   Fig 8: Identifying Thrust Needle Roller Bearing

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4. Install the rear planetary gear assembly.
   Fig 9: Identifying Rear Planetary Gear Assembly

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1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
   Fig 10: Applying Compressed Air Into Transmission Case

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2. Using vernier caliper, measure the level difference (length A) between the upper surface of the 1st and reverse brake piston and the hitting surface of the No. 4 brake flange at both ends across a diameter, and calculate the average.
   NOTE: The 1st and reverse brake piston must be installed tightly to the end face of the transmission case.

   HINT:

   Length A = 36.35 to 37.09 mm (1.431 to 1.460 in.)

   Fig 11: Measuring Level Difference Between Upper Surface Of 1ST And Reverse Brake Piston

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3. Using a vernier caliper, measure the thickness (length B) of the 2 brake flanges, the 7 No. 4 brake plates and the 8 No. 4 brake discs altogether at both ends across a diameter, and calculate the average.

   HINT:

   Pack clearance = Length A - Length B - 0.25 mm to 1.8 mm (0.010 to 0.071 in.) Length B = 36.04 to 37.14 mm (1.419 to 1.462 in.)

   Pack clearance: 0.8 to 1.1 mm (0.031 to 0.043 in.) 

4. If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.
   Fig 12: Measuring Thickness Of Brake Flanges

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   H thickness 

   THICKNESS CHART
   
   

   No.	Thickness	No.	Thickness
   0	0 mm (0 in.)	8	0.8 mm (0.032 in.)
   2	0.2 mm (0.008 in.)	10	1. 0 mm (0.039 in.)
   4	0.4 mm (0.016 in.)	12	1. 2 mm (0.047 in.)
   6	0.6 mm (0.024 in.)	14	1. 4 mm (0.055 in.)

1. Install the 7 plates, 8 discs and 2 flanges.

   Install in order: F-D-P-D-P-D-P-D-P-D-P-D-P-D-P-D-F 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 13: Identifying Plates, DISCS And Flanges

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1. Install the brake stopper spring.
   Fig 14: Locating Brake Plate Stopper Spring

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

   Standard bearing and race diameter 

   BEARING AND RACE SPECIFICATION
   
   

   Item	Inside	Outside
   No. 7 thrust bearing race	33.4 mm (1.315 in.)	49.0 mm (1.929 in.)
   Thrust needle roller bearing	32.1 mm (1.264 in.)	49.35 mm (1.943 in.)
   No. 8 thrust bearing race	32.1 mm (1.264 in.)	49.0 mm (1.929 in.)

   Fig 15: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing, No. 7 Thrust Bearing Race

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1. Install the No. 3 1-way clutch assembly and the 1-way clutch inner race to the intermediate shaft.
   Fig 16: Identifying No. 3 1-Way Clutch Assembly

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1. Install the intermediate shaft with the No. 3 1-way clutch assembly to the case.
   Fig 17: Installing Intermediate Shaft

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2. Using SST, install the snap ring.

   SST 09350-30020 (09350-07050, 09350-07060) 

   Fig 18: Installing Snap Ring

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1. Install the center planetary gear assembly and planetary sun gear to the case.
2. Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary ring gear.

   Standard race diameter 

   STANDARD RACE DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Race	53.7 mm (2.114 in.)	74.0 mm (2.913 in.)

   Fig 19: Identifying Center Planetary Gear Assembly, Planetary Sun Gear And No. 4 Thrust Bearing Race

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1. Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.
2. Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.
3. Install the No. 2 brake piston to the case.
   Fig 20: Identifying O-Rings

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1. Install the flange, 3 plates, 3 discs and brake piston return spring.

   Install in order: D-P-D-P-D-P-F 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 21: Identifying Flange, Plates, Discs And Brake Piston Return Spring

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2. Using SST and press, install the No. 2 brake spring snap ring.

   SST 09351-40010 

   Fig 22: Installing No. 2 Brake Spring Snap Ring

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1. Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.
2. Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.
   Fig 23: Identifying O-Rings

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1. Install the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder on the transmission case.
   Fig 24: Identifying Brake Piston Return Spring

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1. Using SST and a press, install the brake piston return spring snap ring.

   SST 09351-40010 

   Fig 25: Installing Brake Piston Return Spring Snap Ring

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1. Install the 3 plates, 3 discs and flange.

   Install in order: P-D-P-D-P-D-P-D-F 

   HINT:

   P = Plate, D = Disc, F = Flange

   Fig 26: Identifying No. 1 Brake Plates, Discs And Flange

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1. Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear.
   Fig 27: Identifying Center Planetary Ring Gear And Front Planetary Ring Gear Flange

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2. Using a screwdriver, install the snap ring.
   Fig 28: Installing Snap Ring

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1. Install the front planetary ring gear and thrust needle roller bearing on the case.

   Standard thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	55.7 mm (2.193 in.)	76.4 mm (3.008 in.)

   Fig 29: Identifying Front Planetary Ring Gear And Bearing

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1. Install the thrust needle roller bearing and thrust washer.
2. Coat the thrust race with petroleum jelly, and install it onto the front planetary ring gear.

   Standard thrust needle roller bearing and race diameter 

   THRUST NEEDLE ROLLER BEARING SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	43.4 mm (1.709 in.)	58.3 mm (2.295 in.)

   Fig 30: Identifying Thrust Needle Roller Bearing And Thrust Washer

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   THRUST NEEDLE ROLLER BEARING SPECIFICATION
   
   

   Item	Inside	Outside
   Race	38.0 mm (1.496 in.)	57.0 mm (2.244 in.)

3. Install the front planetary gear assembly and 1-way clutch inner race from the case.
   Fig 31: Identifying Front Planetary Gear Assembly And 1 -Way Clutch Inner Race

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1. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
   Fig 32: Applying Compressed Air Into Transmission Case

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2. Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.

   Standard piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 in.) 

   If the piston stroke is outside the specification, parts may have been assembled incorrectly.

   Perform the reassembly again.

   If the piston stroke is still outside the specification, select another flange.

   HINT:

   There are 4 different thicknesses for the flange.

   Fig 33: Measuring B3 Brake Pack Clearance Between Snap Ring And Flange

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   Standard flange thickness 

   FLANGE THICKNESS CHART
   
   

   No.	Thickness	No.	Thickness
   0	2.0 mm (0.079 in.)	2	2.4 mm (0.094 in.)
   1	2.2 mm (0.087 in.)	3	2.6 mm (0.102 In.)

1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
2. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands.
   Fig 34: Identifying O-Rings

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3. Using SST and press, install the snap ring. SST 09351-40010
   NOTE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.
   Fig 35: Installing Snap Ring

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1. Install the 2nd brake cylinder to the case.
   Fig 36: Identifying 2Nd Brake Cylinder

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1. Install the 1 -way clutch and thrust washer to the case.
   Fig 37: Identifying 1-Way Clutch Assembly

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 38: Installing 2nd Brake Piston Hole Snap Ring

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1. install the flanges, 4 discs, 4 plates and cushion plate to the case.

   Install in order: C-P-D-P-D-P-D-P-D-F 

   HINT:

   P = Plate, D = Disc, F = Flange C = Cushion

   Fig 39: Identifying Flanges, Discs, Plates & Cushion Plate

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1. Using a screwdriver, install the snap ring.
   Fig 40: Installing No. 3 Brake Snap Ring

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1. Coat the race with petroleum jelly and install it onto the No. 2 clutch drum thrust washer.
2. Install the No. 2 1-way clutch assembly washer.
   Fig 41: Identifying No. 2 1 -Way Clutch Assembly

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1. Install the thrust needle roller bearing.
2. Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.

   Standard thrust needle roller bearing and diameter 

   THRUST NEEDLE ROLLER BEARING SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
   Race	73.6 mm (2.898 in.)	102.0 mm (4.016 in.)

3. Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.
   Fig 42: Identifying Thrust Needle Roller Bearing

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   Fig 43: Installing Input Shaft Sub-Assembly

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1. Install the No. 1 thrust bearing race to the front oil pump.

   Standard No. 1 thrust bearing race diameter 

   THRUST BEARING RACE DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Race	74.2 mm (2.921 in.)	87.74 mm (3.454 in.)

   Fig 44: Identifying No. 1 Thrust Bearing Race

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2. Coat a new O-ring with ATF, and install it around the oil pump assembly.
3. Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.
4. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.
   NOTE: Do not push on the oil pump strongly, as the oil seal ring will stick to the direct clutch drum.
   Fig 45: Identifying O-Ring

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5. Install the 10 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 46: Installing Oil Pump Assembly Bolts

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1. Using SST, tap in 2 new oil seals.

   SST 09350-30020 (09350-07110) 

2. Coat the oil seal lips with MP grease.

1. Install a new spacer to the manual valve lever.
2. Install the manual valve lever shaft to the transmission case through the manual valve lever.
   Fig 48: Installing Manual Valve Lever Shaft To Transmission Case

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3. Using a hammer, tap in a new spring pin.
   Fig 49: Tapping In Spring Pin

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4. Align the manual valve lever indentation with the spacer hole, and stake them together with a punch and hammer.
5. Make sure the shaft rotates smoothly.
   Fig 50: Aligning Manual Valve Lever

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1. Install the E-ring to the shaft.
2. Install the parking lock pawl, shaft and spring.
   Fig 51: Identifying Parking Lock Pawl, Shaft And Spring

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1. Connect the parking lock rod to the manual valve lever.
   Fig 52: Connecting Parking Lock Rod

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

   Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

   Fig 53: Installing Bolts And Parking Lock Pawl Bracket

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2. Shift the manual valve lever to the P position, and confirm that the planetary ring gear is correctly locked up by the lock pawl.
   Fig 54: Identifying Shift Manual Valve Lever And Planetary Ring Gear

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1. Coat a new O-ring with ATF, and install it to the piston.
   Fig 55: Identifying Accumulator Valve

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2. Install the spring and accumulator valve to the hole.

   Standard accumulator spring 

   STANDARD ACCUMULATOR SPRING REFERENCE
   
   

   Spring	Free Length Outer Diameter	Color
   C-1 Inner	30.40 mm (1.197 in.) 11.40 mm (0.449 in.)	Pink
   C-1 Outer	48.76 mm (1.920 in.) 16.60 mm (0.654 in.)	Light green

   Fig 56: Identifying Spring And Accumulator Valve

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1. Coat a new O-ring with ATF, and install it to the piston.
   Fig 57: Identifying C-3 Accumulator Piston

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2. Install the spring and accumulator piston to the hole.

   Standard accumulator spring 

   STANDARD ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free Length Outer Diameter	Color
   C-3 Inner	44.0 mm (1.732 in.) 14.0 mm (0.551 in.)	Yellow
   C-3 Outer	73.35 mm (2.888 in.) 19.90 mm (0.784 in.)	Red

   Fig 58: Identifying Spring And Accumulator Piston

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1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 59: Identifying B-3 Accumulator Piston

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2. Install the spring and accumulator piston to the hole.

   Standard accumulator spring 

   STANDARD ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length Outer diameter	Color
   B-3	70.5 mm (2.776 in.) 19.7 mm (0.776 in.)	Purple

   Fig 60: Identifying Spring And Accumulator Piston

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1. Coat 2 new O-rings with ATF, and install them to the piston.
   Fig 61: Identifying C-2 Accumulator Piston

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2. Install the spring and accumulator piston to the hole.

   Standard accumulator spring 

   STANDARD ACCUMULATOR SPRING SPECIFICATION
   
   

   Spring	Free length Outer diameter	Color
   C-2	62.0 mm (2.441 in.) 15.9 mm (0.6260 in.)	White

   Fig 62: Identifying Spring And Accumulator Piston

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1. Install the check ball body and spring.
   Fig 63: Identifying Check Ball Body And Spring

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1. Install the 3 new brake drum gaskets.
   Fig 64: Identifying Brake Drum Gaskets

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1. Install the 3 transaxle case gaskets.
   Fig 65: Identifying Transaxle Case Gaskets

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1. Align the groove of the manual valve with the pin of the lever.
   Fig 66: Aligning Groove Of Manual Valve With Pin Of Lever

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2. Install the 19 bolts.

   Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) 

   HINT:

   Each bolt length is indicated below.

   Standard bolt length: 

   25 mm (0.98 in.) for bolt A 

   36 mm (1.42 in.) for bolt B 

   Fig 67: Identifying Transmission Bolts

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1. Install a new O-ring to the transmission wire.
2. Install the transmission wire harness.
3. Install the bolt.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

4. Connect the solenoid connector.
   Fig 68: Locating Case Bolt

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5. Connect the 7 solenoid connectors.
6. Install the ATF temperature sensor.
7. Install the clamp and the 2 bolts.

   Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf) for bolt A 

   11 N*m (112 kgf*cm, 8 ft.*lbf) for bolt B 

   HINT:

   Each bolt length is indicated below.

   Standard bolt length: 

   12 mm (0.47 in.) for bolt A 

   36 mm (1.42 in.) for bolt B 

   Fig 69: Identifying Transmission Wire Bolts

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1. Coat a new O-ring with ATF, and install them to the valve body oil strainer.
2. Install the oil strainer with the 4 bolts.

   Torque: 10 N*m (100 kgf*cm, 7 ft.*lbf) 

   Fig 70: Locating Valve Body Oil Strainer Assembly Bolts

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1. Install the 4 transmission oil cleaner magnets.

1. Install a new gasket on the oil pan.
2. Install the 20 bolts.

   Torque: 4.4 N*m (45 kgf*cm, 39 in.*lbf) 

3. Install the drain plug.

   Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

   Fig 71: Identifying Transmission Oil Cleaner Magnets

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1. Using SST and a hammer, tap in a new oil seal.

   SST 09226-10010 

   Fig 72: Tapping In Oil Seal

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1. Apply seal packing or equivalent to the 8 bolts.

   Seal breadth: 1.0 to 1.5 mm (0.4 to 0.06 in.) 

   Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent. 

   Fig 73: Identifying Transmission Case Adapter Sub-Assembly

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2. Install the transmission case adapter sub-assembly with the 8 bolts.

   Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) 

   HINT:

   Each bolt length is indicated below.

   Standard bolt length: 

   50 mm (1.969 in.) for bolt A 

   45 mm (1.772 in.) for bolt B 

   Fig 74: Identifying Transmission Case Adapter Bolts

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1. Clean the threads of the bolts and case with white gasoline.
2. Install the transmission housing with the 10 bolts.

   Torque: 34 N*m (345 kgf*cm, 25 ft.*lbf) for bolt A 

   57 N*m (581 kgf*cm, 42 ft.*lbf) for bolt B 

   34 N*m (345 kgf*cm, 25 ft.*lbf) for bolt C 

   HINT:

   Each bolt head is indicated bellow.

   14 mm for bolt A and C

   17 mm for bolt B

   Fig 75: Locating Automatic Transmission Housing Bolt

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1. Install a new O-ring to the breather tube.
2. Install the breather tube with the 3 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 76: Identifying Automatic Transaxle Breather Tube

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1. Coat 2 new O-rings with AFT, and install it to the transmission revolution sensor.
2. Install the 2 transmission revolution sensors.
3. Install the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 77: Locating Bolts And Speed Sensor

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1. Coat a new O-ring with ATF, and install it to oil cooler tube union.
2. Install the oil cooler tube union.

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   Fig 78: Identifying Oil Cooler Tube Union

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1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.
2. Install the new lock washer. Install and torque the nut.

   Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

   Fig 79: Locating Nut, Lock Washer And Bolt

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3. Push the control shaft rearward as much as possible.
4. Return the control shaft lever 2 notches to the N position.
   Fig 80: Adjusting Shift Lever Position

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5. Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

   Fig 81: Aligning Neutral Basic Line With Switch Groove

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6. Using a screwdriver, bend the tabs of the lock washer.

   HINT:

   Bend at least 2 of the lock washer tabs.

   Fig 82: Bending Tabs Of Lock Washer

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1. Install the washer and nut to the control shaft lever LH.

   Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

   Fig 83: Identifying Control Shaft Lever N Position

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