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Low and Reverse Brake: Installation

  1. Install the low and reverse piston.
    CAUTION:
    • Be careful not to tilt the piston when installing.
    • Be careful not to damage the lip seal.
    Fig 1: Installing Low & Reverse Piston
    G02053456
  2. Install return spring
    Fig 2: Installing Return Spring
    G02053457
  3. Install spring retainer.
    Fig 3: Installing Spring Retainer
    G02053458
  4. Install the one-way clutch inner race.
  5. Tighten eight socket head bolts from the rear side of the transmission case.

    Tightening torque: 

    1. 25 N.m (2.5 kgf-m, 18.1 ft-lb)
    CAUTION: Be sure to tighten evenly.
    Fig 4: Tightening Eight Socket Head Bolts
    G02053459
  6. Install thrust needle bearing.
    NOTE: Place transmission case with the front facing up.
  7. Installation of the low & reverse brake: Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.
    NOTE: Pay attention to the orientation of the dish plate.
    Fig 5: Installing Dish Plate, Driven Plates, Drive Plates, Retaining Plate & Securing Snap Ring
    G02053460
  8. Apply compressed air intermittently to check for operation.
    Fig 6: Applying Compressed Air Intermittently, To Confirm Operation
    G02053461
  9. Check the clearance. (Selection of retaining plate)
    NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.

    Standard value: 

    1. 0.7 - 1.2 mm (0.028 - 0.047 in)

    Allowable limit: 

    1. 2.2 mm (0.087 in)
    Fig 7: Checking Retaining Plates Clearance
    G02053462
    Fig 8: Retaining Plates Chart
    G02053463
  10. Install leaf spring of low and reverse brake.
    CAUTION: Pay attention to the direction and position of leaf spring during installation.
    Fig 9: Installing Leaf Spring
    G02053464
  11. Install 2-4 brake piston, retainer and return spring to transmission case. See 2-4 Brake  .
  12. Position snap ring in transmission. Using ST, press the snap ring into place.

    ST 498677100 COMPRESSOR

    Fig 10: Positioning Snap Ring In Transmission
    G02053465
  13. Install planetary gear and low clutch assembly to transmission case.

    Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring. See Planetary Gear and Low Clutch  .

  14. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
    Fig 11: Installing Pressure Plate, Driven Plates, Drive Plates, Retaining Plate & Securing Snap Ring
    G02053466
  15. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
    Fig 12: Applying Compressed Air Intermittently, To Confirm Brake Operation
    G02053467
  16. Install leaf spring of 2-4 brake.
    NOTE: Be careful not to mistake the location of the leaf spring to be inserted.
    Fig 13: Installing Leaf Spring Of 2-4 Brake
    G02053468
  17. Install snap ring and thrust needle bearing.
    NOTE: Install thrust needle bearing in the correct direction.
    Fig 14: Installing Snap Ring & Thrust Needle Bearing
    G02053469
  18. Install front sun gear and thrust needle bearing.
    NOTE: Install thrust needle bearing in the correct direction.
    Fig 15: Installing Front Sun Gear & Thrust Needle Bearing
    G02053470
  19. 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.

    NOTE: Install thrust needle bearing in the correct direction.
    Fig 16: Installing High Clutch Hub & Thrust Needle Bearing
    G02053471
  20. Install the high clutch assembly. See High Clutch and Reverse Clutch  .
  21. Install the oil pump housing assembly.
  22. Secure the housing with two nuts and the bolt.

    Tightening torque: 

    1. T: 41 N.m (4.2 kgf-m, 30.4 ft-lb)
    Fig 17: Securing Housing
    G02053472
  23. Apply proper amount of liquid gasket to the entire torque converter clutch case mating surface.

    Liquid gasket: 

    1. THREE BOND 1215
    NOTE: Make sure that the rubber seal and seal pipe are fitted in position.
    Fig 18: Applying Liquid Gasket
    G02053473
  24. 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: 

    1. 41 N.m (4.2 kgf-m, 30.4 ft-lb)
  25. Install reduction drive gear. Reduction Drive Gear  .
  26. Without VTD: Install reduction driven gear. See Reduction Driven Gear  .

    With VTD: Install reduction driven gear. See Reduction Driven Gear  .

  27. Install the extension case to the transmission case. See INSTALLATION  .
  28. Install the rear vehicle speed sensor.

    Tightening torque: 

    1. 7 N.m (0.7kgf-m, 5.1 ft-lb)
  29. Install air breather hose. See INSTALLATION  .
  30. Insert inhibitor switch and transmission connector into stay.
    Fig 19: Inserting Inhibitor Switch & Transmission Connector
    G02053474
  31. Install the oil cooler pipes. See INSTALLATION  .
  32. Install the oil charger pipe with O-ring. See INSTALLATION  .
  33. Insert the input shaft while turning lightly by hand.
    CAUTION: Be careful not to damage the bushing.

    Normal protrusion A: 

    1. 50 - 55 mm (1.97 - 2.17 in)
    Fig 20: Identifying Protrusion "A"
    G02053475
  34. Install the torque converter clutch assembly. See INSTALLATION  .
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