Automatic Transmission Unit: Reassembly

Fig 1: Installing Bearing

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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: Installing O-Rings To Brake Reaction Sleeve

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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: Installing 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: Installing 1st & Reverse Brake Piston

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

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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 Using SST

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1. Install the thrust needle roller bearing.

   Standard thrust needle roller bearing diameter 

   THRUST NEEDLE ROLLER BEARING DIAMETER SPECIFICATION
   
   

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

   Fig 7: Installing 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 DIAMETER 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: Installing Thrust Needle Roller Bearing

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4. Install the rear planetary gear assembly.
   Fig 9: Installing 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: Inspecting Pack Clearance Of First & Reverse Brake

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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: Identifying Level Difference Between 1st & Reverse Brake Piston Upper Surface & No. 4 Brake Flange Hitting Surface

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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.) 

   Fig 12: Identifying Thickness Of Brake Flanges

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4. If the pack clearance is outside the standard, select and install a brake flange that makes the pack clearance within the standard.

   H thickness 

   FLANGES SPECIFICATION
   
   

   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: Installing Plates, Discs & Flanges

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1. Install the brake stopper spring.
   Fig 14: Installing Brake 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 DIAMETER 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: Installing No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing & No. 7 Thrust Bearing Race

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1. Install the No. 3 one-way clutch assembly and the one-way clutch inner race to the intermediate shaft.
   Fig 16: Installing No. 3 One-Way Clutch Assembly & One-Way Clutch Inner Race To Intermediate Shaft

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1. Install the intermediate shaft with the No. 3 one-way clutch assembly to the case.
   Fig 17: Installing Intermediate Shaft With No. 3 One-Way Clutch Assembly To Case

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2. Using SST, install the snap ring.

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

   Fig 18: Installing Snap Ring Using SST

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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 

   RACE DIAMETER SPECIFICATION
   
   

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

   Fig 19: Installing Center Planetary Gear Assembly & Planetary Sun Gear

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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: Installing O-Ring To No. 2 Brake Piston

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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: Installing Flange, Plates, Discs & 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 Using SST & Press

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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: Installing O-Rings On No. 1 Brake Piston

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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: Installing Brake Piston Return Spring & No. 1 Brake Piston With No. 1 Brake Cylinder

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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 Using SST & Press

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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: Installing Plates, Discs & 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: Installing Center Planetary Ring Gear & Front Planetary Ring Gear Flange On Front Planetary Ring Gear

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

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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 DIAMETER SPECIFICATION
   
   

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

   Fig 29: Installing Front Planetary Ring Gear & Thrust Needle Roller Bearing On Case

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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 

   Fig 30: Installing Thrust Needle Roller Bearing & Thrust Washer

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   THRUST NEEDLE ROLLER BEARING AND RACE DIAMETER SPECIFICATION
   
   

   Item	Inside	Outside
   Thrust needle roller bearing	43.4 mm (1.709 in.)	58.3 mm (2.295 in.)
   Race	38.0 mm (1.496 in.)	57.0 mm (2.244 in.)

3. Install the front planetary gear assembly and one-way clutch inner race from the case.
   Fig 31: Installing Front Planetary Gear Assembly & One-Way Clutch Inner Race From Case

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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: Inspecting No. 1 Piston Stroke Of Brake Piston

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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.

   Standard flange thickness 

   FLANGE THICKNESS SPECIFICATION
   
   

   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.)

   Fig 33: Measuring B3 Brake Pack Clearance Between Snap Ring & Flange Using Feeler Gauge

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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: Installing O-Ring To 2nd Brake Piston

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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 Using SST & Press

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1. Install the 2nd brake cylinder to the case.
   Fig 36: Installing 2nd Brake Cylinder To Case

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1. Install the one-way clutch and thrust washer to the case.
   Fig 37: Installing One-Way Clutch & Thrust Washer To Case

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1. Using SST, install the snap ring.

   SST 09350-30020 (09350-07060) 

   Fig 38: Installing Snap Ring Using SST

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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: Installing Flanges, Discs, Plates & Cushion Plate To Case

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1. Using a screwdriver, install the snap ring.
   Fig 40: Installing Snap Ring Using Screwdriver

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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 one-way clutch assembly washer.
   Fig 41: Installing No 2 One-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 AND DIAMETER 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: Installing 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 

   NO. 1 THRUST BEARING RACE DIAMETER SPECIFICATION
   
   

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

   Fig 44: Installing No. 1 Thrust Bearing Race To Front Oil Pump

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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: Installing O-Ring Around Oil Pump Assembly

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5. Install the 10 bolts.

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

   Fig 46: Installing 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 New Spacer To Manual Valve Lever

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

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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 Indentation With Spacer Hole & Staking With Punch & Hammer

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

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

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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 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: Locking Planetary Ring Gear With Lock Pawl

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1. Coat a new O-ring with ATF, and install it to the piston.
   Fig 55: Installing O-Ring To C-1 Accumulator Valve Piston

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

   Standard accumulator spring 

   ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION
   
   

   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: Installing Spring Into C-1 Accumulator Valve

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

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

   Standard accumulator spring 

   ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER 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: Installing Spring Into C-3 Accumulator Valve

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

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

   Standard accumulator spring 

   ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION
   
   

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

   Fig 60: Installing Spring Into B-3 Accumulator Valve

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

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

   Standard accumulator spring 

   ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION
   
   

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

   Fig 62: Installing Spring Into C-2 Accumulator Valve

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

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

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1. Install the 3 transaxle case gaskets.
   Fig 65: Installing 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: Installing 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: Installing Transmission Wire

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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: Connecting Solenoid Connectors

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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: Installing Valve Body Oil Strainer Assembly

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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: Installing 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 New Oil Seal Using SST & Hammer

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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: Applying Seal Packing

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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: Installing Transmission Case Adapter Sub-Assembly

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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: Installing Automatic Transmission Housing

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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: Installing 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: Installing Transmission Revolution 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: Installing 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: Installing Park/Neutral Position Switch Assembly

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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: Returning Control Shaft Lever To N Position

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5. Align the neutral basic line with the switch groove as shown, then 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 Using Screwdriver

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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: Installing Transmission Control Shaft Lever LH

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