REASSEMBLY

Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.

Install the No. 4 brake piston to the reaction sleeve.

NOTICE:

Be careful not to damage the 4 O-rings.

NOTICE:

Be careful not to damage the O-rings.

Install the O-ring on the 1st and reverse brake piston.

With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

NOTICE:

Be careful not to damage the O-ring.

Place the brake return spring onto the brake piston.

SST

09350-30020   (09350-07050)

Using the SST, install the snap ring.

SST

09350-30020   (09350-07070)

Thrust needle roller bearing diameter:

	Inside	Outside
Thrust needle roller bearing	40.6 mm (1.598 in.)	58.0 mm (2.284 in.)

Coat the No. 9 thrust bearing race and thrust bearing race with petroleum jelly, and install them onto the rear planetary gear.

Bearing and race diameter:

	Inside	Outside
Bearing	20.8 mm (0.819 in.)	38.5 mm (1.516 in.)
Thrust bearing Race	19.0 mm (0.748 in.)	35.0 mm (1.378 in.)
No. 9 thrust bearing Race	43.3 mm (1.705 in.)	56.7 mm (2.232 in.)

NOTICE:

The 1st and reverse brake piston must be securely installed to the end face of the transmission case.

HINT:

Dimension A = 23.32 to 24.18 mm (0.9181 to 0.952 in.)

HINT:

Dimension B = 23.64 to 26.00 mm (0.9307 to 1.0236 in.)

Pack Clearance = Dimension A - Dimension B - 0.18 mm (0.0071 in.) + 1.8 mm (0.071 in.)

Pack Clearance:

0.5 to 0.8 mm (0.0197 to 0.0315 in.)

If the pack clearance is outside the standard range, select and install a brake flange that brings the pack clearance to be within the standard range.

HINT:

There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Thickness H:

NO.	Thickness H	NO.	Thickness H
0	0 mm (0 in.)	8	0.8 mm (0.03150 in.)
2	0.2 mm (0.00787 in.)	10	1.0 mm (0.03937 in.)
4	0.4 mm (0.01575 in.)	12	1.2 mm (0.04724 in.)
6	0.6 mm (0.02362 in.)	14	1.4 mm (0.05512 in.)

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P - D - P - D - F

Bearing and race diameter:

	Inside	Outside
No. 7 thrust bearing race	29.6 mm (1.165 in.)	44.9 mm (1.768 in.)
Thrust needle roller bearing	27.8 mm (1.095 in.)	43.85 mm (1.726 in.)
No. 8 thrust bearing race	27.8 mm (1.095 in.)	43.7 mm (1.721 in.)

SST

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

Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

Race diameter:

	Inside	Outside
Race	55.2 mm (2.173 in.)	71.2 mm (2.803 in.)

Press the No. 2 brake piston into the No. 2 brake cylinder.

NOTICE:

Be careful not to damage the 2 O-rings.

Install the No. 2 brake piston to the case.

HINT:

Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.

Install in order:

P = Plate, D = Disc, F = Flange

F -D - P - D - P - D - P - D - F

SST

09351-40010   (09351-04010, 09351-04020, 09351-04040, 09351-04050)

Inspect piston stroke of the No. 2 brake piston.

1. Make sure that the No. 2 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.
   

2. Using SST and a dial indicator, measure the moving distance (dimension A) of the clutch disc at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
   

   SST

   09350-30020   (09350-06120)
   

   Piston stroke:

   0.6 to 0.9 mm (0.024 to 0.035 in.)
   

3. If the piston stroke is outside the standard range, select and install a brake flange that brings the piston stroke within the standard range.
   

   HINT:

   There are 8 types of flanges that can be used to adjust the piston stroke. Select one with the most appropriate thickness.

   Flange thickness:

   No.	Thickness
   0	2.0 mm (0.079 in.)
   1	2.1 mm (0.083 in.)
   2	2.2 mm (0.087 in.)
   3	2.3 mm (0.091 in.)
   4	2.4 mm (0.094 in.)
   5	2.5 mm (0.098 in.)
   6	2.6 mm (0.102 in.)
   7	2.7 mm (0.106 in.)

Press the No. 1 brake piston into the No. 1 brake cylinder.

NOTICE:

Be careful not to damage the 2 O-rings.

HINT:

Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.

SST

09351-40010   (09351-04010, 09351-04030, 09351-04040, 09351-04050)

Install the thrust needle roller bearing to the front planetary ring gear flange.

Thrust needle roller bearing diameter:

	Inside	Outside
Thrust needle roller bearing	58.5 mm (2.303 in.)	73.5 mm (2.894 in.)

Using a screwdriver, install the snap ring.

Using a screwdriver, install the snap ring.

NOTICE:

Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.

Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

Thrust needle roller bearing and race diameter:

	Inside	Outside
Bearing	38.6 mm (1.520 in.)	53.1 mm (2.091 in.)
Race	34.9 mm (1.374 in.)	50.8 mm (2.0 in.)

Inspect piston stroke of the No. 1 brake piston.

1. Make sure the No. 1 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.
   

2. Using vernier calipers, measure the level difference (dimension A) between the upper surface of the No. 1 brake piston and the hitting surface of the No. 1 brake flange at both ends across the No. 1 brake piston diameter.
   

3. Using vernier calipers, measure the thickness (dimension B) of the brake flange, the No. 1 brake plates and the 3 No. 1 brake discs altogether at the both ends across a diameter, and calculate the average.
   

   HINT:

   Dimension A = 15.27 to 15.92 mm (0.60118 to 0.62677 in.)

   Dimension B = 14.50 to 15.54 mm (0.57087 to 0.61180 in.)

   Piston stroke = Dimension A - Dimension B

   Piston stroke:

   0.42 to 0.72 mm (0.017 to 0.028 in.)
   

   If the piston stroke is outside the specified range, parts may have been assembled incorrectly, so check and reassemble them again.
   If the piston stroke is not still outside the specified range, select another flange that brings the piston stroke within the specified range.
   

   HINT:

   There are 4 different thicknesses for the flange.

   Flange thickness:

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

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P

SST

09350-30020   (09350-07060)

Install in order:

P = Plate, D = Disc, F = Flange

F - D - P - D - P - D - P

SST

09350-30020   (09350-07060)

Check that the No. 2 one way clutch assembly turns freely clockwise and locks counterclockwise.
If there is a problem with the one way clutch, replace the one way clutch.

Coat the race and washer with petroleum jelly and install them onto the clutch drum and input shaft assembly.

Thrust needle roller bearing and diameter:

	Inside	Outside
Thrust needle roller bearing A	71.9 mm (2.831 in.)	85.6 mm (3.370 in.)
Bearing Race	37.0 mm (1.457 in.)	51.2 mm (2.016 in.)
Thrust needle roller bearing B	33.5 mm (1.319 in.)	48.0 mm (1.890 in.)

Coat a new O-ring with ATF, and install it around the oil pump assembly.

Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.

Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

Torque:

21 N*m{ 214 kgf*cm , 15 ft.*lbf }

SST

09350-30020   (09350-07110)

Coat the oil seal lips with MP grease.

HINT:

When inspecting the O/D direct clutch, check the operating sound with the C3 accumulator piston hole closed.

If there is no sound, disassemble and check the installation condition of the parts.

1. No. 2 Clutch (C2)
   

2. No. 4 Clutch (C4)
   

3. No. 3 Clutch (C3)
   

4. No. 1 Clutch (C1)
   

5. No. 3 Brake (B3)
   

6. No. 1 Brake (B1)
   

7. No. 2 Brake (B2)
   

8. No. 4 Brake (B4)
   

Install the manual valve lever shaft to the transmission case through the manual valve lever.

Make sure that the shaft rotates smoothly.

Install a new parking lock pawl, the shaft and the spring.

Torque:

7.3 N*m{ 74 kgf*cm , 65 in.*lbf }

B-1 accumulator spring:

Free length	Outer diameter	Color
46.36 mm (1.8252 in.)	17.10 mm (0.6732 in.)	Natural

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

C-3 accumulator spring:

Inner spring: 

Free length	Outer diameter	Color
44.0 mm (1.732 in.)	14.0 mm (0.551 in.)	Yellow

Outer spring: 

Free length	Outer diameter	Color
76.65 mm (3.0178 in.)	20.10 mm (0.7913 in.)	White

Install the spring and the accumulator piston to the hole.

Accumulator spring:

Free length	Outer diameter	Color
64.5 mm (2.539 in.)	19.5 mm (0.768 in.)	Orange

Install the spring and the accumulator piston to the hole.

Accumulator spring:

Free length	Outer diameter	Color
65.07 mm (2.5618 in.)	16.2 mm (0.6378 in.)	Pink

Torque:

11 N*m{ 110 kgf*cm , 8 ft.*lbf }

HINT:

Each bolt length is indicated below.

Bolt length:

Bolt A:

25 mm (0.98 in.)

Bolt B:

36 mm (1.42 in.)

Bolt C:

45 mm (1.77 in.)

Bolt D:

50 mm (1.97 in.)

Torque:

10 N*m{ 102 kgf*cm , 7 ft.*lbf }

Install the O-ring to the transmission wire.

Install the bolt.

Torque:

5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

Torque:

10 N*m{ 102 kgf*cm , 7 ft.*lbf }

Torque:

Bolt A:

6.4 N*m{ 65 kgf*cm , 57 in.*lbf }

Bolt B:

10 N*m{ 102 kgf*cm , 7 ft.*lbf }

Torque:

10 N*m{ 102 kgf*cm , 7 ft.*lbf }

Install a new gasket on the oil pan.

Torque:

4.4 N*m{ 45 kgf*cm , 39 in.*lbf }

Install a new gasket and the drain plug.

Torque:

20 N*m{ 204 kgf*cm , 15 ft.*lbf }

Install a new gasket and the overflow plug.

Torque:

20 N*m{ 204 kgf*cm , 15 ft.*lbf }

Coat the lip of a new oil seal with MP grease.

SST

09325-40010  

Oil seal drive in depth:

5.4 to 5.8 mm (0.213 to 0.228 in.)

SST

09950-60020   (09951-01030)

Using a snap ring pliers, install the snap ring.

Using a snap ring expander, install the snap ring.

Clearance:

0.02 to 0.12 mm (0.0008 to 0.0047 in.)

HINT:

There are 12 different thicknesses for the race.

Flange thickness:

NO.	Thickness	NO.	Thickness
1	3.80 mm (0.1496 in.)	7	4.10 mm (0.1614 in.)
2	3.85 mm (0.1516 in.)	8	4.15 mm (0.1634 in.)
3	3.90 mm (0.1535 in.)	9	4.20 mm (0.1653 in.)
4	3.95 mm (0.1555 in.)	10	4.25 mm (0.1673 in.)
5	4.00 mm (0.1575 in.)	11	4.30 mm (0.1693 in.)
6	4.05 mm (0.1594 in.)	12	4.35 mm (0.1713 in.)

Clean the threads of the bolts and the case with white gasoline.

FIPG:

Seal Packing 1281, THREE BOND 1281 or equivalent

Torque:

34 N*m{ 345 kgf*cm , 25 ft.*lbf }

HINT:

Each bolt length is indicated below.

Bolt length:

Bolt A:

45 mm (1.772 in.)

Bolt B:

35 mm (1.378 in.)

Install the transmission housing with the 10 bolts.

Torque:

A {14 mm (0.551 in.) bolt}:

34 N*m{ 347 kgf*cm , 25 ft.*lbf }

B {17 mm (0.669 in.) bolt}:

57 N*m{ 581 kgf*cm , 42 ft.*lbf }

Install the 2 bolts.

Torque:

5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

Install the 2 transmission revolution sensors.

Install the 2 bolts.

Torque:

5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

Torque:

21 N*m{ 214 kgf*cm , 16 ft.*lbf }

Install a new lock washer. Install and tighten the nut.

Torque:

6.9 N*m{ 70 kgf*cm , 61 in.*lbf }

Torque:

13 N*m{ 130 kgf*cm , 9 ft.*lbf }

HINT:

Bend at least 2 of the lock washer tabs.

Torque:

16 N*m{ 163 kgf*cm , 12 ft.*lbf }

Torque:

5.4 N*m{ 55 kgf*cm , 48 in.*lbf }