GSIC - Global Service Information Center

# AUTOMATIC TRANSMISSION UNIT > REASSEMBLY

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1. BEARING POSITION

Bearing diameter:

  Mark | Front Race Diameter Inside / Outside | Thrust Bearing Diameter Inside / Outside | Rear Race Diameter Inside / Outside
  A | 73.6 mm (2.898 in.) / 102.0 mm (4.016 in.) | 71.9 mm (2.831 in.) / 85.6 mm (3.370 in.) | -
  B | 38.0 mm (1.496 in.) / 57.0 mm (2.244 in.) | 43.4 mm (1.709 in.) / 58.3 mm (2.295 in.) | -
  C | - | 55.7 mm (2.193 in.) / 76.4 mm (3.008 in.) | 53.7 mm (2.114 in.) / 74.0 mm (2.913 in.)
  D | 33.4 mm (1.315 in.) / 49.0 mm (1.929 in.) | 32.1 mm (1.264 in.) / 49.35 mm (1.943 in.) | 32.1 mm (1.2649 in.)/ 49.0 mm (1.929 in.)
  E | - | 21.5 mm(0.847 in.) / 40.8 mm (1.606 in.) | -
  F | 48.5 mm (1.909 in.) / 62.7 mm (2.469 in.) | 45.9 mm (1.807 in.) / 64.0 mm (2.520 in.) | -

2. INSTALL NO. 4 BRAKE PISTON

1. Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.

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

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

3. INSTALL BRAKE REACTION SLEEVE

1. Coat a new O-ring with ATF, and install it to the reaction sleeve.

1. With the No. 1brake piston1 underneath (the rear side), install the brake reaction sleeve and No. 1 brake piston to the transmission case.

   NOTICE:
     Be careful not to damage the O-rings.

4. INSTALL 1ST AND REVERSE BRAKE PISTON

1. Coat a new O-ring with ATF.

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

1. 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.

1. Place the piston return spring onto the No. 4 brake piston.

5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

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

   SST
     09350-30020 (09350-07050)

1. Using SST, install the snap ring.

   SST
     09350-30020 (09350-07070)

6. INSTALL REAR PLANETARY GEAR ASSEMBLY

1. Install the thrust needle roller bearing.

   Thrust needle roller bearing diameter:

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

1. Install the thrust needle roller bearing.

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

   Bearing and race diameter:

     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.)

1. Install the rear planetary gear assembly.

7. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

1. 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.

   NOTICE:
     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.)

1. 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.)

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

   H thickness:

     No. | Thickness | No. | Thickness
     0 | 0 mm (0 in.) | 8 | 0.8 mm (0.031 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.)

8. INSTALL NO. 4 BRAKE DISC

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

9. INSTALL BRAKE PLATE STOPPER SPRING

1. Install the brake stopper spring.

10. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

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.

   Bearing and race diameter:

     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.)

11. INSTALL NO. 3 1-WAY CLUTCH ASSEMBLY

1. Install the No. 3 1-way clutch assembly and 1-way clutch inner race to the intermediate shaft.

12. INSTALL INTERMEDIATE SHAFT

1. Install the intermediate shaft with the No. 3 1-way clutch assembly to the case.

1. Using SST, install the snap ring.

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

13. INSTALL CENTER PLANETARY GEAR ASSEMBLY

1. Install the center planetary gear assembly and planetary sun gear to the case.

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

   Race diameter:

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

14. INSTALL NO. 2 BRAKE PISTON

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

1. Be careful not to damage the O-rings. Press the No. 2 brake piston into the No. 2 brake cylinder with both hands.

1. Install the No. 2 brake piston to the case.

15. INSTALL NO, 2 BRAKE DISC

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

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

   HINT:
     P = Plate, D = Disc, F = Flange

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

   SST
     09351-40010

16. INSTALL NO. 1 BRAKE PISTON

1. Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.

1. Be careful not to damage the O-rings. Press the No. 1 brake piston into the No. 1 brake cylinder with both hands.

17. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

1. Install the brake piston return spring and the No. 1 brake piston with No. 1 brake cylinder on the transmission case.

18. INSTALL BRAKE PISTON RETURN SPRING SNAP RING

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

   SST
     09351-40010

19. INSTALL NO. 1 BRAKE DISC

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

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

   HINT:
     P = Plate, D = Disc, F = Flange

20. INSTALL CENTER PLANETARY RING GEAR

1. Install the center planetary ring gear and front planetary ring gear flange on the front planetary ring gear.

1. Using a screwdriver, install the snap ring.

21. INSTALL FRONT PLANETARY RING GEAR

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

   Thrust needle roller bearing diameter:

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

22. INSTALL FRONT PLANETARY GEAR ASSEMBLY

1. Install the thrust needle roller bearing and the thrust washer.

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

   Thrust needle roller bearing and race diameter:

     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.)

1. Install the front planetary gear assembly and 1-way clutch inner race from the case.

23. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON

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

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

   Piston stroke:
     0.42 to 0.72 mm (0.017 to 0.028 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.

   Flange thickness:

     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.)

24. INSTALL 2ND BRAKE PISTON

1. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.

1. Be careful not to damage the O-rings. Press the 2nd brake cylinder into the 2nd brake piston with both hands.

1. Using SST and press, install the snap ring.

   SST
     09351-40010

   NOTICE:
     Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

25. INSTALL 2ND BRAKE CYLINDER

1. Install the 2nd brake cylinder fro the case.

26. INSTALL 1-WAY CLUTCH ASSEMBLY

1. Install the 1-way clutch assembly and thrust washer to the case.

27. INSTALL 2ND BRAKE PISTON HOLE SNAP RING

1. Using SST, install the snap ring.

   SST
     09350-30020 (09350-07060)

28. INSTALL NO. 3 BRAKE DISC

1. Install the 2 flanges, the 4 discs, the 4 plates and cushion plate on the case.

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

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

29. INSTALL NO. 3 BRAKE SNAP RING

1. Using a screwdriver, install the snap ring.

30. INSTALL NO. 2 1-WAY CLUTCH ASSEMBLY

1. Coat the race with petroleum jelly and install it onto the No. 2 clutch drum thrust washer.

1. Install the No. 2 1-way clutch assembly washer.

31. INSTALL CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

1. Install the thrust needle roller bearing.

1. Coat the race with petroleum jelly and install it onto the clutch drum and input shaft assembly.

   Thrust needle roller bearing and diameter:

     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.)

1. Install the input shaft sub-assembly with the direct and reverse multiple disc assembly onto the transmission case.

32. INSTALL OIL PUMP ASSEMBLY

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

   Thrust bearing race diameter:

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

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

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

1. 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, as the oil seal ring will stick to the direct clutch drum.

1. Install the 10 bolts.

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

33. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL

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

   SST
     09350-30020 (09350-07110)

1. Coat the oil seal lips with MP grease.

34. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION

1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

   HINT:
     When inspecting the O/D direct clutch, check with the C3 accumulator piston holes indicated in the illustration.
     If there is no sound, disassembly and check the installation condition of the parts.
   1. (1) No. 2 clutch (C2)
   2. (2) No. 3 clutch (C3)
   3. (3) No. 1 clutch (C1)
   4. (4) No. 3 brake (B1)
   5. (5) No. 1 brake (B1)
   6. (6) No. 2 brake (B2)
   7. (7) No. 4 brake (B4)

35. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY

1. Install a new spacer to the manual valve lever.

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

1. Using a hammer, tap in a new spring pin.

1. Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.

1. Make sure the shaft rotates smoothly.

36. INSTALL PARKING LOCK PAWL SHAFT

1. Install the E-ring to the shaft.

1. Install the parking lock pawl, shaft and spring.

37. INSTALL PARKING LOCK ROD SUB-ASSEMBLY

1. Connect the parking lock rod to the manual valve lever.

38. INSTALL PARKING LOCK PAWL BRACKET

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 }

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

39. INSTALL C-1 ACCUMULATOR VALVE

1. Coat a new O-ring with ATF, and install it to the piston.

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

   Accumulator spring:

     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

40. INSTALL C-3 ACCUMULATOR PISTON

1. Coat a new O-ring with ATF, and install it to the piston.

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

   Accumulator spring:

     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

41. INSTALL B-3 ACCUMULATOR PISTON

1. Coat 2 new O-rings with ATF, and install them to the piston.

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

   Accumulator spring:

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

42. INSTALL C-2 ACCUMULATOR PISTON

1. Coat 2 new O-rings with ATF, and install them to the piston.

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

   Accumulator spring:

     Spring | Free length Outer diameter | Color
     C-2 | 62.0 mm (2.441 in.) 15.9 mm (03626 in.) | White

43. INSTALL CHECK BALL BODY

1. Install the check ball body and the spring.

44. INSTALL BRAKE DRUM GASKET

1. Install the 3 brake drum gaskets.

45. INSTALL TRANSAXLE CASE GASKET

1. Install the 3 transaxle case gaskets.

46. INSTALL TRANSMISSION VALVE BODY ASSEMBLY

1. Align the groove of the manual valve with the pin of the lever.

1. Install the 19 bolts.

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

   HINT:
   1. Each bolt length is indicated bellow.
   2. Bolt length:
      25 mm (0.98 in.) for bolt A
      36 mm (1.42 in.) for bolt B

47. INSTALL TRANSMISSION WIRE

1. Install a new O-ring to the transmission wire.

1. Install the transmission wire harness.

1. Install the bolt.

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

1. Connect the solenoid connector.

1. Connect the 7 solenoid connectors.

1. Install the ATF temperature sensor.

1. 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:
   1. Each bolt length is indicated bellow.
   2. Bolt length:
      36 mm (1.42 in.) for bolt A
      12 mm (0.47 in.) for bolt B

48. INSTALL VALVE BODY OIL STRAINER ASSEMBLY

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

1. Install the oil strainer with the 4 bolts.

   Torque:
     10 N*m{ 100 kgf*cm , 7 ft.*lbf }

49. INSTALL TRANSMISSION OIL CLEANER MAGNET

1. Install the 4 transmission oil cleaner magnets.

50. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

1. Install a new gasket on the oil pan.

1. Install the 20 bolts.

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

1. Install the drain plug.

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

51. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

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

   SST
     09710-30050
     09950-70010 (09951-07100)

52. INSTALL EXTENSION HOUSING DUST DEFLECTOR

1. Using SST and a hammer, tap in a new extension housing dust deflector.

   SST
     09223-15020
     09950-70010 (09951-07100)

53. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

1. Install the thrust needle roller bearing and the 2 bearing races.

1. Using a snap ring expander, install the snap ring.

1. Using feeler gauge, measure the clearance between the snap ring and the race.

   Clearance:
     0.05 to 0.33 mm (0.002 to 0.013 in.)
   1. If the Clearance is still standard, select another race.

   HINT:
     There are 6 different thickness for the race.

   Race thickness:

     No. | Thickness | No. | Thickness
     1 | 3.7 mm (0.146 in.) | 4 | 4.0 mm (0.158 in.)
     2 | 3.8 mm (0.150 in.) | 5 | 4.1 mm (0.161 in.)
     3 | 3.9 mm (0.154in.) | 5 | 4.2 mm (0.165 in.)

1. Install the gasket to the extension housing.

   HINT:
     Take care not to drop the gasket.

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

1. Apply FIPG to the extension housing.

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

1. Install the extension housing with new 6 bolts.

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

   HINT:
   1. Each bolt length is indicated below.
   2. Bolt length:
      45 mm (1.722 in.) for bolt A
      35 mm (1.378 in.) for bolt B

54. INSTALL AUTOMATIC TRANSMISSION HOUSING

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

1. 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:
   1. Each bolt length is indicated bellow.
   2. Bolt length:
      Bolt A: 14 mm
      Bolt B: 17 mm
      Bolt C: 14 mm

55. INSTALL AUTOMATIC TRANSAXLE BREATHER TUBE

1. Install a new O-ring to the breather tube.

1. Install the breather tube with the 3 bolts.

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

56. INSTALL SPEED SENSOR

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

1. Install the 2 transmission revolution sensor.

1. Install the 2 bolts.

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

57. INSTALL OIL COOLER TUBE UNION

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

1. Install the oil cooler tube union.

   Torque:
     29 N*m{ 296 kgf*cm , 21 ft.*lbf }

58. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY

1. Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.

1. Install a new lock washer and the nut.

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

1. Push the control shaft rearward as much as possible.

1. Return the control shaft lever 2 notches to the N position.

1. 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 }

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

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

59. INSTALL TRANSMISSION CONTROL SHAFT LEVER LH

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

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