Page 409 of 2248
G3M0393
16) Apply vaseline to the groove on the oil pump cover,
and install two (R) seal rings and two (H) seal rings.
NOTE:
Fit the seal ring after compressing, and rub vaseline into
the seal ring to avoid expansion.
The“R”seal ring has a large diameter, while“H”has
small diameter.
G3M0394
17) Install the rubber seal to the torque converter clutch
case.
CAUTION:
Be careful not to lose the rubber seal.
G3M0395
2. TRANSMISSION CASE SECTION
1) Press-fit the roller bearing to the transmission case with
ST.
ST 398487700 DRIFT
G3M0396
2) Using a plastic hammer, force-fit the oil seal.
G3M0397
3) Install the manual plate and shaft, and secure with a
spring pin.
CAUTION:
Be careful not to damage the oil seal lip.
NOTE:
After installation, make sure of smooth movement.
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G3M0398
4) Assemble the manual lever and parking rod to the
inside shaft, and secure with a nut.
Tightening torque:
47±2 N⋅m (4.8±0.2 kg-m, 34.7±1.4 ft-lb)
G3M0364
5) Install the detention spring.
NOTE:
Position the spring so that its center is aligned with the
center of the manual plate.
Tightening torque:
6±1 N⋅m (0.6±0.1 kg-m, 4.3±0.7 ft-lb)
G3M0399
6) Install the lathe cut seal rings to the I.D./O.D. of the low
and reverse piston. Then install the piston into the case
with a press, ST1 and ST2.
ST1 398673600 COMPRESSOR
ST2 498627000 SEAT
CAUTION:
Be careful not to tilt the piston when installing.
Be careful not to damage the lip seal.
G3M0400
7) Install the one-way clutch inner race.
(1) Using a press and ST1, install the needle bearing
to the inner race.
ST1 398497701 INSTALLER
NOTE:
Use the following ST when removing.
ST 398527700 PULLER ASSY
B3M0403A
(2) Install four seal rings and thrust washer.
NOTE:
Apply vaseline to the groove of the inner race and to the
seal ring after installation, so that the seal ring will not
expand.
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G3M0402
(3) Place the spring retainer on the inner race. Install
the spring to the recessed portion of the piston. Then
tighten eight socket head bolts from the rear side of the
transmission case.
Tightening torque:
25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
CAUTION:
Be sure to tighten evenly.
G3M0403
8) Install the band servo sub assembly.
9) Press the O.D. servo retainer into position with ST1 and
ST2, and secure with a snap ring.
ST1 498677010 COMPRESSOR
ST2 399703600 PULLER ASSY
CAUTION:
Perform the following operations with the transmis-
sion case set vertically on wooden blocks.
B3H0013A
10) Installation of the low & reverse brake:
(1) 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.
Driven plate : 6
Drive plate : 6
Dish plate : 1
1Snap ring
2Retaining plate
3Transmission case
4Lathe cut seal ring
5Dish plate
6Piston
7Bolt
8Lathe cut seal ring
9Clutch spring retainer
10Forward clutch drum
11Drive plate
12Driven plate
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G3M0405
(2) Apply compressed air intermittently to check for
operation.
G3M0406
(3) Check the clearance. (Selection of retaining plate)
Standard value:
1.1—1.7 mm (0.043—0.067 in)
Allowable limit:
2.7 mm (0.106 in)
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent retaining plate from tilting.
Available retaining platesPart No. Thickness mm (in)
31667AA180
31667AA190
31667AA200
31667AA210
31667AA220
31667AA230
31667AA240
31667AA2506.5 (0.256)
6.8 (0.268)
7.1 (0.280)
7.4 (0.291)
7.7 (0.303)
8.0 (0.315)
8.2 (0.323)
8.4 (0.331)
B3M0404A
11) Install the forward clutch drum.
(1) Install carefully while rotating the drum slowly pay-
ing special attention not to damage the seal ring.
(2) Installation is complete when the drum recedes 2.5
mm (0.098 in) from the inner race surface.
G3M0408
12) Assemble the overrunning clutch hub.
CAUTION:
Install thrust needle bearing in the correct direction.
NOTE:
Join the thrust needle bearing and thrust washer with
vaseline, and then install them together.
Make sure that the splines are engaged correctly.
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G3M0409
13) Install the one-way clutch outer race.
NOTE:
Make sure the forward clutch splines are engaged cor-
rectly.
B3M0117A
14) Assemble the rear internal gear.
(1) Join the thrust needle bearing and thrust washer to
the gear with vaseline, and install the gear while rotat-
ing it.
(2) Securely engage the bearing with the dog of the
overrunning clutch hub.
CAUTION:
Install thrust needle bearing in the correct direction.
NOTE:
Installation is complete when the snap ring top surface of
the forward clutch drum recedes approximately 3.5 mm
(0.138 in).
G3M0890
15) Install the rear planetary carrier.
Attach the thrust needle bearing to the inside of the carrier
with vaseline. Then install the carrier while rotating slowly.
CAUTION:
Install thrust needle bearing in the correct direction.
G3M0891
16) Install the rear sun gear.
NOTE:
Install the gear with the oil groove facing up.
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G3M0413
17) Install the front planetary carrier.
Attach the thrust needle bearings to both sides of the car-
rier with vaseline. Install the carrier carefully, while aligning
with the splines of the forward clutch drum, and while rotat-
ing the pinion.
CAUTION:
Install thrust needle bearing in the correct direction.
G3M0414
18) Install the front sun gear.
Attach the thrust needle bearing to the gear, and install the
gear while turning slowly.
CAUTION:
Install thrust needle bearing in the correct direction.
G3M0415
19) Install the high clutch hub.
Attach the thrust needle bearing to the hub with vaseline
and install the hub by correctly engaging the splines of the
front planetary carrier.
CAUTION:
Install thrust needle bearing in the correct direction.
G3M0416
20) Install the high clutch assembly.
NOTE:
Correctly engage the high clutch hub and clutch splines.
G3M0417
21) Install the reverse clutch assembly.
NOTE:
Engage the high clutch outer spline with the reverse clutch
spline and the front sun gear with the cut-out portion of the
reverse clutch drum correctly when installing.
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G3M0418
22) Install the brake band.
CAUTION:
Be careful not to damage the brake band when install-
ing.
NOTE:
Install the strut to the band servo piston stem. Then tighten
it temporarily to avoid tilting the band.
23) Adjustment of total end play and reverse clutch end
play
(1) Measure the distance from the transmission case
mating surface to the recessed portion of the high
clutch drum“L”, and the distance to the top surface of
the reverse clutch drum“M”.
G3M0419
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Page 416 of 2248
(2) Measure the distance from the oil pump housing
mating surface to the top surface of the oil pump cover
with needle bearing, and to the thrust surface of the
reverse clutch.
G3M0420
(3) Equation for calculation
Total end play
Unit: mm
C = (L + 0.4)
C : Clearance between concave portion of high clutch
and end of clutch drum support
L : Length from case mating surface to concave portion
of high clutch
0.4 : Gasket thickness
: Height from housing mating surface to upper surface
of clutch drum support
Select suitable bearing race from
among those listed in this table
so that clearance C is in the 0.25—
0.55 mm (0.0098—0.0217 in) range.Part No. Thickness mm (in)
803031021
803031022
803031023
803031024
803031025
803031026
8030310270.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.4 (0.055)
1.6 (0.063)
1.8 (0.071)
2.0 (0.079)
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4. Overall Transmission