Page 345 of 2395
SAT523GA
2. Install accumulator piston.
a. Install O-rings onto accumulator piston.
IApply ATF to O-rings.
Accumulator piston O-rings
Unit: mm (in)
Accumulator A B C D
Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14)
Large diameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77)
SAT938A
b. Install return spring for accumulator A onto transmission case.
Free length of return spring:
Refer to SDS, AT-357.
SAT939AA
c. Install accumulator pistons A, B, C and D.
IApply ATF to transmission case.
SAT941A
3. Install band servo piston.
a. Install return springs onto servo piston.
SAT942A
b. Install band servo piston onto transmission case.
IApply ATF to O-ring of band servo piston and transmis-
sion case.
c. Install gasket for band servo onto transmission case.
ASSEMBLY
Assembly (1) (Cont'd)
AT-340
Page 346 of 2395
SAT940A
d. Install band servo retainer onto transmission case.
SAT943A
4. Install rear side clutch and gear components.
a. Place transmission case in vertical position.
SAT944A
b. Slightly lift forward clutch drum assembly. Then slowly rotate it
clockwise until its hub passes fully over clutch inner race inside
transmission case.
SAT945A
c. Check to be sure that rotation direction of forward clutch
assembly is correct.
SAT946A
d. Install thrust washer onto front of overrun clutch hub.
IApply petroleum jelly to the thrust washer.
IInsert pawls of thrust washer securely into holes in over-
run clutch hub.
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ASSEMBLY
Assembly (1) (Cont'd)
AT-341
Page 347 of 2395
SAT947A
e. Install overrun clutch hub onto rear internal gear assembly.
SAT948A
f. Install needle bearing onto rear of overrun clutch hub.
IApply petroleum jelly to needle bearing.
SAT949A
g. Check that overrun clutch hub rotates as shown while holding
forward clutch hub.
SAT527G
h. Place transmission case into horizontal position.
SAT951A
i. Install rear internal gear, forward clutch hub and overrun clutch
hub as a unit onto transmission case.
ASSEMBLY
Assembly (1) (Cont'd)
AT-342
Page 348 of 2395

SAT952A
j. Install needle bearing onto rear internal gear.
IApply petroleum jelly to needle bearing.
SAT953A
k. Install bearing race onto rear of front internal gear.
IApply petroleum jelly to bearing race.
ISecurely engage pawls of bearing race with holes in front
internal gear.
SAT954A
l. Install front internal gear on transmission case.
SAT546J
5. Install rear extension assembly on transmission case (2WD
model only).
a. Install revolution sensor on rear extension.
b. Install rear extension gasket on transmission case.
c. Install parking rod on transmission case.
d. Install parking gear and needle bearing.
IInsert rear extension assembly into place while holding
parking gear and needle bearing by hand.
SAT216B
6. Install output shaft and parking gear (4WD model only).
a. Insert output shaft from rear of transmission case while slightly
lifting front internal gear.
IDo not force output shaft against front of transmission
case.
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ASSEMBLY
Assembly (1) (Cont'd)
AT-343
Page 349 of 2395
SAT957A
b. Carefully push output shaft against front of transmission case.
Install snap ring on front of output shaft.
ICheck to be sure output shaft cannot be removed in rear
direction.
SAT217B
c. Install needle bearing on transmission case.
IPay attention to its direction Ð Black side goes to rear.
IApply petroleum jelly to needle bearing.
SAT218B
d. Install parking gear on transmission case.
SAT960A
e. Install snap ring on rear of output shaft.
ICheck to be sure output shaft cannot be removed in for-
ward direction.
SAT759I
7. Install adapter case (4WD model only).
a. Install oil seal on adapter case.
IApply ATF to oil seal.
ASSEMBLY
Assembly (1) (Cont'd)
AT-344
Page 350 of 2395
SAT757I
b. Install O-ring on revolution sensor.
IApply ATF to O-ring.
c. Install revolution sensor on adapter case.
SAT963A
d. Install adapter case gasket on transmission case.
SAT964A
e. Install parking rod on transmission case.
SAT755I
f. Install adapter case on transmission case.
SAT974A
8. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
IPay attention to its direction.
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Assembly (1) (Cont'd)
AT-345
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SAT967A
b. Make sure needle bearing is on front of front planetary carrier.
IApply petroleum jelly to needle bearing.
c. Make sure needle bearing is on rear of front planetary carrier.
IApply petroleum jelly to bearing.
IPay attention to its direction Ð Black side goes to front.
SAT969A
d. While rotating forward clutch drum clockwise, install front plan-
etary carrier on forward clutch drum.
SAT970A
ICheck that portion A of front planetary carrier protrudes
approximately 2 mm (0.08 in) beyond portion B of forward
clutch assembly.
SAT971A
e. Make sure bearing races are on front and rear of clutch pack.
IApply petroleum jelly to bearing races.
ISecurely engage pawls of bearing races with holes in
clutch pack.
SAT973A
f. Install clutch pack into transmission case.
ASSEMBLY
Assembly (1) (Cont'd)
AT-346
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Adjustment=NBAT0156When any parts listed in the following table are replaced, total end
play or reverse clutch end play must be adjusted.
Part name Total end play Reverse clutch end play
Transmission caseII
Low one-way clutch inner raceII
Overrun clutch hubII
Rear internal gearII
Rear planetary carrierII
Rear sun gearII
Front planetary carrierII
Front sun gearII
High clutch hubII
High clutch drumII
Oil pump coverII
Reverse clutch drum ÐI
SAT975A
1. Adjust total end play.
Total end play ªT
1º:
0.25 - 0.55 mm (0.0098 - 0.0217 in)
SAT976A
a. With needle bearing installed, place J34291-1 (bridge),
J34291-2 (legs) and the J34291-5 (gauging cylinder) onto oil
pump. The long ends of legs should be placed firmly on
machined surface of oil pump assembly. The gauging cylinder
should rest on top of the needle bearing. Lock gauging cylin-
der in place with set screw.
SAT977A
b. Install J34291-23 (gauging plunger) into gauging cylinder.
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ASSEMBLY
Adjustment
AT-347