Transmission Assembly: Assembly
- As shown in the figure, use a drift [22 mm (0.87 in) dia. commercial service tool] to drive manual shaft oil seals into the transmission case until it is flush.CAUTION:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.
- Install detent spring
to transmission case. Tighten detent spring bolt to the specified torque.
: Bolt
- Install manual shaft to transmission case.
- Install parking rod
to manual plate
.
- Install manual plate (with parking rod) to manual shaft.
- Install retaining pin
into the manual plate and manual shaft.
- Install retaining pin into the transmission case and manual shaft.
- Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
- Use a hammer to tap the retaining pin into the transmission case.CAUTION: Drive retaining pin to 5+/-1 mm (0.20+/-0.04 in) over the transmission case.
- Install D-rings to reverse brake piston.
- Install reverse brake piston to transmission case.
- Install needle bearing to drum support edge surface.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install seal rings to drum support.
- Install reverse brake spring retainer and reverse brake return spring in transmission case.
- Set the clutch spring compressor on reverse brake spring retainer and install snap ring (fixing spring retainer) to transmission case while compressing return spring.CAUTION:
- Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
- Be careful not to damage snap ring.
- Install reverse brake component part (dish plates, driven plates, and drive plates) to transmission case.
: Snap ring
: Retaining plate
: Drive plate (eight pieces)
: Driven plate (eight pieces)
: Dish plate
: Dish plate
CAUTION: Check order of plates. - Assemble N-spring.
- Install reverse brake retaining plate to transmission case.
- Install snap ring to transmission case.CAUTION: Be careful not to damage snap ring.
- Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
Specified clearance (A)
Standard: Reverse Brake Clearance .
Retaining plate: Refer to Reverse Brake Clearance
- Install needle bearing to transmission case.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install output speed sensor
to transmission case and tighten output speed sensor mounting bolt (
) to the specified torque.
CAUTION:- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.
- As shown in the figure, use the drift to drive rear oil seal into the rear extension
until it is flush.
(1)
: Drift [SST: 33400001 (J-26082)]
CAUTION:- Never reuse rear oil seal.
- Apply ATF to rear oil seal.
- Never incline to rear oil seal.
- Install return spring
to parking pawl
.
- Install parking pawl (with return spring) and pawl shaft to rear extension.
- Install parking actuator support to rear extension.
- Install needle bearing
to rear extension.
CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races . - Install rear extension assembly according to the following procedures.
- Install seal rings
to output shaft.
- Install parking gear
to output shaft
.
- Install output shaft in transmission case.CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
- Install bearing race to output shaft.
- Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to Recommended Chemical Products and Sealants
.) to rear extension assembly as shown in the figure.
Sealant starting point and end-point
: Start and finish point shall be in the center of two bolts.
Overlap width of sealant starting point and end-point (B)
: 3 - 5 mm (0.12 - 0.20 in)
Sealant width (C)
: 1.0 - 2.0 mm (0.04 - 0.08 in)
Sealant height (C)
: 0.4 - 1.0 mm (0.016 - 0.04 in)
CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces. - Install rear extension assembly to transmission case.CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
- Tighten rear extension assembly bolts to the specified torque.
: Bracket
: Bolt
: Self-sealing bolt
- Install seal rings
- Install needle bearing to drum support.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install direct clutch assembly to reverse brake.CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
- Install high and low reverse clutch assembly to direct clutch.
- Align the drive plate using a flat-bladed screwdriver.
- Install high and low reverse clutch hub, mid sun gear assembly, and rear sun gear assembly as a unit.CAUTION: Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.
- Install needle bearing to rear carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install bearing race to rear carrier assembly.CAUTION: Check the direction of bearing race. Refer to Location of Needle Bearings and Bearing Races .
- Install rear carrier assembly to direct clutch drum.
- Install needle bearing (rear side) to mid carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install needle bearing (front side) to mid carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install mid carrier assembly to rear carrier assembly.
- Install seal rings
to input clutch assembly.
- Install needle bearing
to front carrier assembly.
CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races . - Install input clutch assembly (with front carrier assembly and rear internal gear)
to transmission case.
CAUTION: Check that the needle bearingis securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.
- Install 1st one-way clutch
to front brake hub (with under drive carrier)
.
- Check operation of 1st one-way clutch.
- Install under drive carrier (with 1st one-way clutch)
to transmission case.
- Install snap ring
to transmission case.
CAUTION: Be careful not to damage snap ring. - Install front brake component part (retaining plates, drive plates, and driven plate) to transmission case.
: Retaining plate (thin)
: Drive plate
: Driven plate
: Retaining plate (thick)
: Front
CAUTION: Check order of plates. - Install needle bearing
to under drive carrier assembly.
CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races . - Install under drive sun gear
to under drive carrier assembly.
- Adjustment of total end play "T".
- Measure clearance between bearing race
and oil pump cover
.
- Select proper thickness of bearing race so that end play is within specifications.
- Measure dimensions "K" and "L", and calculate dimension "J".
1
: Transmission case
2
: Under drive sun gear
A
: Straightedge
"J"
: Distance between the oil pump fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
J = K - L
- Measure dimension "K" between the converter housing fitting surface of transmission case
and the needle bearing mating surface of under drive sun gear
.
CAUTION:- Never change the straightedge (A) installation position before the completion of "L" measurement.
- Measure dimension "K" in at least three places, and take the average.
- Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
: Transmission case
(A)
: Straightedge
CAUTION: Measure dimension "L" in at least three places, and take the average. - Calculate dimension "J".
J = K - L
- Measure dimension "K" between the converter housing fitting surface of transmission case
- Measure dimensions "M 1
" and "M 2
", and calculate dimension "M".
: Bearing race
: Needle bearing
: Oil pump assembly
(A)
: Straightedge
"M"
: Distance between the transmission case fitting surface of oil pump and the needle bearing on oil pump.
M = M 1 - M 2
- Place bearing race
and needle bearing
on oil pump assembly
.
- Measure dimension "M 1
" between the transmission case fitting surface of oil pump and the end of oil pump.
: Bearing race
: Needle bearing
: Oil pump assembly
(A)
: Straightedge
CAUTION: Measure dimension "M 1 " in at least three places, and take the average. - Measure dimension "M 2
" between the needle bearing on oil pump and the end of oil pump.
: Bearing race
: Needle bearing
: Oil pump assembly
(A)
: Straightedge
CAUTION: Measure dimension "M 2 " in at least three places, and take the average. - Calculate dimension "M".
M = M 1 - M 2
- Place bearing race
- Adjust total end play "T ".
: Bearing race
: Oil pump assembly
T = J - M
Total end play "T"
: Refer to Total End Play .
- Select proper thickness of bearing race so that total end play is within specifications.
Bearing races
: Refer to Total End Play .
- Select proper thickness of bearing race so that total end play is within specifications.
- Measure clearance between bearing race
- Adjustment of front brake clearance "C".
- Measure clearance between front brake piston
and front brake retaining plate
.
- Select proper thickness of front brake retaining plat so that clearance is within specifications.
- Measure dimensions "O" and "P", and calculate dimension "N".
: Transmission case
: Front brake retaining plate
(A)
: Straightedge
"N"
: Distance between the oil pump fitting surface of transmission case and the front brake retaining plate.
N = O - P
- Measure dimension "O" between the converter housing fitting surface of transmission case
and the front brake retaining plate
.
CAUTION:- Never change the straightedge (A) installation position before the completion of "P" measurement.
- Measure dimension "O" in at least three places, and take the average.
- Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
: Transmission case
(A)
: Straightedge
CAUTION: Measure dimension "P" in at least three places, and take the average. - Calculate dimension "N".
N = O - P
- Measure dimension "O" between the converter housing fitting surface of transmission case
- Measure dimensions "Q 1
" and "Q 2
", and calculate dimension "Q".
: Front brake piston
: Oil pump assembly
(A)
: Straightedge
"Q"
: Distance between the transmission case fitting surface of oil pump and the front brake piston.
Q = Q 1 - Q 2
- Measure dimension "Q 1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
: Front brake piston
: Oil pump assembly
(A)
: Straightedge
CAUTION: Measure dimension "Q 1 " in at least three places, and take the average. - Measure dimension "Q 2
" of the straightedge.
: Front brake piston
: Oil pump assembly
(A)
: Straightedge
- Calculate dimension "Q".
Q = Q 1 - Q 2
- Measure dimension "Q 1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
- Adjust front brake clearance "C".
: Front brake piston
: Front brake retaining plate
C = N - Q
Front brake clearance "C"
: Refer to Front Brake Clearance .
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
Retaining plate
: Refer to Front Brake Clearance .
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
- Measure clearance between front brake piston
- Remove under drive sun gear
from under drive carrier assembly.
- Install needle bearing
to under drive sun gear.
CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races . - Install O-ring
to oil pump assembly.
- Install seal ring
to oil pump assembly.
- Install bearing race
to oil pump assembly.
- Install under drive sun gear (with needle bearing)
to oil pump assembly
.
- Install oil pump assembly (with under drive sun gear) to transmission case.CAUTION: Apply ATF to oil pump bearing.
- Apply recommended sealant to oil pump assembly as shown in the figure.
: Apply Genuine RTV silicone sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
CAUTION: Completely remove all moisture, oil and old sealant, etc. from the oil pump mounting bolts and oil pump mounting bolt mounting surfaces. - Tighten oil pump bolts (
) to the specified torque.
CAUTION: Apply ATF to oil pump bushing. - Install O-ring to input clutch assembly.
- Install converter housing to transmission case, and tighten converter housing bolts (
) to the specified torque.
- Connect TCM connector
.
- Install joint connector
to the control valve & TCM.
CAUTION: Apply ATF to O-ring of joint connector. - Install the control valve & TCM
to transmission case.
CAUTION:- Make sure that input speed sensor securely installs input speed sensor holes
.
- Hang down output speed sensor harness toward outside so as not to disturb installation of the control valve & TCM.
- Adjust joint connector of the control valve & TCM to terminal hole of transmission case.
- Assemble it so that manual valve cutout is engaged with manual plate projection.
- Make sure that input speed sensor securely installs input speed sensor holes
- Install bolts and clip (1) to the control valve & TCM. Tighten bolt (E) to the specified torque before tightening the other than bolts.
: Front
Bolt symbol
Length mm (in)
Number of bolts
43 (1.69)
3
40 (1.57)
2
54 (2.13)
6
50 (1.97)
2
*
50 (1.97)
1
*: Reamer bolt
- Connect output speed sensor connector
.
- Engage output speed sensor harness with terminal clips (
).
- Pull down joint connector
.
CAUTION: Be careful not to damage connector. - Install snap ring
to joint connector
.
- Install magnets
in oil pan.
- Install oil pan gasket to transmission case.CAUTION:
- Never reuse oil pan gasket.
- Install it in the direction to align hole positions.
- Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.
- Install oil pan
and clips
to transmission case.
: Front
: Oil pan mounting bolt
CAUTION:- Be careful not to pinch harnesses.
- Completely remove all moisture, oil and old gasket, etc. from oil pan mounting surface.
- Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure after temporarily tightening them. Tighten oil pan mounting bolts to the specified torque.
: Front
CAUTION: Never reuse oil pan mounting bolts. - Install drain plug and drain plug gasket to oil pan. Tighten drain plug to the specified torque.CAUTION: Never reuse drain plug and drain plug gasket.
- Pour ATF into torque converter.
- Approximately 2 liter (2-1/8 US qt, 1-3/4 Imp qt) of ATF is required for a new torque converter.
- When reusing old torque converter, add the same amount of ATF as was drained.
- Install torque converter while aligning notches of torque converter with notches of oil pump.CAUTION: Install torque converter while rotating it.
- Measure dimension "A" to make sure that torque converter is in proper position.
(B)
: Scale
(C)
: Straightedge
Dimension (A)
: Refer to Torque Converter .