1. Install the low & reverse piston.
NOTE:
Do not let the lip seal be damaged.
2. Install the return spring.
3. Install the spring retainer.
4. Install the one-way clutch inner race.
5. Tighten the socket head bolts evenly from the rear side of transmission case.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
6. Place the front side of transmission body up.
7. Install the thrust needle bearing.
8. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
9. Set the micro gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is zero point.
10. Scale and record the weight “Z” of a flat board which will be put on retaining plate.
NOTE:
• Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
• Use a flat board weighing less than 83 N (8.5 kgf, 18.7 lb).
11. Put the flat board on retaining plate.
12. Using the following formula, read the push/pull gauge, and calculate “N”.
N = 83 N (8.5 kgf, 18.7 lb) − Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb) : Load applied to clutch plate
Z: Flat board weight
13. Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three or more locations spaced by equal distances and take the average value.
NOTE:
If measuring in three locations, measure every 120°. If in four locations, measure every 90°.
|
(A) |
Dish plate |
|
(B) |
Driven plate |
|
(C) |
Drive plate |
|
(D) |
Retaining plate |
14. Installation of the low & reverse brake:
Install the dish plate, driven plate, drive plate and retaining plate, and then secure them with a snap ring.
NOTE:
Pay attention to the orientation of the dish plate.
|
(A) |
Snap ring |
15. Apply compressed air intermittently to check for operation.
16. Measure the clearance.
(1) Place same thickness shims on both sides to prevent plate from tilting, then measure and record the clearance B.
(2) Piston stroke calculation
Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limit, replace the drive plate with a new part and select and adjust the retaining plate to be within the default specification values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Turbo model
Initial standard:
2.7 — 3.2 mm (0.106 — 0.126 in)
Limit thickness:
3.9 mm (0.153 in)
Non-turbo model
Initial standard:
2.15 — 2.65 mm (0.085 — 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
|
Retaining plate | |
|
Part number |
Thickness mm (in) |
|
31667AA320 |
4.1 (0.161) |
|
31667AA330 |
4.4 (0.173) |
|
31667AA340 |
4.7 (0.185) |
|
31667AA350 |
5.0 (0.197) |
|
31667AA360 |
5.3 (0.209) |
|
31667AA370 |
5.6 (0.220) |
|
31667AA380 |
5.9 (0.232) |
17. Install the leaf spring of the low & reverse brake.
|
(A) |
Leaf spring |
18. Install the 2-4 brake piston and 2-4 brake retainer by aligning the hole of the 2-4 brake retainer with the hole on the transmission case.
|
(A) |
2-4 brake piston |
|
(B) |
2-4 brake piston retainer |
19. Install 2-4 brake piston spring retainer to the transmission case.
20. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.
| ST 498677100 | COMPRESSOR |
21. Install the planetary gear and low clutch assembly to the transmission case.
NOTE:
Install carefully while rotating the low clutch and planetary gear assembly slowly, paying special attention not to damage the seal ring.
22. Measure the amount of drive plate compression and record that value. (Non-turbo model)
(1) Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
(2) Set the micro gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is zero point.
(3) Scale and record the weight “Z” of a flat board which will be put on retaining plate.
NOTE:
• Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
• Use a flat board weighing less than 100 N (10.2 kgf, 22.5 lb).
(4) Put the flat board on retaining plate.
(5) Using the following formula, read the push/pull gauge, and calculate “N”.
N = 100 N (10.2 kgf, 22.5 lb) − Z
N: Value indicated on push/pull gauge
100 N (10.2 kgf, 22.5 lb) : Load applied to clutch plate
Z: Flat board weight
(6) Press the center of retaining plate by applying a force of N using push/pull gauge, and then measure and record the height A. Measure at three or more locations spaced by equal distances and take the average value.
NOTE:
If measuring in three locations, measure every 120°. If measuring in four locations, measure every 90°.
|
(A) |
Drive plate |
|
(B) |
Driven plate |
|
(C) |
Retaining plate |
23. Install the pressure rear plate, 2-4 brake drive plate, driven plate, retaining plate and snap ring.
24. Install a new 2-4 brake seal to transmission case.
25. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
26. Check the piston stroke. (Non-turbo model)
(1) Measure the clearance B between the retaining plate and snap ring.
(2) Piston stroke calculation
Calculate with A and B dimensions recorded before. If the service limits from the calculation formula are exceeded, replace the drive plate and select and adjust the retaining plate to be with in standard values.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard:
1.7 — 2.1 mm (0.067 — 0.082 in)
Limit thickness:
2.3 mm (0.091 in)
|
Retaining plate | |
|
Part number |
Thickness mm (in) |
|
31567AA991 |
5.6 (0.220) |
|
31567AB001 |
5.8 (0.228) |
|
31567AB011 |
6.0 (0.236) |
|
31567AB021 |
6.2 (0.244) |
|
31567AB031 |
6.4 (0.252) |
|
31567AB041 |
6.6 (0.260) |
27. Measure the clearance between the retaining plate and snap ring. (Turbo model)
If the clearance exceeds the service limits, replace the driven plate and select and adjust the retaining plate so that the clearance is within default standard values.
Initial standard:
0.8 — 1.2 mm (0.031 — 0.047 in)
Limit thickness:
1.5 mm (0.059 in)
|
Retaining plate | |
|
Part number |
Thickness mm (in) |
|
31567AA991 |
5.6 (0.220) |
|
31567AB001 |
5.8 (0.228) |
|
31567AB011 |
6.0 (0.236) |
|
31567AB021 |
6.2 (0.244) |
|
31567AB031 |
6.4 (0.252) |
|
31567AB041 |
6.6 (0.260) |
28. Install the 2-4 brake leaf spring.
NOTE:
Make sure to install in the correct position.
|
(A) |
Leaf spring |
|
(B) |
Retaining plate |
29. Install the thrust needle bearing in the correct direction.
|
(A) |
Snap ring |
|
(B) |
Thrust needle bearing |
|
(C) |
Upside |
|
(D) |
Downside |
30. Install the front sun gear and the thrust needle bearing.
|
(A) |
Front sun gear |
|
(B) |
Thrust needle bearing |
31. Apply vaseline, then attach the thrust needle bearing to the high clutch hub. Install the high clutch hub by correctly engaging the splines of the front planetary carrier.
32. Install the thrust needle bearing in the correct direction.
|
(A) |
High clutch hub |
|
(B) |
Thrust needle bearing |
|
(C) |
Upside |
|
(D) |
Downside |
|
(E) |
Outside |
33. Install the high clutch assembly and reverse clutch assembly.
|
(A) |
High clutch and reverse clutch ASSY |
34. Adjust the total end play. 
35. Install the thrust needle bearing in the correct direction.
|
(A) |
High clutch and reverse clutch ASSY |
|
(B) |
Thrust needle bearing |
|
(C) |
Upside |
|
(D) |
Downside |
|
(E) |
Outside |
36. Install the oil pump housing assembly along with a new gasket.
37. Install the converter case assembly to the transmission case assembly.
38. Insert the inhibitor switch and transmission connector to the stay.
|
(A) |
Transmission harness |
|
(B) |
Inhibitor switch harness |
39. Install the air breather hose.
40. Install the ATF cooler pipe.
41. Install the oil charge pipe together with an O-ring.
42. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
43. Install the torque converter clutch assembly.
44. Install the transmission assembly to the vehicle.