1. Apply ATF to the lip, and install the low & reverse brake piston.
NOTE:
Take care not to damage the lip seal.
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, 18.4 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 retaining plate, 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 the flat board that will be placed on the 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 of weight less than 8.5 kg (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 lbf) − Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lbf) : Load applied to clutch plate
Z: Flat board weight
13. Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record height “A”. Measure at three locations or more 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) |
Dish plate |
|
(B) |
Drive plate |
|
(C) |
Driven 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. Place same thickness shims on both sides to prevent plate from tilting, then measure and record clearance “B”.
NOTE:
Do not push the shim down with force to a point where the waves on the drive plate will become crushed.
17. Piston stroke calculation
Calculate from recorded dimensions A and B, and when the usage limit is exceeded, replace with a new drive plate and adjust the retaining plate so that it is within the initial standard value.
T = A + B
T: Piston stroke
A: Amount of drive plate compression
B: Clearance between retaining plate and snap ring
Initial standard:
2.15 — 2.65 mm (0.085 — 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
|
Retaining plate | |
|
Part No. |
Thickness mm (in) |
|
31667AA420 |
3.8 (0.150) |
|
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) |
18. Install the leaf spring of the low & reverse brake.
|
(A) |
Leaf spring |
19. 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 |
20. Install the 2-4 brake piston spring retainer to the transmission case.
21. Position the snap ring in the transmission. Using ST, press the snap ring into the specified location.
| ST 498677100 | COMPRESSOR |
22. 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.
23. Measure the amount of drive plate compression and record that value.
(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 the flat board that will be placed on the retaining plate.
NOTE:
• For the flat board to place on the retaining plate, use a stiff board that will not bend against the load.
• Use a flat board of weight less than 10.2 kg (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 the clutch plate
Z: Flat board weight
(6) Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record 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) |
Driven plate |
|
(B) |
Drive plate |
|
(C) |
Retaining plate |
24. Install the pressure rear plate, 2-4 brake drive plate, driven plate, retaining plate and snap ring.
25. Install a new 2-4 brake seal to transmission case.
26. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
27. Check the piston stroke.
(1) Measure and record the clearance “B” between the retaining plate and snap ring.
At this time, do not press down the retaining plate.
(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:
1.5 L DOHC model
1.4 — 1.8 mm (0.055 — 0.071 in)
2.0 L DOHC model
1.7 — 2.1 mm (0.067 — 0.083 in)
Limit thickness:
1.5 L DOHC model
1.95 mm (0.077 in)
2.0 L DOHC model
2.3 mm (0.091 in)
|
Retaining plate | |
|
Part No. |
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. Make sure to install the leaf spring 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 |
|
(E) |
Outside |
30. Install the front sun gear and the thrust needle bearing.
|
(A) |
Front sun gear |
|
(B) |
Thrust needle bearing |
|
(C) |
Upside |
|
(D) |
Downside |
|
(E) |
Outside |
31. Apply vaseline, and attach the thrust needle bearing to the high clutch hub, then engage the splines of the front planetary carrier correctly to install the high clutch hub.
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 ASSY and reverse clutch ASSY |
34. Adjust the total end play. 
35. Install the thrust needle bearing in the correct direction.
|
(A) |
High clutch ASSY and reverse clutch ASSY |
|
(B) |
Thrust needle bearing |
|
(C) |
Upside |
|
(D) |
Downside |
|
(E) |
Outside |
36. Install a new gasket along with the oil pump housing assembly.
37. Attach the converter case to the transmission case assembly.
38. Insert the inhibitor switch and transmission harness connector to the stay.
|
(A) |
Transmission harness connectors |
|
(B) |
Inhibitor switch connector |
39. Install the air breather hose.
40. Install the ATF cooler pipe.
41. Install the oil charge pipe with 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.