Warnings:
- Do not reuse gaskets, seals and rubber parts. Replace them with new ones each time you disassemble them. The O-ring for the oil dipstick does not need to be replaced.
- Do not use other grease than petrolatum and petroleum jelly. Before installation, apply automatic transmission fluid to all rubbing elements, rotating and sliding parts. For automatic transmission fluid, see specifications.
- New clutch discs must be immersed in automatic transmission fluid for more than two hours before installation.
- Do not apply sealants or adhesives to the gasket.
- If bushings need to be replaced, replace the assembly containing them.
- Do not use purchased towels during disassembly and assembly operations.
- The oil in the cooler should also be changed.
1. Insert the manual control shaft into the gearbox housing and slide it as far as it will go in the direction of the manual control lever.
At this time, do not install the O-ring (more of two o-rings) on the manual shaft.
2. After installing the O-ring on the manual shaft, slide the shaft back into the housing, then install the set screw and spacer. Also install the retaining ball, seat and spring.
3. Install the parking spacer bar on the stopper plate. Install the rod bracket and tighten the two bolts (20-27 Nm).
4. Before assembling the gearbox, measure the axial play of the brake (clutch) first gear and reverse and select the pressure plate so» so that the axial play has a normal value. For this:
- 1) Install the clutch base plate, plate and disc into the gearbox housing.
Warning. When using new discs, be sure to submerge them in automatic transmission fluid for two hours or more.
- 2) Install pressure plate and return spring.
- 3) Apply grease to the wave spring and install it on the support.
- 4) Attach special tool (09453-21310) to the support and install the circlip.
- 5) Install watch special tool (09453-21400, 09453-33100) and hour indicator on the back of the gearbox housing.
- 7) Pump air with a hand pump from the position shown in the figure. Take the indicator reading and select a pressure plate that will provide the normal clearance.
- Normal value - 0.675-1.987 mm
- Pressure plate - 5.6-6.8 mm
- 8) After selecting the pressure plate, remove the hub, brake plate, disc, reaction and pressure plate.
5. Install the transmission shaft and fit the bearing outer race very tightly onto the transmission housing.
6. Install the transmission shaft snap ring.
7. Install the spacer sleeve on the transmission shaft.
8. Fit the rolling bearing holder into the housing.
9. Place the driven gear very tightly on the transmission shaft.
10. Torque lock nut (200-230 Nm).
11. Using a dial indicator, measure the axial play of the transmission shaft; then select spacer washer (washers), required to obtain its nominal value (0-0.06mm).
12. Using a chisel, secure the lock nut to prevent it from turning.
13. Install the drive shaft drive gear assembly:
14. Install the special tool on the rear side of the gearbox housing.
15. Using it, connect the gear to the drive at the transfer shaft.
16. Install retainer plate and circlip.
17. Apply Three Bond 1216 Special Compound to the back cover.
18. Install the back cover.
- Tightening torque - 17-22 Nm
19. Install the snap ring.
20. Install the bearing holder. Tighten the screws to the required torque (17-22 Nm). Apply sealing material 5 mm wide (3 M Stud Locking N 1303). The material must not go over the screw heads.
21. Apply a spray of petrolatum to the #12 tire thrust poi and yak and install it into the planetary gear mount.
22. Install the planetary gear carrier into the crankcase.
23. Reassemble the reverse sun wheel and forward sun wheel in the following order:
- 1) Install the o-ring and circlip to the reverse sun gear. When installing, compress the O-ring as shown in the figure.
- 2) Install a #9 thrust bearing to the forward sun gear.
- 3) Install a #10 spacer ring to the forward sun gear.
- 4) Assemble the reverse sun gear and then the forward sun gear.
24. Install both previously assembled sun gears into the planetary carrier.
25. Install the brake disc and brake plate.
26. Install the selected brake pressure plate.
27. Install the return spring.
28. Apply a layer of petrolatum to the wave spring and install it on the center caliper.
29. Install two new o-rings on the center support.
30. After applying a coat of automatic transmission fluid to the o-rings, install the special tool (09453-21310) on the center support and install it in the crankcase.
Warning: Make sure the wave spring is in the correct position.
31. Install the circlip.
32. Install a new O-ring (larger diameter) and D ring (small diameter) on the positive downshift servo piston and install a new O-ring in the groove around the bushing; then install the servo spring, piston and bushing into the transaxle case.
33. Press in the servo and bushing and install the circlip.
34. Install the termination shaft. Install in the long keyway towards the front as shown.
35. Rotate the thrust washer towards the return spring on the end sleeve side.
36. Install the end sleeve hub onto the end sleeve.
37. Use petrolatum to install a #13 thrust bearing onto the termination hub.
38. Install the termination assembly.
39. Install a new o-ring and D-ring on the end cap.
Warnings:
- Install the D-ring so that it does not twist.
- Apply a sufficient amount of automatic transmission fluid to the bearing.
40. Install the end cover and secure it with four bolts.
41. Install the servo drum so that its splines engage the sun wheel. Place the servo band on the drum and tighten the servo adjustment screw to hold the band.
42. Apply a coat of petrolatum to the #8 thrust bearing and install it in the pusher drum.
43. Apply a coat of petrolatum to the #7 thrust bearing race and install it into the rear clutch hub.
44. Install the clutch hub on the spokes of the sun wheel.
45. Using petrolatum, install a #6 thrust bearing onto the hub.
46. Apply a coat of petrolatum to Thrust Ring #2 and Thrust Bearing #4. Install the rear clutch.
47. Connect the rear and front couplings.
48. Install the clutch assembly.
49. If the end play measured and recorded during disassembly is out of range, adjust it by selecting Thrust Ring #3.
- Nominal value - 0.3-1.0 mm
If a thrust washer of one thickness is replaced with a thrust washer of a different thickness, the spacer washer #1 located between the oil pump and the front coupling must be replaced at the same time. Use a spacer ring that matches the thickness of the thrust ring.
Find the right pair: thrust ring (metallic) and spacer washer (fiber) from the following table.
50. Install a used #1 spacer or one of those selected in step 51 onto the front coupling using petrolatum.
51. Install special tool (09452-21401) on the crankcase.
52. Install a used #3 thrust washer or one of those selected in step 50 to the oil pump using petrolatum.
53. Install a new gasket on the oil pump and oil pump.
54. Install a new o-ring into the oil pump housing groove and apply a light coat of automatic transmission fluid to the outer surface of the o-ring.
55. Install the oil pump by evenly tightening the six bolts.
When installing the oil pump, make sure that the spacer washer remains in place.
56.Check the axial play of the input shaft. Adjust if necessary (see paragraph 50).
- Rated value: 0.3-1.0mm
57. Install the O-ring in the top center of the valve box body. Install the valve box body by securing the thrust plate pin (manual control shaft) in the slot of the manual control valve.
58. Replace the solenoid valve connector o-ring with a new one.
59. Tighten the valve body mounting bolts to 10-12 Nm.
- A - length 25 mm
- B - length 35 mm
- C - length 40 mm
60. Install the oil filter. Tighten the four oil filter mounting bolts to 5-7 Nm.
61. Install five magnets in the five recesses made in the oil pan.
62. Install a new oil pan gasket and oil pan. Tighten 12 bolts to 10-12 Nm.
63. Install a new D ring on the servo switch. Press it into the crankcase and secure with a circlip.
64. Install the transmission switch and manual control lever.
Adjust the transmission switch.
65. Install pulse generators A and B.
66. Install the differential assembly.
67. Place two inserts (soft solder), approximately 10 mm long and 3 mm in diameter, onto the differential bearing retainer ring at the locations shown by the arrows in the figure.
68. Install the differential bearing retainer and tighten the bolts to the correct torque (43-55 Nm).
69. Remove the differential bearing retainer.
70. Remove the flattened insert from the differential bearing retainer ring.
71; Using a micrometer, measure the thickness of the flattened insert.
Select and install the spacer ring so that the differential bearing preload maintains the standard value (0-0.15mm).
72. Apply automatic transmission fluid to the new ring and install the differential bearing retainer.
73. Install the differential bearing cap.
- Tightening torque - 60-80 Nm
74. Install differential cover with new Gasket.
- Tightening torque - 10-12 Nm
75. Install the speedometer drive.
76. After applying automatic transmission fluid to the outer surface of the cylindrical part of the torque converter from the oil pump side, carefully install the torque converter so as not to damage the seal lip. Make sure the torque converter is engaged with the oil pump drive gear.
77. Measure the distance between the ends of the ring gear and the torque converter housing. This distance is approximately 12 mm.