Part 2

31. INSTALL OIL PUMP INTO CASE
a. Coat the race with petroleum jelly and install it onto stator shaft.

NOTE: After installing the oil pump, measure the input shaft thrust play.

If the thrust play is in excess of standard, select and insert one of the two different size races.

b. Install the O-ring around the pump body.




c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.




e. Install the seven bolts.

Torque: 225 kg-cm (16 ft-lb, 22 N.m)




32. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)

NOTE: There are two thickness of races for the end of stator shaft. If necessary, select one of them.

Race thickness: 0.8 mm (0.031 in.) 1.4 mm (0.055 in.)




33. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.




34. INSTALL SECOND COAST BRAKE PISTON
a. Install the outer spring with the piston.
b. Place the cover into the bore.
c. Using SST, install the snap ring while pressing the cover.
SST 09350-32013 (09351-32050)

d. Check that the front end of the piston rod contacts the center of the second brake band depression.

35. CHECK SECOND COAST BRAKE PISTON STROKE




a. Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.




b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

If the stroke is more than standard value, replace the piston rod with a longer one.

Piston rod length: 72.9 mm (2.870 in.) 71.4 mm (2.811 in.)

Re-measure the stroke. If it is still more than standard value, replace the brake band with a new one.

36. INSTALL ACCUMULATOR PISTONS AND SPRINGS







a. Install the springs and pistons into the bore.




b. Place the cover with a new gasket and gradually tighten the bolts a little a time in sequence.

NOTE: Each bolt length (mm) is indicated in the figure.

37. INSTALL SECOND BRAKE APPLY GASKET (GOVERNOR APPLY GASKET)
38. INSTALL GOVERNOR OIL STRAINER




39. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to damage the O-ring.
Check for full seating.

CAUTION: In subsequent work, do not roll the case over the cable to avoid breaking the cable fitting.




40. PLACE VALVE BODY ON TRANSMISSION
a. While holding the cam down with your hand, slip the cable end into the slot.
b. Lower valve body into place.

CAUTION: Do not entangle the kick-down switch wire.




41. INSTALL BOLTS IN VALVE BODY

NOTE: Each bolt length (mm) is indicated in the figure. Hand tighten the fourteen bolts first, then torque with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




42. PLACE MANUAL VALVE AND BODY ON TRANSMISSION
a. Align the manual valve with the pin on the manual valve lever.
b. Lower the manual valve body into place.
c. Hand tighten the four bolts first. Then, tighten them with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




43. INSTALL DETENT SPRING

NOTE: Each bolt length (mm) is indicated in the figure.

a. Hand tighten the two bolts first. Then, tighten them with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)

b. Check that the manual valve lever is touching the center of the detent spring tip roller.




44. INSTALL OIL TUBES
Using a plastic hammer, install the tubes into the positions indicated in the figure.

CAUTION: Be careful not to bend or damage the tubes.




45. INSTALL TUBE BRACKET
Each bolt length (mm) is indicated in the figure.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




46. INSTALL OIL STRAINER
Each bolt length (mm) is indicated in the figure.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




47. INSTALL MAGNET IN PLACE AS SHOWN

CAUTION: Make sure that the magnets do not interfere with the oil tubes.




48. INSTALL OIL PAN WITH NEW GASKET

Torque: 50 kg-cm (43 in.-lb, 4.9 N.m)




49. INSTALL GOVERNOR BODY
a. Install the governor body adaptor.
b. Install the governor body with the plate washer.
c. Install the thrust washer onto the governor body.
d. Install the cover over the O-ring.
e. Install the cover bracket with the two bolts.




50. INSTALL THROTTLE CABLE RETAINING PLATE
51. INSTALL TUBE AND FILLER GAUGE




52. INSTALL NEUTRAL START SWITCH
a. Install the seal gasket, facing the lip inward.
b. Tighten the nut and stake it with the lock washer.

Torque: 70 kg-cm (61 in.-lb, 6.9 N.m)

53. INSTALL MANUAL SHIFT LEVER

54. ADJUST NEUTRAL START SWITCH




a. Align the groove and neutral basic line.




b. Lock the switch with two bolts.

Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)




55. INSTALL THE TWO OIL COOLER PIPES
a. Install the bracket onto the case.
b. Connect the pipes to the union.
c. Clamp the two pipes onto the bracket.
d. Tighten the union nuts.

Torque: 350 kg-cm (25 ft-lb, 34 N.m)