Assembly (2)

*: Refer to GI section.

Fig 1: Applying Locking Sealant To Transmission Case

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• Apply locking sealant to the mating surface of transmission case. 

Fig 2: Setting Side Cover On Transmission Case

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• Do not mix bolts A and B. 
• Always replace bolts A as they are self-sealing bolts. 

Fig 3: Tightening Side Cover Fixing Bolts

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• Apply petroleum jelly to thrust washer. 

Fig 4: Installing Thrust Washer On Bearing Retainer

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• Align teeth of low & reverse brake drive plates before installing. 
• Make sure that bearing retainer seal rings are not spread. 
• If forward clutch assembly is correctly seated, points 1 and 2 are at almost same level. 

Fig 5: Installing Forward Clutch Assembly

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• Apply petroleum jelly to thrust needle bearing. 
• Pay attention to direction of thrust needle bearing. 

Fig 6: Installing Thrust Needle Bearing On Bearing Retainer

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• Apply petroleum jelly to thrust washers. 
• Align teeth of overrun clutch drive plates before installing. 

Fig 7: Installing Overrun Clutch Hub

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Check overrun clutch hub for correct directions of lock and unlock.

• If not shown as illustrated, check installed direction of forward one-way clutch. 

Fig 8: Checking Locking Direction Of Overrun Clutch Hub

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• Align teeth of forward clutch drive plates before installing. 
• Check that three hooks of thrust washer are correctly aligned after installing. 

Fig 9: Installing Forward Clutch Hub And Rear Internal Gear Assembly

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1. Install needle bearings on rear planetary carrier.
   • Apply petroleum jelly to needle bearings. 
   • Pay attention to direction of needle bearings. 
   Fig 10: Installing Needle Bearing On Rear Planetary Carrier

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2. Install rear sun gear on rear planetary carrier.
   • Pay attention to direction of rear sun gear. 
   Fig 11: Installing Rear Sun Gear On Rear Planetary Carrier

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3. Install rear planetary carrier on transmission case.

Fig 12: Installing Rear Planetary Carrier On Transmission Case

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• Apply petroleum jelly to thrust needle bearing. 
• Pay attention to direction of thrust needle bearing. 

Fig 13: Installing Thrust Needle Bearing On Front Planetary Carrier

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1. Set and align return springs to transmission case gutters as shown in illustration.
   Fig 14: Setting And Aligning Return Springs To Transmission Case Gutters

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2. Set and align piston with retainer.
   Fig 15: Setting And Aligning Piston With Retainer

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3. Install piston and retainer assembly on the transmission case.
   • Align bracket to specified gutter as indicated in illustration. 
   Fig 16: Installing Piston And Retainer Assembly On Transmission Case

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4. Check that each protrusion of piston is correctly set to corresponding return spring as follows.
   • Push piston and retainer assembly evently and confirm they move smoothly. 
   • If they can not move smoothly, remove piston and retainer assembly and align return spring correctly as instructed in step "a". 
   Fig 17: Checking Smooth Movement Of Piston And Retainer Assembly

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5. Push down piston and retainer assembly and install snap ring.

Fig 18: Installing Snap Ring Pushing Piston And Retainer Assembly Down

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• Forward clutch and bearing must be correctly installed for snap ring to fit into groove of transmission case. 

Fig 20: Installing Snap Ring

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• Apply petroleum jelly to needle bearing. 
• Pay attention to direction of needle bearing. 

Fig 21: Installing Needle Bearing On Transmission Case

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• Apply petroleum jelly to needle bearing. 
• Pay attention to direction of needle bearing. 

Fig 22: Identifying Bearing Race, Needle Bearing, High Clutch Hub and Front Sun Gear

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• Apply petroleum jelly to needle bearing. 
• Pay attention to direction of needle bearing. 

Fig 24: Installing Needle Bearing On High Clutch Drum

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• Align teeth of reverse clutch drive plates before installing. 

Fig 25: Installing Input Shaft Assembly In Reverse Clutch

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