Transmission Installation
INSTALLATION1. Flush the ATF cooler.
2. Install the starter motor and the two 14 x 20 mm dowel pins on the torque converter housing.
3. Install the torque converter assembly securely in the torque converter housing, over the mainshaft, with a new O-ring.
CAUTION: While installing the torque converter assembly in the torque converter housing, be sure not to allow dust or other foreign particles to enter the transmission.
4. Place the transmission on a jack, and raise it to the engine assembly level.
5. Attach the transmission to the engine, then install the transmission housing mounting bolts, rear engine mounting bolts, and the intake manifold bracket bolts.
6. Install the remaining transmission housing mounting bolts.
7. Tighten the front engine mount bracket bolts to the specified torque.
8. Install the transmission mount bracket. Tighten the bolt loosely, tighten the nuts to the specified torque, then tighten the bolt to the specified torque.
9. Remove the transmission jack.
10. Attach the torque converter to the drive plate with eight drive plate bolts and torque:
Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates freely.
11. Tighten the crankshaft pulley bolt.
12. Install the engine stiffener.
13. Install the control lever with the shift cable on the control shaft.
NOTE: Do not bend the shift cable excessively when installing the control lever.
14. Install the lock bolt with a new lock washer, then bend the lock washer tab against the bolt.
15. Install the shift cable cover, then install the shift cable holder on the shift cable cover.
NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover.
16. Install the intermediate shaft with a new set ring.
CAUTION: While installing the intermediate shaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission.
17. Install the right radius rod and damper fork. If the radius rods bushings are worn or damaged, replace them.
18. Install new set ring on the right driveshaft.
19. Install the right and left driveshafts.
CAUTION: While installing the driveshaft(s) in the differential, be sure not to allow dust or other foreign particles to enter the transmission.
NOTE: Turn the right and left steering knuckles fully outward, and slide the driveshafts into the differential and intermediate shaft until you feel the set rings engage the side gear and the intermediate shaft.
20. Install the damper fork to the lower arm. Then install the ball joint to the lower arm. Use the castle nuts with new cotter pins.
21. Install the center beam.
22. Install the splash shield.
23. Connect the vehicle speed sensor connector and the 2nd clutch pressure switch connector.
NOTE: Do not allow water, fluid, oil, dust, or other foreign particles to enter the connectors.
24. Connect the countershaft speed sensor connector, and the A/T gear position switch connector, then install the connector and clamps on the connector bracket.
25. Connect the shift control solenoid valve B and C connectors.
26. Connect the ATF cooler hoses to the ATF cooler lines.
27. Connect the lock-up control solenoid valve/shift control solenoid valve A assembly connector.
28. Install the transmission ground cable terminal on the terminal bracket.
29. Connect the mainshaft speed sensor connector, and connect the A/T clutch pressure control solenoid valve A and B connectors.
30. Connect the starter motor cables.
NOTE: When installing the starter motor cables, make sure the crimped side of the ring terminal is facing out.
31. Install the breather tube and radiator hose on their clamps.
32. Install the battery base bracket and battery base.
33. Install the battery cable bracket on the battery base, and install the ground terminal on the body.
34. Install the battery tray and battery, then secure the battery with its hold-down bracket.
35. Install the intake air duct and air cleaner housing assembly.
36. Refill the transmission with ATF.
37. Connect the battery positive and negative cables to the battery terminals.
38. Set the parking brake. Start the engine, and shift the transmission through all gears three times. Check the shift lever operation and the A/T gear position indicator operation.
39. Check and adjust the front wheel alignment.
40. Let the engine reach normal operating temperature (the radiator fan comes on) with the transmission in H or [E position, then turn it off and check the ATF level.
41. Road test as described.
42. Loosen the front engine mount bracket bolts after the road test, and retighten them to the specified torque.
43. Enter the anti-theft code for the radio, then enter the customer's radio station presets.