Assembling the automatic transmission

61. Before assembling the gearbox, measure the load lock/reverse gear end play and select a pressure plate of a thickness that, once installed, will give the correct end play (pic. 11.168). To do this, install a brake jet disc, a brake plate and a brake disc in the box crankcase. Install the correct pressure plate and return spring (pic. 11.169).

Pic. 11.168. Before reassembling the gearbox, measure the load lock/reverse gear end play and select a pressure plate of a thickness that, once fitted, will give the correct end play

Pic. 11.169. Install the brake jet disc, brake plate and brake disc into the crankcase. Install a suitable pressure plate and return spring. 1 - Toward the oil pump; 2 - Return spring; 3 - Pressure plate; 4 - Brake disc; 5 - Brake plate; 6 - Brake jet disc

box type	Number of brake discs	Number of brake plates
F4A21	4	3
F4A22, F4A23	6	5

62. Apply refined natural petroleum jelly to the shaft spring and fix it on the intermediate support (pic. 11.170). Install the two O-rings removed during disassembly and lubricate them with ATF transmission fluid.



63. Install a special tool on the intermediate support and insert it into the gearbox housing (pic. 11.171).

Attention! When installing the intermediate support, make sure that the shaft spring does not move. Install the intermediate support so that both O-rings point towards the oil holes in the gearbox housing.

64. Remove the special tool.

65. Install the circlip (pic. 11.172).



66. Install the dial indicator on the back of the gearbox (pic. 11.173). Make sure the measuring pin MD998913 is inserted into the idler shaft hole and is in contact with the brake reaction disc (on right) in the right corner (fig.11.174).

Pic. 11.173. Install a dial gauge on the back of the gearbox

Pic. 11.174. Make sure the measuring pin MD998913 is inserted into the hole for the idler shaft and is in contact with the brake disc in the right corner

67. Using a hand pump, apply pressure and at the same time mark the reading of the dial indicator (pic. 11.175). Based on your measurements, select a pressure plate that provides the required clearance.

Nominal gap: F4A21 - 0.8-1.0mm, F4A22, F4A23 - 1.0-1.2mm.



68. After choosing a pressure plate of the appropriate thickness, remove all installed parts.

69. Using the special tool, press in the outer rotating rings (pic. 11.176, 11.177).

Pic. 11.176. Pressing in the outer rotating ring

Pic. 11.177. Pressing in the outer rotating ring

70. Install the output shaft in the gearbox housing (pic. 11.178).



71. Install a special tool on the gearbox housing to support the output shaft (pic. 11.179).



72. Install the thickest shim (1.80 mm) (pic. 11.180).



73. Install the gear on the output shaft (pic. 11.181).



74. Remove the special tool and fix the output shaft (rice. 11.159).

75. Install the lock nut and tighten it to the required tightening torque of 200-230 Nm (rice. 11.160).

76. Measure the axial clearance by moving the shaft back and forth and select a shim that provides the required clearance (pic. 11.182). Required clearance; 0-0.025 mm.



77. Bend locknut lock plate (pic. 11.183).



78. Lay the gearbox housing on the workbench with the mounting side of the pallet up. Insert the output shaft flange as a single unit (with two mounted ball bearings and output shaft drive gear) into the gearbox housing (rice. 11.156).

79. Insert a snap ring into the groove of the mounting flange of the output shaft (rice. 11.155).

80. Apply refined petroleum jelly to the shim and install it on the gearbox housing (rice. 11.154).

81. Insert the outer and inner rotating rings into the intermediate gear (pic. 11.184).



82. Insert the intermediate gear into the gearbox housing, install the shaft in the appropriate position (rice. 11.153).

83. Use the special tool to screw in the intermediate gear shaft (rice. 11.152).

84. Install an indicator on the output shaft flange and measure the bearing preload (pic. 11.85). Adjust the preload to the desired value by tightening or loosening the idler shaft. Rated value: automatic transmission F4A21, F4A22 - 0.8 Nm, automatic transmission F4A23 - 1.5 Nm.



85. After adjusting the preload, install the idler shaft lock washer (rice. 11.151).

86. Install the bearing bracket and tighten the bolts of its fastening to a torque of 17-22 Nm (pic. 11.186).



87. Using a chisel, fix the bolt head in the appropriate position (pic. 11.187).



88. Coat the #12 thrust bearing with refined Vaseline and secure it to the planetary gear set (pic. 11.188).



89. Install the planetary gear set in the gearbox housing (pic. 11.189).



90. Install the #10 thrust bearing rotating race and the #9 thrust bearing onto the forward sun gear. Then install the reverse sun gear (pic. 11.190).



91. Install the sun gear set in the planetary gear set (pic. 11.191).



92. Install the brake discs and plates (pic. 11.192). The arrangement of brake disks and plates is shown in fig. 11.169.



93. Install the brake pressure plate selected in accordance with paragraph 61 (pic. 11.193).



94. Install the return spring (pic. 11.194).



95. Apply refined petroleum jelly to the shaft spring and install it on the intermediate support (pic. 11.170).

96. Install two new o-rings on the intermediate support (pic. 11.195). Coat the O-rings with ATF transmission fluid.



97. Install the special tool on the intermediate support (rice. 11.145). Slowly install the intermediate support into the crankcase while holding the special tool.

Attention! When installing, make sure that the shaft spring does not fall out. The intermediate support must be installed so that both O-rings point towards the oil holes in the gearbox housing.

98. Remove the special tool from the intermediate support.

99. Install the circlip to secure the intermediate support. The ends of the snap ring must not interfere with the mounting holes of the pulse generator (pic. 11.196).



100. Install the rigid mount rod in the gearbox housing (rice. 11.143).

101. Install a new Teflon sealing ring and a new oil seal in the grooves of the servo booster piston, apply transmission fluid to the ring (pic. 11.197).



102. Install the servo piston into the bushing.

103. Install the spring on the servo piston and bushing and insert them into the transaxle case, making sure that the rear Teflon O-ring slot of the piston does not block the fluid inlet to the transaxle case (pic. 11.198).



104. Press in the piston and servo bushing, and then install the circlip (rice. 11.141).

105. Install the brake band so that the arrow points towards the oil pump (F4A23). Connect its ends to the ends of the rigid hitch rod and the servo piston rod (pic. 11.199).



106. When installing the drum in the brake band, the key grooves of the drum must be engaged with the grooves of the reverse gear sun gear. Install the brake band on the drum and tighten the servo booster adjusting bolt to lock the brake band in position (rice. 11.139).

107. Coat the #8 thrust bearing with refined petroleum jelly and install it on the drum (pic. 11.200).



108. Coat the #7 thrust bearing rotating race with refined petroleum jelly and install it on the rear clutch hub (pic. 11.201).



109. Install the clutch hub into the forward gear sun gear keyways (pic. 11.202).



110. Coat the #6 thrust bearing with refined Vaseline and install it on the clutch hub (pic. 11.203).



111. Coat the #2 thrust bearing rotating race and the #4 thrust bearing with refined petroleum jelly and install both parts to the rear clutch (pic. 11.204).



112. Connect the rear and front couplings together (pic. 11.205).



113. Install the clutch assembly in the gearbox housing (rice. 11.135).

114. Install differential (pic. 11.206).



115. Install the #3 thrust bearing rotating race and #1 shim on the back of the oil pump, lubricating them with pre-refined petroleum jelly (pic. 11.207).



116. Install special tool MD998336 on the box crankcase. Using the special tool MD998336 as a guide, install the oil pump with a new gasket into the gearbox housing (pic. 11.208).



117. Remove the special tool.

118. Tighten the oil pump bolts to the correct torque.

119. Measure the axial clearance of the input shaft (pic. 11.209). If the measured value is out of range, replace the thrust bearing rotating race #3 and shim #1 to obtain the correct clearance. Required clearance: 0.3-1.0 mm.



120. Apply 10mm long x 1.6mm wide solder to the differential (F4A21, F4A22) (pic. 11.210).



121. Install two pieces of solder wire 10 mm long and 1.6 mm in diameter on the GTR body and install the outer rotating ring (F4A23) (pic. 11.211).



122. Install the GTR body in the gearbox housing without installing a metal gasket with a rubber layer, and tighten the fastening bolts to the required torque (rice. 11.130).

123. Unscrew the bolts and remove the GTR body to remove the soldering agent (F4A21, F4A22).

124. Unscrew the bolts and remove the outer rotating ring from the GTR body. Remove compressed solder wire (F4A23).

125. If the wire is not compressed, use a large diameter wire and repeat steps 122-124.

126. Using a micrometer, measure the thickness of the pressed wire (rice. 11.15). Add up the measured thickness T with a value of 0.38 mm, which corresponds to the thickness of the gasket.

Then subtract from the sum the amount corresponding to the prescribed axial clearance. The result obtained corresponds to the thickness of the required shim.

127. Select a shim whose thickness is within the range calculated using the following formulas:

• Automatic transmission F4A21, F4A22 - from (T +0.38 mm -0.15 mm) before (T +0.38 mm -0 mm).
• Automatic transmission F4A23 - from (T +0.38 mm +0.13 mm) before (T +0.38 mm -0.08 mm).

128. Install on the outer rotating ring of the differential bearing an adjusting washer selected in accordance with paragraph 127 (F4A21, F4A22, F4A23) (pic. 11.212).



129. Apply silicone grease to all contact surfaces of the gearbox housing (pic. 11.213).



130. Install a new gasket on the gearbox housing.

Attention! Never use a gasket that has been removed before.

131. Install the GTR body and tighten the fourteen bolts to the required torque: 19-23 Nm (rice. 11.130).

132. Insert the rear clutch shaft with the longer keyway side (rice. 11.129).

133. Install the shim on the end of the return spring on the rear clutch side (pic. 11.214).



134. Install the hub on the rear clutch (pic. 11.215),



135. Apply refined petroleum jelly to the #13 thrust bearing and install it to the rear clutch hub (pic. 11.216).



136. Install rear clutch (pic. 11.217).



137. Install a new o-ring in the groove of the rear clutch cover (pic. 11.218).



138. Lubricate the thrust bearing with transmission fluid.

139. Install the rear clutch cover and tighten the bolts of its fastening to a torque of 6-8 Nm (pic. 11.219).

Attention! When installing the rear coupling cover, make sure that the threaded holes are centered. Rotating the rear clutch cover can cause the O-ring to rotate.

140. Install the automatic transmission lock drive rod when parking on the gear lever shaft. After that, insert the shaft into the gearbox housing without pressing the O-ring into the groove (pic. 11.220).



141. Install a new O-ring on the shift lever shaft and insert the shaft into the gearbox housing, then install the set bolt and gasket (rice. 11.164a). Insert detent steel ball, stop and spring (models up to 1992 c.).

142. Install lock plate (models since 1993) (rice. 11.164b).

143. Install the gearbox housing with the mounting side of the pallet up.

144. Install the drive rod support and tighten both bolts to a torque of 20-27 Nm (rice. 11.163).

145. Install the o-ring on top of the valve block (pic. 11.221).



146. Install a new sealing ring on the solenoid valve connector.

147. With the valve body installed, connect the solenoid valve connector to the block with your flat (fig.11.222).



148. Insert wiring harness (arrow) solenoid valve from the inside through the hole in the gearbox housing (pic. 11.223).



149. Install the valve block into the transaxle case, at the same time insert the lock plate pin into the groove at the end of the valve block (pic. 11.224). Tighten ten bolts of fastening of the block of valves (pic. 11.225a,b). Bolt A - length 18 mm, bolt B - length 25 mm, bolt C - length 40 mm.

Pic. 11.225a. Valve block bolts on models up to 1992 onwards.

Pic. 11.225b. Valve block mounting bolts on models from 1993 onwards.

149. Install the oil filter and tighten the four bolts of its fastening (pic. 11.226).



151. Install five magnets in five recesses in the inside of the pallet (pic. 11.227).



152. Remove metal particles adhering to the magnets and clean the inside of the bottom. Clean the contact surfaces of the gearbox housing and under the bottom.

153. Install a new pallet gasket and tighten the twelve bolts of its fastening to a torque of 10-12 Nm (pic. 11.228).



154. Adjust the servo amplifier as follows:

• insert the grip of the special tool into the groove of the piston so as to prevent the piston from turning, and fix it with the adapter (pic. 11.229);

• Loosen the locknut until it just touches the V-groove in the adjusting rod. Install the special tool MD998916 on the adjusting rod and rotate until it touches the lock nut (pic. 11.230);

• install the internal special tool on the locknut (pic. 11.231) Rotate the outer tool counterclockwise and the inner tool clockwise until the locknut is locked by the inner tool;

• install a torque wrench on the inner tool, tighten it to 10 Nm, and then loosen it again (pic. 11.232). Repeat this procedure twice, and then tighten the inner tool with another 5 Nm. After that, loosen the outer tool by 2-2 25 turns;

• turn the outer tool clockwise and the inner tool counterclockwise to disengage the inner tool from the locknut (pic. 11.233);

• tighten the locknut with your fingers until it touches the piston. After that, using a torque wrench, tighten the locknut to a torque of 25-32 Nm (pic. 11.234);

155. Install a new O-ring on the power steering switch, insert the switch into the gearbox housing and secure with a snap ring (pic. 11.235a,b).

Pic. 11.235a. Install a new O-ring on the power steering switch, insert the switch into the gearbox housing and secure with a snap ring (models until 1992)

Pic. 11.235b. Install a new O-ring on the power steering switch, insert the switch into the gearbox housing and secure with a snap ring (modelis 1993 onwards)

156. Install the starter interlock switch and shift lever (pic. 11.236a,b).

Pic. 11.236a. Install the starter override switch and shift lever (models until 1992)

Pic. 11.236b. Install the starter override switch and shift lever (models since 1993)

157. Adjust the starter interlock switch as follows:

• set the gear lever to the position «N»,
• rotate the switch body until the end of the 12mm wide shift lever aligns with the flange of the switch body, or rotate the switch body until the 5mm hole in the shift lever aligns with the same hole in the switch body (pic. 11.237a,b);
• tighten the mounting bolts to a torque of 10-12 Nm and make sure that the switch does not move.

Pic. 11.237a. Adjustment of the starter interlock switch on models up to 1992 onwards.

Pic. 11.237b. Adjustment of the starter interlock switch on models from 1993 onwards.

158. Install pulse generators A and B and tighten the bolts to a torque of 10-12 Nm (pic. 11.238a,b)

Pic. 11.238a. Install pulse generators A and B and tighten their fastening bolts (models until 1992)

Pic. 11.2386. Install pulse generators A and B and tighten their fastening bolts (models since 1993)

159. Apply gear oil to the outside of the cylindrical part of the GTR facing the oil pump and carefully install the GTR so as not to damage the working lip of the shaft seal. Check that the GTR engages with the oil pump drive gear.

160. Measure the distance between the ring gear and the GTR body. If it is about 12 mm, the transformer is installed correctly (pic. 11.239).