Part 2

39. Apply petrolatum jelly to thrust bearing # 8 and attach the thrust bearing to the kickdown drum.




40. Apply petrolatum jelly to thrust race # 7 and attach the thrust race to the rear clutch hub.




41. Install the rear clutch hub, engaging it with the forward sun gear splines.




42. Apply petrolatum jelly to thrust bearing # 6 and attach it to the clutch hub.




43. Apply petrolatum jelly to thrust washer # 2 and thrust bearing # 4 and attach the washer and bearing to the rear clutch assembly.




44. Mate the rear clutch assembly with the front clutch assembly.




45. Install the clutch assembly.




46. Install the differential.




47. Attach thrust race # 3 and thrust washer # 1 to the rear end face of the oil pump with petrolatum jelly.




48. Attach the special tool to the transaxle case. Using the tool as a guide, first install a new oil pump gasket and then the oil pump in the case.
49. Remove the special tool.
50. Tighten the oil pump bolts to the specified torque.




51. Measure the end play of the input shaft. If the measurement is out of specification, replace thrust race # 3 and thrust washer # 1 to meet the specification.

Standard value: 0.3-1.0 mm (0.012-0.039 in.)




52. Place approx, 10 mm (0.394 in.) long and 2.5 mm (0.10 in.) dia. pieces of solder at the locations shown on the differential assembly.




53. Place approx, 10mm (0.394 in.) long and 2 mm (0.06 in.) dia, pieces of solder at the illustrated locations on the converter housing. Place the outer race of transfer shaft front bearing in solution.




54. Install the converter housing directly to the transaxle case without installing the rubber coated metal gasket.

55. Tighten the bolts to the specified torque.

56. Loosen the bolts, remove the converter housing and remove the flattened solder pieces.




57. Measure the thinkness of the flattened solder using a micrometer. Add the measured solder thinkness (T) to the value 0.38mm (0.015 in.), which corresponds to the gasket thinkness. Then add to or subtract from that sum a value corresponding to the specified preload or end play range. The result obtained is the thinkness of the spacer to be selected.
For the transfer shaft, select a spacer whose thinkness falls within the range determined by the formulas below.

[T + 0.38 mm (.015 in. ) + 0.1 mm (0.004 in.)] to [T + 0.38 mm (0.015 in. ) + 0.15 mm (.006 in.)]

For the differential case spacer, determine the thinkness using the following formulas.

[T + 0.38 mm (0.015 in. ) - 0.15 mm (0.006 in.)] to [T + 0.38 mm (0.015 in. ) - 0 mm (0 in.)]

Transfer shaft preload:

0.1-0.15 mm (0.004 - 0.006 in.)

Differential case end play:

0-0.15 mm (0-0.006 in.)




58. Place the spacer for the transfer shaft which was selected in step 57 in the transfer shaft bearing hole in the converter housing, and insert the bearing outer race in the case.




59. Place the spacer for the differential case which was selected in Step 57 on the bearing outer race.




60. Coat the gasket surface of the transaxle case with silicone grease.

61. Install a new gasket on the transaxle case.

Caution: Do not reuse the gasket which was previously removed.

62. Install the converter housing with the 14 bolts. Tighten the bolts to the specified torque.

Specified torque: 21 Nm (16 ft.lbs.)




63. Install the parking sprag rod to the manual control shaft. Then, insert the shaft in the transaxle as shown in the illustration. In doing this work, do not install O-ring in the O-ring groove.




64. After installing a new O-ring on the manual control shaft assembly, draw the shaft back into the case, then install the set screw and gasket. Also install the detent steel ball, seat and spring at the same time.




65. Place the case with the oil pan mounting surface up.

66. Install the sprag rod support and tighten the two bolts to the specified torque.

Specified torque: 24 Nm (18 ft.lbs.)




67. Install the O-rings in the O-ring grooves at three locations on the valve body.




68. Install new seal rings in the groove of the accumulator piston and coat the rings with automatic transaxle fluid.

69. Install the accumulator piston in the transaxle case and install the two springs.




70. Install the valve body in the transaxle case while fitting the detent plate pin in the gap between the lands of the manual valve.




71. Tighten the valve body mounting bolts (10 pieces) to the specified torque.

A. bolt 18 mm (.709 in.) long
B. bolt 25 mm (.984 in.) long
C. bolt 40 mm (1.575 in.) long




72. Install the oil filter and tighten the four oil filter mounting bolts to the specified torque.

Specified torque: 11 Nm (8 ft.lbs.)




73. Install the magnet to one of the recesses provided inside the oil pan.

Be sure to remove metal particles from the magnets and clean the inside of the oil pan beforehand.




74. Clean the gasket surfaces of both the transaxle case and oil pan. Using a new oil pan gasket, install the oil pan by tightening the 12 bolts to the specified torque.




75. Install the park/neutral position switch and manual control lever, and tighten the manual control lever nut to the specified torque.




76. Measure the distance between the ring gear end and the converter housing end.

The torque converter has been properly installed if the measurement is approx. 12 mm (0.47 in.).