Part 2
40. Using the special tools, push in the kickdown servo piston and sleeve assembly, and the install the snap ring.
41. Install the kickdown band: attach the ends of the band to the ends of the anchor rod and servo piston rod.
42. When putting the kickdown drum in the kickdown band, engage the splines of the kickdown drum with those of the reverse sun gear. Place the kickdown bend on the kickdown drum and tighten the kickdown servo adjusting screw to keep the band in position.
43. Apply petroleum jelly to thrust bearing # 8 and attach the thrust bearing to the kickdown drum.
44. Apply petrolatum jelly to thrust race # 7 and attach the thrust race to the rear clutch hub.
45. Install clutch hub engaging it with the forward sun gear splines.
46. Apply petrolatum jelly to thrust bearing # 6 and attach it to the clutch hub.
47. Apply petrolatum jelly to thrust washer # 2 and thrust bearing # 4 and attach the washer and bearing to the rear clutch assembly.
48. Mate the rear clutch assembly with the front clutch assembly.
49. Install the clutch assembly.
50. Install the differential.
51. Attach thrust race # 3 and thrust washer # 1 on the rear end face of the oil pump with petrolatum jelly.
52. Install the special tool on the transaxle case. Using the special tool as a guide, install a new oil pump gasket and the oil pump in the case.
53. Remove the special tool.
54. Tighten the oil pump bolts to the specified torque.
55. 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.)
56. 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.
57. Install the converter housing directly to the transaxle case without installing the rubber coated metal gasket.
58. Tighten the bolts to the specification.
59. Loosen the bolts and remove the converter housing and remove the pieces of flattened solder.
60. Measure the thickness of the flattened solder using a micrometer. Add the measured solder thickness (T) to the value 0.38 mm (0.015 in.), which corresponds to the gasket thickness.
Then subtract from that sum a value corresponding to the specified end play.
The result obtained is the thickness of the spacer to be selected.
Select a spacer whose thickness falls within the range determined by the formulas below:
[T +0.38 mm (.015 in.) -0.15 mm (0.006 in.)] to [T +0.38 mm (0.015 in.) -0 mm (0 in.)]
61. Place the spacer which was selected in Step 60 on the outer race of the differential bearing.
62. Apply silicone grease to all gasket surfaces of the transaxle case.
63. Install a new gasket on the transaxle case.
CAUTION: Do not reuse the gasket which was previously removed.
64 Install converter housing and tighten the 14 bolts indicated by arrows to specified torque.
Tightening torque: 21 Nm (16 ft.lbs.)
65. Install the end clutch shaft, inserting the end that has the longer splines first.
66. Install the thrust washer on the return spring at the end clutch side.
67. Install the end clutch hub on the end clutch assembly.
68. Attach thrust bearing # 13 to the end clutch hub with petrolatum jelly.
69. Install the end clutch assembly.
70. Install new O-ring in the groove of the end clutch cover. Check the bearing for smooth rotation and replace it if defects are evident.
Apply an ample amount of automatic transaxle fluid to the bearing.
71. Secure the end clutch cover by tightening its mounting bolts to specified torque.
Tightening torque: 7 Nm (5 ft.lbs.)
72. 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.
73. 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.
74. Place the case with the oil pan mounting surface up.
75. Install the sprag rod support and tighten the two bolts to specified torque.
Tightening torque: 24 Nm (18 ft.lbs.)
76. Install the O-ring at the top of the valve body.
77. Replace the O-ring of the solenoid valve connector with a new one.
78. When installing the valve body, insert the solenoid valve connector in the case, while making sure that cut of connector is positioned as shown in the illustration.
79. Install the valve body in the transaxle case while fitting the detent plate pin in the gap between the lands of the manual valve.
80. Tighten the valve body mounting bolts (10 pieces) to the specified torque.
A. bolt 18 mm (0.709 in.) long
B. bolt 25 mm (0.984 in.) long
C. bolt 40 mm (1.575 in.) long
81. Install the oil filter and tighten the tour oil filter mounting bolts to the specified torque.
82. Install five magnets in the five depressions provided inside the oil pan.
Be sure to remove metal particles from the magnets and clean the inside of the oil pan beforehand.
83. Clean the gasket surfaces of the transaxle case and oil pan. Install a new oil pan gasket and then the oil pan by tightening the 12 bolts to the specified torque.
Tightening torque: 11 Nm (8 ft.lbs.)
84. Set a new D-ring in the kickdown servo switch, push the switch into the case and secure it with the snap ring.
85. Install the park/neutral position switch and manual control lever, and tighten the manual control lever nut to the specified torque.
86. Install pulse generators "A" and "B" and tighten the bolt to the specified torque.
Tightening torque: 11 Nm (8 ft.lbs.)
87. After applying automatic transmission fluid to the outside surface of the oil pump-side cylindrical portion of the torque converter, install the torque converter carefully so as not to give damage to the oil seal lip. Make certain that the torque converter is in mesh with the oil pump drive gear.
88. Measure the distance between the ring gear end and the converter housing end.
The torque converter has been properly installed when the measurement is about 12 mm (0.47 in.).