Part 1
REASSEMBLYCaution
Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. The O-ring of the oil level dipstick need not be replaced.
Do not use grease other than petrolatum or industrial Vaseline. Apply automatic transaxle fluid to friction elements, rotating parts, and sliding parts before installation. New clutch discs should be immersed in automatic transaxle fluid for a minimum of two hours before installation.
Do not apply sealer or adhesive to gaskets.
When bushings must be replaced, replace their complete assembly which.
Do not use shop towels during disassembly and reassembly operation.
The oil in the cooler should also be replaced.
1. After installing the detent spring assembly and the sprag rod assembly on manual control shaft, insert manual control shaft into transaxle ease end push it fully toward manual control lever. At this time, do not install the O-ring (large one of two O-rings) on manual control shaft.
2. After installing the new O-ring on manual control shaft, draw shaft back into case, then install set screw and gasket.
3. Install the sprag rod support and tighten two bolts. Install the washer and tighten the bolt of the detent spring assembly.
Sprag rod support bolts: 20 - 27 Nm (200 - 270 kg. cm, 15 - 19 ft. lbs.)
Detent sprag assembly bolt: 10 - 12 Nm (100 - 120 kg. cm, 7.5 - 8.4 ft. lbs.)
4. Before assembly of the transaxle, measure the end play of the low-reverse brake, and select a pressure plate to be used so that the end play will be the standard value.
1) Install the brake reaction plate, brake plate and brake disc to the transaxle case.
Caution: If new brake discs are used, be sure to immerse them in ATF for a minimum of two hours.
2) Install the appropriate pressure plate and then install the return spring.
Caution: Be sure that the return spring is installed so that it faces in the correct direction.
3) Apply a coating of petroleum jelly to the wave spring and attach it to the center support.
4) Install the special tool (09453-21310) to the center support.
5) Install the snap ring.
6) Install the special tools (09454-21400, 09453-33100) and a dial gauge at the rear side of the transaxle case.
Caution: Install the dial gauge so that it contacts the brake reaction plate at a right angle from the transfer idler shaft hole.
7) Using a manual pump, pump air (5 kg/cm2) in from the position shown in the illustration. Read the dial indicator gauge, and select the pressure plate that will provide the standard value.
8) After selecting pressure plate, remove center support, brake plate, brake disc, brake reaction plate and pressure plate
5. Install the transfer shaft, and press-fit the bearing outer race to the transaxle case.
6. Install the transfer shaft snap ring.
7. Insert the spacer on the transfer shaft.
8. Install the bearing cage on the case.
9. Press-fit the transfer driven gear to the transfer shaft.
10. Tighten the lock nut to the specified torque.
Transfer lock nut: 200 - 230 Nm (2000 - 2300 kg.cm, 146 - 166 ft. lbs.)
11. After installing the dial gauge, measure the end play of the transfer shaft: then select the spacer(s) needed to obtain the standard value, and refit.
Transfer shaft end play: 0 - 0.06 mm (0 - 0.002 inch)
12. Using a punch, lock the lock nut to prevent rotation.
13. Install the transfer drive gear assembly.
14. Install the special tool at the rear side of the transaxle case.
15. Using the special tool, insert an assembly of the annulars gear into the transfer drive gear.
16. Install the stopper plate and snap ring.
17. Apply specified sealant to the rear cover.
Specified sealant: THREE BOND 1216
18. Install the rear cover assembly.
Tightening torque: 17 - 22 Nm (170 - 220 kg.cm, 12.3 - 15.9 ft. lbs.)
19. Install snap ring.
20. Install the bearing retainer. Tighten the screws to the specified torque. Apply a 5 mm (0.2 inch) width of sealant (3M Stud Locking No.1303). Sealant should not stick out of screw head.
Screw: 17 - 22 Nm (170 - 220 kg.cm, 13 - 15 ft. lbs.)
Identification of thrust bearings, thrust races and thrust washers
21. Apply a coating of petroleum jelly to thrust bearing #12 and attach to the planetary carrier.
22. Install the planetary carrier to the case.
23. Assemble the reverse sun gear and the forward sun gear in the following order:
1) Attach the seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in the figure.
2) Attach thrust race #10 to the forward sun gear.
3) Attach thrust bearing #9 to the forward sun gear.
4) Assemble the reverse sun gear, and then the forward sun gear.
24. Install both of the previously assembled sun gears into the planetary carrier.
25. Install the brake disc and brake plate.
26. Install the selected brake pressure plate.
27. Install the return spring.
28. Apply a coating of petroleum jelly to the wave spring and attach it to the center support.
29. Install the two new O-rings to the center support.
30. After applying a coating of ATF to the O-rings, install the special tool (09453-21310) to the center support, and install into the case.
CAUTION: Be sure that the wave spring is not out of position
31. Install the snap ring.
32. Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.
33. Press the kickdown servo and sleeve, and install the snap ring.
34. Install the end clutch shaft. Be sure to install the longer spline toward the front as shown.
35. Fit the thrust washer toward the return spring at the end clutch side.
36. Install the end clutch hub to end clutch.
37. Attach, using petroleum, thrust bearing #13 to the end clutch hub.
38. Install the end clutch assembly.
39. Attach a new O-ring and D-ring to the end clutch cover.
CAUTION: Install so that the D-ring is not twisted. Apply a sufficient amount of automatic transaxle fluid to the bearing.