Part 1

REASSEMBLY

CAUTION
- Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
- Never use grease other than blue petrolatum jelly and white Vaseline.
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- Never apply sealant or adhesive to gaskets.
- When replacing a bushing, replace the assembly which it belongs to.
- Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.





1. Tap the differential bearing outer race into the transaxle case using special tools tools (09500-11000 and 09532-11500).





2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500-11000).
3. Install the spacer and the snap ring.





4. Install the low-reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measure the thickness and compare it to the chart under Application and ID.





6. Install the wave spring.

NOTE: In steps 7 through 9, you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.





7. Replace the pressure plate of the low-reverse brake with special tool, then install the brake discs, brake plates and the snap ring.





8. Install the low and reverse reaction plate and the old snap ring.
9. With a dial indicator installed, move the special tool up and down to measure the end play.
Standard Value: 0 - 0.16 mm (0 - 0.0063 inch)
If the end play is incorrect, measure the old snap ring, then select the proper snap ring from the chart shown and recheck the clearance. Refer to Application and ID.





10. Remove the special tool.

NOTE: In steps 11 through 16, you will determine the actual clearance between the second brake discs and plates when the clutch is released.

11. Install the 3 second brake discs and 2 plates.
12. Install the second brake return spring, second brake piston, and snap ring.





13. Install a dial indicator as shown in the illustration.
14. Move up and down, while observing the end play.
15. To determine the proper thickness of the second brake pressure plate, use this formula and record your answer. (Dial indicator reading + S.S.T. thickness - 1.25 mm) to (Dial indicator reading + S.S.T. thickness - 0.79 mm) = ______.
Standard value
0.79 - 1.25 mm (0.0311 - 0.0492 inch); F4A42 Model
1.0 - 1.55 mm (0.0429 - 0.0610 inch); F5A51 Model





16. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart and recheck the clearance. Refer to Application and ID

NOTE: In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.

17. Install the special tool in place of the low/reverse brake pressure plate.
18. Install the 5 brake discs, 4 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.





21. To determine the proper thickness of the low/reverse brake pressure plate, use this formula and record your answer; (Dial indicator reading + S.S.T thickness - 1.81 mm) to (Dial indicator reading + S.S.T. thickness - 1.35 mm) = _____.
Standard Value
1.35 - 1.81 mm (0.0531 - 0.0713 inch); F4A42
1.62 - 2.11 mm (0.0637 - 0.0831 inch); F5A51

22. If the standard value is incorrect, select a pressure plate of the proper thickness from the chart and recheck the clearance. Refer to Application and ID.
23. Remove the special tool.





24. Install the needle bearing (F5A51 Model).
25. Install the seal rings (2EA) (F5A51 Model).





26. Install the oneway clutch (F5A51 Model).
27. Install the output shaft.





28. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 ft. lbs.) of torque.





29. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).

NOTE: The output shaft lock nut is left-hand thread.





30. Apply ATF and install the old lock nut and tighten to 167 Nm (123 ft. lbs.). Loosen the nut 1 full turn, then re-tighten to specifications. Do not stake the lock nut unless instructed to do so by the instructor.





31. Install a dial indicator as shown in the illustration.
32. Move the output shaft in and out to measure the end lay.
Standard value 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
33. If the standard value is incorrect, use this formula to select the correct spacer from the chart. [Measured amount] + [thickness of the old spacer] + [0.01 mm (0.0004 inch) to [measured amount] + [thickness of old spacer + 0.09 mm (0.0035 inch) = _____. Refer to Application and ID.





34. Install the output shaft protective cap.





35. Install the transfer drive gear using special tool (09500-11000).





36. Install the 4 transfer gear mounting bolts. Tighten the bolts to 19 Nm (14 ft. lbs.).





37. Install the parking pawl, spacer and spring, then install the parking pawl shaft.





38. Install the parking roller support, then the two parking roller support shafts.

CAUTION: Be sure to install the thrust bearing in the proper direction.





39. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.

CAUTION: Be sure to install the thrust bearing in the proper direction.





40. Install the output planetary carrier and thrust bearing #4.





41. Install the overdrive planetary carrier.

NOTE: Rotating the output shaft will help align the clutch teeth and help the carrier seat.





42. Install the reverse planetary sun gear.





43. Install the wave spring.





44. Install the pressure plate, 6 brake discs, and 5 brake plates.





45. Install the snap ring.





46. Install the reaction plate.





47. Install the snap ring.





48. Install the pressure plate, brake discs, and brake plates.





49. Install the return spring and second brake piston.





50. Install the snap ring.

CAUTION: Be sure to install the thrust bearing in the proper direction.





51. Install thrust bearing #5.

CAUTION: Be sure to install the thrust bearing in the proper direction.





52. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.

CAUTION: Be sure to install the thrust bearing in the proper direction.





53. Install the reverse and overdrive clutch and thrust bearing #7.





54. Install the direct clutch, the accumulator spring, the piston, and the O-ring (F5A51 Model).





55. Install the o-rings (6 EA) (F5A51 Model).





56. Install the three O-rings.