Part 2

REASSEMBLY(continued)





31. INSTALL BRAKE APPLY TUBE
a. Install the clamp to the brake apply tube.

NOTICE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

b. Install the clutch apply tube.





c. Install the brake apply tube and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: The tube should be securely inserted until it reaches the stopper.





32. INSTALL NEEDLE ROLLER BEARING
a. Using SST and a press, press the needle roller bearing into the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 inch)

NOTICE:
^ The engraved mark side of the bearing should face upward.
^ Repeat the press fit until the specified value is obtained.

b. Coat a needle roller bearing with ATF.





33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
a. Coat 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover.

NOTICE: The snap ring should be fully engaged in the groove of the drum.





34. INSTALL TRANSAXLE CASE NO.1 PLUG
a. Coat 4 new O-rings with ATF.
b. Install the 4 O-rings to the 4 transaxle case No.1 plugs.
c. Install the 4 transaxle case No.1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





35. INSTALL TRANSAXLE REAR COVER SUB-ASSEMBLY
a. Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.
b. Apply FIPG to the cover.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent.

NOTICE: Make sure that the FIPG is applied in a bead (section diameter. [diameter]1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.





c. Apply liquid sealer to the "A" bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
d. Install the 11 bolts.
Torque:
Bolt A 19 Nm (190 kgf-cm, 14 ft. lbs.)
Other bolts: 25 Nm (250 kgf-cm, 18 ft. lbs.)





36. INSTALL UNDERDRIVE CLUTCH DISC NO.2
a. Coat the 4 discs with ATF.
b. Install the 4 discs, 4 plates and flange to the transaxle case.

NOTICE: Be careful about the order of discs, plate and flange assembly.





c. Using a screwdriver, install the snap ring.

NOTICE: The snap ring should be fully engaged in the groove of the drum.





37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
a. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 inch)

HINT: Select an appropriate flange from the table so that it will meet the specified value.

Flange Thickness: mm (inch):

b. Temporarily remove the snap ring and attach it to the flange.
c. Reinstall the snap ring.





38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
a. Install the underdrive clutch assembly to the 1-way clutch.
b. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.





39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
a. Install the outer race retainer to the 1-way clutch.

NOTICE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly.





b. Install the 1-way clutch to the transaxle case.

NOTICE: Make sure that the mark on the 1-way clutch outer race is visible.





c. Using a screwdriver, install the snap ring to the transaxle case.

NOTICE: The snap ring should be fixed fully engaged in the groove of the transaxle case.





40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch.

Bearing and Bearing Race Diameter: mm (inch):

b. Install the underdrive clutch assembly to the transaxle case.

NOTICE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.





41. INSTALL PARKING LOCK PAWL
a. Install the pawl pin and spring to the parking lock pawl.





b. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.





42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
a. Install the underdrive planetary gear assembly to the transaxle case.

NOTICE: Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.





b. Install the parking lock pawl shaft.





c. Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)





d. Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E).

NOTICE: Record dimension E for the following process.





e. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below.

NOTICE: Record dimension F for the following process.

HINT: Dimension F = Dimension (1) - Dimension (2)





43. INSTALL MULTIPLE DISC CLUTCH HUB
a. Install the thrust bearing race No. 1 to the transaxle case while checking its direction.

Bearing Race Diameter: mm (inch):

b. Coat the thrust needle roller bearing and race with yellow petrolatum, install them onto the multiple disc clutch hub.

Thrust Bearing and Race Diameter: mm (inch):

c. Coat the needle roller bearing with ATF.





d. Install the needle roller bearing to the multiple clutch hub.

Bearing Diameter: mm (inch):

e. Install the multiple clutch hub to the transaxle case.





44. INSTALL FORWARD CLUTCH ASSEMBLY
a. Coat the thrust needle roller bearing with ATF.
b. Install the thrust needle roller bearing to the forward clutch.

Thrust Bearing Diameter: mm (inch):

NOTICE: Install the thrust bearing properly so that the no-colored race or blue ink jet race will be visible.





c. Install the forward clutch to the forward clutch assembly.

NOTICE:
^ Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.
^ Be careful not to damage the bushing inside of the forward clutch hub during installation.





45. INSTALL OVERDRIVE BRAKE GASKET
a. Install 2 new overdrive brake gaskets.





46. INSTALL DIFFERENTIAL GEAR ASSEMBLY
a. Install the differential gear assembly to the transaxle case.





47. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2
a. Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly





48. INSTALL THRUST NEEDLE ROLLER BEARING
a. Coat the thrust needle roller bearing with ATF.
b. Calculate the end play value using the following formula and values of Dimension E and F that are measured when installing the cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install the selected bearing race.
End play: 0.498 to 0.993 mm (0.01961 to 0.03909 inch)

HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 inch) - underdrive thrust bearing race No.2 thickness.

Race Thickness: mm (inch):

Bearing and Bearing Race Diameter: mm (inch):

49. INSTALL OIL PUMP ASSEMBLY
a. Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22 Nm (226 kgf-cm, 16 ft. lbs.)





b. Coat the O-ring of oil pump with ATF.

NOTICE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.





50. INSTALL TRANSAXLE HOUSING
a. Remove any packing material and be careful not to spill oil on the contact surface of the transaxle case or transaxle housing.
b. Apply FIPG to the transaxle case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





c. Install the transaxle housing and 16 bolts to the transaxle case.
Torque:
Bolt A 25 Nm (255 kgf-cm, 18 ft. lbs.)
Bolt B 33 Nm (337 kgf-cm, 24 ft. lbs.)
Bolt C 29 Nm (295 kgf-cm, 21 ft. lbs.)
Bolt D 22 Nm (226 kgf-cm, 16 ft. lbs.)

HINT: Apply seal packing or equivalent to bolts A and D.

Seal packing: THREE BOND 2403 or equivalent

Bolt length
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)
Bolt D: 72 mm (2.835 inch)

NOTICE: Tighten the bolts within 10 minutes of sealant application.





51. INSPECT INPUT SHAFT END PLAY
a. Using a dial indicator, measure the input shaft end play
End play: 0.262 to 1.249 mm (0.0100 to 0.0494 inch)





52. FIX AUTOMATIC TRANSAXLE ASSEMBLY
a. Fix the transaxle assembly





53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
a. Coat a new oil seal with MP grease.
b. Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010 (09951-07100)
Oil seal installation depth: 0 ± 0.5 mm (0 ± 0.197 inch)





54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
a. Install the parking lock rod to the manual valve lever.





55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
a. Install a new spacer and manual valve lever shaft to the transaxle case.

NOTICE: Do not damage the oil seal when installing the shaft to the transaxle case.





b. Using a pin punch and hammer, drive in a new pin.





c. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
d. Using a pin punch, stake the spacer through the small hole.
e. Check that the spacer does not turn.





56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
a. Using needle-nose pliers, install the retainer spring.

NOTICE: Hang the spring on the shaft firmly.





57. INSTALL PARKING LOCK PAWL BRACKET
a. Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt length: 25 mm (0.984 inch)

NOTICE: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.





58. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY
a. Install the manual detent spring and cover with the 2 bolts.

NOTICE: Make sure to install the manual detent spring and cover in this order.

HINT: Tighten bolt A first, and then bolt B.

Torque:
Bolt A 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt B 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt length:
Bolt A: 27 mm (1.063 inch)
Bolt B: 16 mm (0.630 inch)





59. INSTALL B-3 ACCUMULATOR PISTON
a. Coat a new O-ring with ATF, install it to the B-3 accumulator piston.

NOTICE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.





b. Coat the piston with ATF, install it to the transaxle case.

NOTICE: Install the springs to each accumulator piston, checking the identification color or each spring.

Accumulator Spring:

60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON
a. Coat 2 new O-rings with ATF, install them to the reverse accumulator piston.

NOTICE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position.





b. Coat the piston with ATF, install it to the transaxle case.

NOTICE: Install the springs to each accumulator piston, checking the identification color or each spring.