AUTOMATIC TRANSAXLE ASSEMBLY

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Assembly

Bearing and race locations

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1

2

3

4

5

6

7

8

9

10

11

Thrust washer (mm {in})

Outer

64.0 {2.52}

101.0 {3.98}

85.0 {3.35}

—

—

—

79.8 {3.14}

104.2 {4.10}

—

—

—

Inner

51.0 {2.01}

75.3 {2.96}

72.7 {2.86}

—

—

—

68.3 {2.69}

69.0 {2.72}

—

—

—

Bearing race (front) (mm {in})

Outer

—

—

—

—

—

—

—

—

—

43.7 {1.72}

—

Inner

—

—

—

—

—

—

—

—

—

25.6 {1.01}

—

Bearing (mm {in})

Outer

—

—

—

61.3 {2.41}

52.6 {2.07}

45.6 {1.80}

—

—

48.7 {1.92}

43.8 {1.72}

75.0 {2.95}

Inner

—

—

—

43.7 {1.72}

39.2 {1.54}

33.2 {1.31}

—

—

35.0 {1.38}

24.25 {0.9547}

50.5 {1.99}

Bearing race (rear) (mm {in})

Outer

—

—

—

68.8 {2.71}

48.5 {1.91}

47.0 {1.85}

—

—

45.6 {1.80}

41.7 {1.64}

—

Inner

—

—

—

46.9 {1.85}

38.1 {1.50}

35.2 {1.39}

—

—

33.2 {1.31}

24.2 {0.953}

—

		1	2	3	4	5	6	7	8	9	10	11
Thrust washer (mm {in})	Outer	64.0 {2.52}	101.0 {3.98}	85.0 {3.35}	—	—	—	79.8 {3.14}	104.2 {4.10}	—	—	—
Inner	51.0 {2.01}	75.3 {2.96}	72.7 {2.86}	—	—	—	68.3 {2.69}	69.0 {2.72}	—	—	—
Bearing race (front) (mm {in})	Outer	—	—	—	—	—	—	—	—	—	43.7 {1.72}	—
Inner	—	—	—	—	—	—	—	—	—	25.6 {1.01}	—
Bearing (mm {in})	Outer	—	—	—	61.3 {2.41}	52.6 {2.07}	45.6 {1.80}	—	—	48.7 {1.92}	43.8 {1.72}	75.0 {2.95}
Inner	—	—	—	43.7 {1.72}	39.2 {1.54}	33.2 {1.31}	—	—	35.0 {1.38}	24.25 {0.9547}	50.5 {1.99}
Bearing race (rear) (mm {in})	Outer	—	—	—	68.8 {2.71}	48.5 {1.91}	47.0 {1.85}	—	—	45.6 {1.80}	41.7 {1.64}	—
Inner	—	—	—	46.9 {1.85}	38.1 {1.50}	35.2 {1.39}	—	—	33.2 {1.31}	24.2 {0.953}	—

Components

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1

Transaxle case plate No.3

2

Transaxle case plate No.2

3

Seal ring

4

O-ring

5

Oil cooler outlet tube

6

Wiring harness clip

7

Transaxle case No.1 plate

8

Pipe clamp

9

Parking pin

10

Parking rod

11

Manual valve lever

12

Parking pawl

13

Parking pawl bracket

14

Torsion spring

15

Spring guide sleeve

16

Pawl return spring

17

Parking pawl shaft

18

Detent spring

19

Detent spring cover

20

Stud bolt

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1

Oil pipe

2

Magnet

3

Oil reservoir lock plate

4

Tube clamp

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1

Thrust bearing

2

C2 clutch component

3

Retaining plate

4

Driven plate

5

Drive plate

6

Retaining plate

7

Snap ring

8

Bearing race

9

Thrust bearing

10

Bearing race

11

Rear planetary gear component and one-way clutch component

12

Snap Ring

13

Spacer

14

Vehicle speed sensor (VSS)

15

Counter drive gear

16

Lock washer

17

Differential component

18

Counter gear component

19

Sun gear input drum

20

Bearing race

21

Thrust bearing

22

C1 clutch component

23

Bearing race

24

Thrust bearing

25

Piston return spring

26

B1 brake piston

27

Brake piston cover

28

Snap ring

29

B1 brake band

30

Brake band anchor bolt

31

Front planetary gear component and input shaft

32

C3 clutch component

33

Oil strainer

34

Oil Pump component

35

Gasket

36

Gasket

37

Transaxle case gasket

38

O-ring

39

Breather pipe

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1

Oil seal (manual shaft)

2

O-ring (transaxle case side)

3

Oil seal (transaxle case side)

4

O-ring (converter housing side) (2WD)

5

Oil seal (converter housing side)

6

Input/turbine speed sensor

7

Gasket

8

O-ring

9

Coupler component

10

Coupler component lock plate

11

Control valve body component

12

Gasket

13

Suction cover

14

Lock plate

15

Control valve body cover

16

TCM

17

O-ring

18

Filler plug

19

Gasket

20

Drain plug

21

Torque converter

22

Oil pipe and O-ring

*1 :The figure shows CX-7 specification.

Assembly Procedure

Caution

• Do not damage the oil seal.

1. Using the SST and a hammer, install a new oil seal to the transaxle case.

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Substitution SST

• 49 F026 102

Outer diameter: 27 mm {1.07 in} or more

Inner diameter: 15—18 mm {0.60—0.70 in}

2. Apply ATF to the new seal rings and sliding surface of the transaxle case.

3. Compress the seal rings as shown in the figure. Then install the seal rings in the transaxle case.

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Caution

• Do not expand the seal rings too much.

• Be careful not to shorten the seal rings too much, when installing the seal rings.

Note

• Inspect that seal rings rotate smoothly after installing them.

4. Install the transaxle case plate No.3.

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Tightening torque

3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60 in·lbf}

5. Install the transaxle case plate No.2.

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Tightening torque

3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60 in·lbf}

6. Apply ATF or grease to the thrust bearing and install it to the C2 clutch component.

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7. Apply ATF to the seal ring and rubbing surface of the C2 clutch component where the bushing is fit.

Caution

• Do not damage the seal ring.

8. Install the C2 clutch component to the transaxle case.

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9. Apply ATF to the driven plates, drive plates and retaining plates.

Note

• Replace with new drive plates after soaking them at least 2 h in ATF.

10. Install driven plates, drive plates and the retaining plate in the following order to the transaxle case as shown in the figure.

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Six drive plates type

• Retaining—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Retaining

Seven drive plates type

• Retaining—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Driven—Drive—Retaining

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Caution

• Inspect the number and order of the retaining plates, drive and driven plates.

11. Using a flathead screwdriver, install the snap ring in the groove.

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Caution

• Align the opening of the snap ring with the position as shown in the figure.

12. Apply ATF to the thrust bearing and the bearing races and install them to the transaxle case.

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Note

• Align the spline of the C2 clutch drive plates and B2 brake drive plates before installing the rear planetary gear component.

13. Apply ATF to each gear and the bushing, and then install the rear planetary gear component to the transaxle case.

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14. Apply ATF to the sliding surface of the one-way clutch.

Note

• For easy installation, while turning the rear planetary gear component, install it.

15. Install the one-way clutch to the transaxle case.

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16. Using a flathead screwdriver, install the snap ring in the groove.

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Caution

• Align the opening of the snap ring with the position shown in the figure.

17. While holding the one-way clutch component, inspect that the planetary gear turns to right (clockwise) but does not turn to left (counterclockwise).

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Caution

• Do not damage the VSS.

18. Install the VSS and spacer to the counter drive gear.

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Tightening torque

3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60 in·lbf}

19. Apply ATF to the spline on the counter drive gear and spline on the ring gear.

Caution

• Do not damage the VSS wiring harness.

• Do not pull hard on the VSS wiring harness.

20. Install the counter drive gear to the transaxle case.

Note

• Verify that the claws of the lockwashers are facing upward.

21. Install the new lockwashers and washers with new bolts.

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Tightening torque

82.7 — 93.6 N·m {8.5 — 9.5 kgf·cm, 61.0 — 69.0 ft·lbf}

Bolt length (measured from below the head)

A: 28 mm {1.102 in}

B: 35 mm {1.378 in}

22. Using a flathead screwdriver and a hammer, pry back the crimp locking the lockwashers.

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23. Apply ATF to the new O-rings.

24. Install the O-rings to the oil cooler outlet tube.

25. Install the oil cooler outlet tube, pipe clamp, transaxle case No.1 plate and the wiring harness clip to the converter housing.

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Caution

• Do not damage the VSS wiring harness.

• Do not pull hard on the VSS wiring harness.

Tightening torque

7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

26. Connect the VSS wiring harness to the wiring harness clip.

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27. Apply ATF to the bearing and gear of the differential component.

28. Install the differential component to the transaxle case.

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29. Apply ATF to the bearing and gear of the counter gear component.

30. Install the counter gear component to the transaxle case.

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Note

• If it is difficult to install the counter driven gear, remove the differential component and then install the counter driven gear. Install the differential component again.

• For easy installation, tilt the counter gear slightly.

31. Install the parking pin to the transaxle case.

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Caution

• Verify to install the parking pin as shown in the figure.

32. Insert the parking rod to the transaxle case.

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33. Install the manual valve lever to the transaxle case.

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34. Connect the parking rod to the manual valve lever.

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35. Install the parking pawl, parking pawl bracket and the parking rod to the transaxle case.

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Caution

• Do not apply too much force to the torsion spring.

Tightening torque

7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

36. Install the spring guide sleeve and the torsion spring.

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Tightening torque

7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

Note

• Install the torsion spring to the position of the parking lock pawl and parking lock pawl bracket shown in the figure together with the spring guide sleeve and torsion spring installed.

Caution

• Do not apply too much force to the pawl return spring.

37. Install the pawl return spring to the parking pawl shaft.

38. Install the pawl return spring and the parking pawl shaft to the transaxle case.

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Caution

• Do not apply too much force to the detent spring.

Note

• When installing the pawl return spring to transaxle case, install the parking pawl side of the spring, then install the parking pawl shaft.

39. Install the detent spring cover and detent spring to the transaxle case.

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Tightening torque

7.8 — 11.8 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

Note

• When installing, ensure that the center of the detent spring’s roller fits the center of the manual valve lever.

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40. Install the sun gear input drum to the transaxle case.

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41. Apply ATF to the bearing race and the thrust bearing, and then install them to the transaxle case.

42. Install the C1 clutch component to the transaxle case.

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43. Apply ATF to the bearing race and the thrust bearing, and then install them to the transaxle case.

Caution

• If the input shaft is not hold during installation, the thrust washer might be come off.

Note

• Align the spline of the C1 clutch drive plates before installing the input shaft and front planetary gear.

• Hold the C1 clutch component and install the front planetary gear while holding the input shaft.

44. Install the input shaft and the front planetary gear to the transaxle case.

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45. Apply ATF to the bushing of the C3 clutch component.

Note

• Before installing the C3 clutch component, align the spline of the C3 clutch drive plates and the spline of the B1 brake drive plates.

46. Install the C3 clutch component to the transaxle case.

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Note

• Install the C3 clutch component so that it engages with the sun gear drum as shown in the figure.

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47. Install the B1 brake band to the transaxle case.

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48. Install the brake band anchor bolt to the transaxle case.

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Tightening torque

133.3 — 199.9 N·m {13.6 — 20.3 kgf·m, 98.3 — 147.4 ft·lbf}

49. Install the piston return spring, B1 brake piston and the brake piston cover to the transaxle case.

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50. Using the SST, press the brake piston cover into the position where the snap ring groove is visible.

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51. Apply ATF to the oil seal.

52. Install the oil strainer and the oil seal to the oil pump component.

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53. Apply ATF to each rubbing surface of the oil pump component.

Caution

• Do not drop the thrust washer.

• Do not damage the oil seal.

54. Install the oil pump component to the transaxle case.

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Tightening torque

19.6 — 29.4 N·m {2.0 — 2.9 kgf·m, 14.5 — 21.6 ft·lbf}

Bolt length (measured from below the head)

A: 22 mm {0.866 in}

B: 35 mm {1.378 in}

55. Verify that the input shaft turns smoothly.

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56. Using a dial indicator, measure the input shaft end play.

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Input shaft end play

0.349 — 1.081 mm {0.01374 — 0.04255 in}

57. Put a mark on the piston rod at the point where it intersects with the case.

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58. Measure the stroke between the transaxle case and the mark on the piston rod when applying compressed air into the oil hole as shown in the figure.

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Air pressure

400 kPa {4.1 kgf/cm², 58 psi}

B1 brake piston stroke

5.50 — 6.00 mm {0.217 — 0.236 in}

• If not within the specification, select an appropriate piston rod.

Piston rod size

Identification mark	Length (mm {in})
—	102.80 {4.0473}
1	103.05 {4.0571}
2	103.30 {4.0669}
3	103.55 {4.0768}
4	103.80 {4.0866}
5	104.05 {4.0965}
6	104.30 {4.1063}
7	104.55 {4.1161}
8	104.80 {4.1260}
9	105.05 {4.1358}
10	105.30 {4.1457}

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Caution

• Do not damage the differential gear lube apply tube.

59. Install the differential gear lube apply tube to the converter housing.

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60. Install the magnets to the oil reservoir lock plate.

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Caution

• Do not damage the oil reservoir lock plate.

61. Install the oil reservoir lock plate and the tube clamp to the converter housing.

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Tightening torque

3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60 in·lbf}

62. Apply ATF to the new gaskets.

63. Install the gaskets to the transaxle case as shown in the figure.

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64. Apply ATF to the new transaxle case gaskets.

65. Install the transaxle case gaskets to the transaxle case as shown in the figure.

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Caution

• Verify to install the transaxle case gasket as shown in the figure.

66. Remove any packing material and be careful not to get oil on the contact surface of the transaxle case and the converter housing.

67. Clean the contact surface of the transaxle case and the converter housing and the bolt holes.

Note

• Completely remove sealant and oil with white gasoline or equivalent.

68. Apply ATF to a O-ring of the oil pump.

69. Apply sealant to the converter housing as shown in the figure.

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Note

• Spread sealant over the contact surface.

• Do not apply sealant to the transaxle case.

Caution

• Do not damage the O-ring on the oil pump component.

• Do not damage the housing oil seal.

70. Install the converter housing to the transaxle case.

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Note

• Tap all around the contact surface with a plastic hammer during installation.

71. Temporarily tighten the bolts by hand as shown in the figure.

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Bolt number

Bolt size

Length (measured from below the head) (mm {in})

A

M8 × 1.25

30 {1.18}

B

M8 × 1.25

35 {1.38}

C

M8 × 1.25

39 {1.54}

D

M10 × 1.25

25 {0.984}

E

M10 × 1.25

40 {1.57}

72. Tighten the bolts.

Tightening torque

A, B, C: 23.5 — 35.3 N·m {2.4 — 3.5 kgf·m, 17.4 — 26.0 ft·lbf}

D, E: 29.4 — 41.2 N·m {3.0 — 4.2 kgf·m, 21.7 — 30.3 ft·lbf}

Caution

• Do not damage the input/turbine speed sensor.

73. Install the input/turbine speed sensor to the transaxle case.

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Tightening torque

3.9 — 6.9 N·m {40 — 70 kgf·cm, 26 — 60 in·lbf}

74. Apply ATF to a new gasket as shown in the figure.

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75. Install the gasket to the coupler component.

Caution

• Do not apply ATF to the O-ring.

76. Install a new O-ring to the coupler component.

Caution

• Do not apply too much force to the coupler component.

• Do not damage the coupler component.

77. Install the coupler component to the transaxle case.

Note

• Install the coupler component to the transaxle case by engaging its claw.

78. Install a new coupler component lock plate.

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Caution

• When installing the control valve body component, do not put the coupler component in the open space of the separate plate in the control valve body component.

• Do not pinch the coupler component between the separate plate and the control valve body component.

79. Connect the manual valve link and install the control valve body component.

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80. Temporarily install the control valve body component with the bolts.

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Bolt length (measured from below the head)

A: 31 mm {1.220 in}

B: 17 mm {0.669 in}

C: 21 mm {0.827 in}

Note

• Aligning the bolt holes, temporarily tighten the bolts by hand.

81. Temporarily install the suction cover and a new gasket with the bolts.

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82. Tighten the bolts in the order shown in the figure.

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Tightening torque

8 — 12 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.

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Caution

• If the control valve body cover is installed with the wiring harnesses overlapped, the wiring harnesses may be pinched between the cover and valve body causing the wiring harnesses to be damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the control valve body cover.

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84. Apply ATF to a new O-ring and install it on the TFT sensor.

85. Install the TFT sensor with the lock plate and a bolt to the control valve body component as shown in the figure.

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Tightening torque

8 — 12 N·m {82 — 122 kgf·cm, 72 — 105 in·lbf}

86. Connect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.

87. Connect the coupler component to the clamps.

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Note

• Completely remove sealant and oil with white gasoline or similar.

88. Clean sealant and oil off the contact surface of the transaxle case with the control valve body cover and the bolt holes.

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Note

• Completely remove oil with white gasoline or similar.

89. Clean oil off the contact surface of the new control valve body cover with the transaxle case.

90. Apply sealant to the new control valve body cover as shown in the figure.

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Caution

• Be careful that the coupler component will not become caught between the control valve body cover and transaxle case.

91. Install the new control valve body cover with new seal bolts.

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Tightening torque

9.8 — 15.7 N·m {100 — 160 kgf·cm, 87 — 138 in·lbf}

92. Inspect the condition of connector pin of the coupler component (foreign material, bent/broken pins) and O-ring.

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93. Align the transaxle case and the coupler component connector.

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94. Be sure to match the position of the TCM marking.

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Caution

• Do not turn more than 60° from the marking.

95. Verify the correct positioning of the TCM and coupler component.

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96. Install the TCM to the transaxle case.

Tightening torque

19.6 — 29.4 N·m {2.0 — 2.9 kgf·m, 14.5 — 21.6 ft·lbf}

Caution

• Do not repair the threads using a tap or other tools.

• Do not damage the transaxle case.

• Do not overtighten the stud bolts. (The stud bolts should remain protruded from the end of the transaxle case more than 47 mm {1.85 in}.)

• If any of the stud bolts is overtightened, the transaxle case may be damaged (holes in the case may result).

• If the transaxle case is damaged, the transaxle must be replaced.

97. Install the double nutted stud bolts to the transaxle case.

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98. Remove the double nutted from the stud bolt.

Caution

• Do not damage the oil seal.

99. Using the SST and a hammer, tap a new oil seal so that the specified oil seal position is obtained.

Transaxle Case Side

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Substitution SST

• 49 H028 202

Outer diameter: 54.5—61 mm {2.15—2.40 in}

Inner diameter: 52 mm {2.05 in} or more

Plate thickness: 2 mm {0.08 in} or more

Converter Housing Side

bawuua00000491

Substitution SST

• 49 F027 009

Outer diameter: 76.8 mm {3.02 in}

Plate thickness: 2 mm {0.08 in} or more

• 49 L033 101

Outer diameter: 73—76.3 mm {2.88—3.00 in}

Inner diameter: 69 mm {2.72 in} or more

Length: 20 mm {0.79 in} or more

Plate thickness: 2 mm {0.08 in} or more

100. Install a new gasket and the drain plug.

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Tightening torque

23.5 — 54.9 N·m {2.4 — 5.5 kgf·m, 17.4 — 40.4 ft·lbf}

Caution

• Do not damage the oil seal.

• Do not drop the torque converter.

• Be careful that fingers do not get caught.

101. Using a flathead screwdriver, position the drive gear on the oil pump component in the center. Then install the torque converter component to the transaxle.

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102. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.

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Distance A (between the end of the torque converter and the end of the converter housing)

31.4 mm {1.24 in}

103. Install the O-rings and oil pipes. (Refer to the Workshop Manual.)

104. Add the ATF.

1	Transaxle case plate No.3
2	Transaxle case plate No.2
3	Seal ring
4	O-ring
5	Oil cooler outlet tube
6	Wiring harness clip
7	Transaxle case No.1 plate
8	Pipe clamp
9	Parking pin
10	Parking rod
11	Manual valve lever
12	Parking pawl
13	Parking pawl bracket
14	Torsion spring
15	Spring guide sleeve
16	Pawl return spring
17	Parking pawl shaft
18	Detent spring
19	Detent spring cover
20	Stud bolt

1	Thrust bearing
2	C2 clutch component
3	Retaining plate
4	Driven plate
5	Drive plate
6	Retaining plate
7	Snap ring
8	Bearing race
9	Thrust bearing
10	Bearing race
11	Rear planetary gear component and one-way clutch component
12	Snap Ring
13	Spacer
14	Vehicle speed sensor (VSS)
15	Counter drive gear
16	Lock washer
17	Differential component
18	Counter gear component
19	Sun gear input drum
20	Bearing race
21	Thrust bearing
22	C1 clutch component
23	Bearing race
24	Thrust bearing
25	Piston return spring
26	B1 brake piston
27	Brake piston cover
28	Snap ring
29	B1 brake band
30	Brake band anchor bolt
31	Front planetary gear component and input shaft
32	C3 clutch component
33	Oil strainer
34	Oil Pump component
35	Gasket
36	Gasket
37	Transaxle case gasket
38	O-ring
39	Breather pipe

1	Oil seal (manual shaft)
2	O-ring (transaxle case side)
3	Oil seal (transaxle case side)
4	O-ring (converter housing side) (2WD)
5	Oil seal (converter housing side)
6	Input/turbine speed sensor
7	Gasket
8	O-ring
9	Coupler component
10	Coupler component lock plate
11	Control valve body component
12	Gasket
13	Suction cover
14	Lock plate
15	Control valve body cover
16	TCM
17	O-ring
18	Filler plug
19	Gasket
20	Drain plug
21	Torque converter
22	Oil pipe and O-ring

Bolt number	Bolt size	Length (measured from below the head) (mm {in})
A	M8 × 1.25	30 {1.18}
B	M8 × 1.25	35 {1.38}
C	M8 × 1.25	39 {1.54}
D	M10 × 1.25	25 {0.984}
E	M10 × 1.25	40 {1.57}