Part 4
DISASSEMBLY AND ASSEMBLYCAUTION:
^ Use a fluid of the designated brand for ATF (automatic transmission fluid). Use of ATF not specified by the manufacturer can affect driveability and the durability of the automatic transmission, and can even lead to damage to the transmission.
^ Perform disassembly work in a clean, dustproof room.
^ Wash sand and mud adhering to the outside of the transaxle well using steam or washing oil outside a dustproof room before disassembly to prevent them from entering the inside during disassembly and assembly. (Do not blow steam in the inside of the transaxle or wash rubber-made parts with washing oil.)
^ Pull out the torque converter from the transaxle after it is cleaned and drain ATF.
^ During the disassembly and assembly work, always use bare hands or vinyl gloves.
^ Do not touch internal parts with your hands which touched the outside of the transaxle. (Wash your hands before touching internal parts.)
^ Use paper towels instead of cotton gloves and shop towels to prevent entry of lint.
^ Check the normal condition before performing disassembly and assembly work.
^ Do not reuse drained ATF.
^ Refer to "GENERAL DESCRIPTION" for the meanings of the symbols used in the illustration.
Steps 1-13:
Steps 1-14:
Steps 1-2:
Steps 3-19:
Steps 1-6:
Steps 7-19:
Steps 1-2:
Steps 3-41:
Steps 1-2:
Steps 3-40:
Steps 1-2:
Steps 3-16:
Steps 1-2:
Steps 3-30:
INSTALLATION LOCATION OF ADJUST SHIM, NEEDLE BEARING AND THRUST WASHER:
ASSEMBLY(continued)
76. Install the lip seals on the transaxle case.
77. Install the detent spring. Refer to the table or the exploded view for tightening torque.
78. Install the bracket on the oil temperature sensor.
Tightening torque: 4.9 Nm (43 in-lb)
79. Install the oil temperature sensor on the control valve. Refer to the table view for tightening torque.
Tightening torque: 7.8 Nm (69 in-lb)
CAUTION: Check the oil pressure switch connectors (each indicated with an arrow) for correct fit.
80. Install the terminal assembly on the control valve.
CAUTION: Apply ATF to the manual valve before installation.
81. Install the manual valve on the control valve.
82. Press the terminal body into the transaxle case.
CAUTION: Ensure that the notch in the manual valve is engaged with the lug on the manual plate.
83. Install the control valve assembly on the transaxle case.
CAUTION:
^ Mounting bolt A is a hexagon head bolt.
^ Mounting bolt B is a hexagon socket head bolt.
84. Install the control valve assembly mounting bolts A and B. Refer to the table or the exploded view for tightening torque.
CAUTION:
^ Never reuse the control valve cover gasket.
^ Thoroughly clean the control valve cover gasket mounting surface of the case so that it is completely free of moisture, lubricant and the old gasket.
85. Install the control valve cover gasket on the transaxle case.
86. Install the control valve cover on the transaxle case. Refer to the table or the exploded view for tightening torque.
CAUTION: Never reuse the snap ring.
87. Install a snap ring on the terminal body.
CAUTION: Never reuse the copper washers.
88. Refer to the table or the exploded view for the tightening torque to install the cooler tube (OUT) onto the side cover.
Eye bolt Tightening torque: 39.2 Nm (29 ft-lb)
Bracket Tightening torque: 21.6 Nm (16 ft-lb)
CAUTION: Never reuse the copper washers.
89. Refer to the table or the exploded view for the tightening torque to install the cooler tube (IN) on the side cover.
Tightening torque: 39.2 Nm (29 ft-lb)
CAUTION: Ensure that the cooler tube (IN) is against the stop on the side cover.
CAUTION: Ensure that the stud bolts protrude from the case as much as indicated in the table.
90. Install stud bolt 1 and 2 on the transaxle case.
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
91. Install an O-ring on the baffle plate.
92. Install the baffle plate on the converter housing. Refer to the table or the exploded view for tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
93. Install an O-ring on the pressure test port bolt.
94. Install the pressure test port bolt on the transaxle case. Refer to the table or the exploded view for tightening torque.
Tightening torque: 7.4 Nm (65 in-lb)
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
95. Install an O-ring on the water-cooled fluid cooler.
96. Install the water-cooled fluid cooler on the transaxle case. Refer to the table or the exploded view for tightening torque.
Tightening torque: 4.2 Nm (37 in-lb)
CAUTION:
^ Never reuse the Park/neutral position switch.
^ When loosely installing the switch, insert it squarely onto the manual shaft. (Do not hold the switch at an angle.)
97. Install an Park/neutral position switch using the following procedure.
(1) Loosely install an Park/neutral position switch on the manual shaft.
(2) Install the shift plate on the manual shaft.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
(3) Set the manual shaft to Range N.
(4) Align the hole in the Park/neutral position switch with the hole in the shift plate. with the holes aligned, insert a pin (5 mm) or equivalent through the holes. Now, tighten the bolt to the specified torque shown in the table or in the exploded view. Refer to the table or the exploded view for tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
98. Install an O-ring on the turbine sensor.
99. Install the turbine sensor on the transaxle case. Refer to the table or the exploded view for tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
100. Install an O-ring on the vehicle speed sensor.
101. Install the vehicle speed sensor on the transaxle case. Refer to the table or the exploded view for tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
102. Install the torque converter on the transaxle. Ensure that the dimension A is to the specification.
103. Install the control cable bracket and breather hose on the transaxle.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
104. Install the oil filler tube and oil level gage on the transaxle.
Tightening torque: 11 ± 1 Nm (97 ± 9 in-lb)
105. Install the harness bracket on the transaxle.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
106. Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle.
Tightening torque: 90 ± 10 Nm (66 ± 7 ft-lb)
107. Install the transfer on the transaxle.
Tightening torque: 68 ± 9 Nm (50 ± 7 ft-lb)