Part 4
TRANSAXLEDISASSEMBLY AND ASSEMBLY (Continued)
30. Install the high clutch hub.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
31. Install the needle bearing on the reduction internal gear.
32. Install the reduction internal gear on the high clutch hub.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
33. Install the needle bearing on the reduction internal gear.
34. Install the reduction carrier.
35. Install the reduction sun gear.
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
36. Measure the reduction sun gear end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified reduction sun gear end play (A).
(1) Measure distance L1 from the reduction carrier to the end face of the transaxle case.
(2) Measure distance L2 from the reduction carrier to the reduction sun gear.
(3) Measure distance L3 from the end face of the side cover to the end face of the high clutch support area.
(4) Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
(5) Select an appropriate spacer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the spacer.
End play standard value 0.4 - 0.7 mm (0.02 - 0.03 in)
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
37. Measure the side cover end play (A) in the following procedure. Refer to "SERVICE DATA" for the specified side cover end play (A).
(1) Measure distance L1 from the reduction carrier to the end face of the transaxle case.
(2) Measure distance L2 from the end face of the side cover to the needle bearing mounting surface.
(3) Measure distance L3 from the contact surface with the needle bearing of the high clutch drum to the snap ring of the cancel cover in the following procedure.
a. Measure distance L4 from the high clutch drum edge to the snap ring of the cancel cover.
b. Measure height L5 of the high clutch drum.
c. Measure distance L6 from the underside of the high clutch drum to the contact surface with the needle bearing.
d. Calculate L3 using the following formula.
L3 = L5 - (L4 + L6) - Thickness of straight bar
(4) Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
(5) Select an appropriate needle bearing so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the needle bearing.
End play standard value 0.70 - 1.05 mm (0.028 - 0.041 in)
38. Install the high clutch assembly.
CAUTION: Ensure that the various plates are installed in the correct order.
39. Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.
CAUTION:
^ Never reuse the O-rings.
^ Apply ATF to the O-rings before installation.
40. Install an O-ring on the transaxle case.
CAUTION:
^ Never reuse the spacer.
^ Apply Vaseline to the spacer and needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
41. Install an appropriate spacer and the needle bearing on the side cover.
CAUTION:
^ Before applying the sealant, thoroughly clean the mounting surface so that it is completely free of moisture, lubricant and the old sealant.
^ The start and finish of the bead should be close to the middle of any pair of the adjoining bolt holes.
42. Apply the sealant to the transaxle case mounting surface of the side cover (almost the center line of the surface).
CAUTION: Mounting bolts are Torx E16 bolts.
43. Install the side cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 27 Nm (20 ft-lb)
CAUTION: Measure the end play at more than two locations and obtain the average of the measurements.
44. Measure the drum support end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified drum support end play (A).
(1) Measure distance L1 between the end face of the RR internal gear splines and the oil pump mounting surface of the transaxle case.
(2) Measure distance L2 between the thrust washer mounting surface of the drum support and the oil pump mounting surface of the transaxle case.
(3) Measure distance L3 using the following procedure.
a. Install the FR carrier on the low clutch assembly.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
b. Install the needle bearing on the FR carrier.
c. Install the FR internal gear on the FR carrier.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
d. Install the needle bearing on the FR sun gear.
e. Install the FR sun gear.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
f. Install the needle bearing on the FR sun gear.
g. Install the 3-5 reverse clutch assembly.
h. Measure distance L3 between A and B.
(4) Calculate the end play using the following formula.
End play = L3 - (L1 - L2) - Thrust washer thickness
(5) Select an appropriate thrust washer so that the specified end play is obtained. Refer to "SERVICE DATA" for selecting the thrust washer.
End play standard value 0 - 0.35 mm (0 - 0.014 in)
45. Install the reduction gear assembly.
46. Install the reduction gear assembly.
47. Install the parking pawl.
48. Install the parking shaft.
49. Install the return spring.
50. Install the parking plate. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.9 Nm (70 in-lb)
51. Install the differential gear assembly.
CAUTION:
^ Ensure that the claws on the thrust washer are correctly engaged with the holes in the drum support.
^ Apply Vaseline to the thrust washer before installation.
52. Install an appropriate thrust washer on the drum support.
53. Install the low clutch assembly.
54. Install the FR carrier on the low clutch assembly.
CAUTION:
^ Apply Vaseline to the needle bearing before installation.
^ Ensure that the needle bearing faces the correct direction.
