Part 3

DISASSEMBLY AND ASSEMBLY

74. Remove the needle bearing from the RR sun gear on the rear side.





75. Remove the RR sun gear on the rear side.





76. Remove the needle bearing from the RR carrier assembly.





77.
CAUTION:
Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.

Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.





78. Using a flat-head screwdriver or equivalent, remove the snap ring.





79. Remove the one-way clutch and RR carrier assembly as one unit.





80. Separate the one-way clutch and RR carrier assembly.





81. Remove the needle bearing from the RR carrier assembly.





82. Using a flat-head screwdriver or equivalent, remove the snap ring.





83.
CAUTION:
Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.

Remove the low-reverse brake retaining plate, drive plate and driven plate.





84. Remove the RR sun gear on the front side.





85. Remove the bearing race from the RR sun gear on the front side.





86. Remove the needle bearing.





87. Using the special tool MB992195, remove the snap ring.





88. Remove the diaphragm spring retainer.





89. Remove the diaphragm spring.





90.
CAUTION:
Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.

Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.





91. Remove D-rings from the low-reverse brake piston.





92.
CAUTION:
Mounting bolts are Torx E18 bolts.

Remove the Output gear set.










93. Remove the O-ring from the transaxle case.





94.
CAUTION:
Do not damage the transaxle case when removing the side oil seal.

Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.





95. Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.





96. Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.

ASSEMBLY





1.
CAUTION:
Never reuse the outer race.

Using the special tool MB991550, Install the outer race of the differential side bearing on the transaxle case.





2.
CAUTION:
Never reuse the outer race.

Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the transaxle case.





















3.
CAUTION:

- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.

- Measure the end play at more than two locations and obtain the average of the measurements.

Measure an interference (A) of the reduction gear assembly in the following procedure.
Refer to "SERVICE DATA" for the interference of the reduction gear assembly.
(1) Install the reduction gear assembly on the transaxle case.
(2) Set the outer race on the reduction gear bearing.
(3) Measure distance L1 from the outer race to the end face of the transaxle case.
(4) Place a block on the end face of the converter housing and measure distance L2 to the reduction gear taper bearing shim mounting surface.
(5) Calculate distance L3 from the end face of the converter housing to the outer race of the reduction gear assembly from the following formula.

L3 =
L2 - Height of block

(6) Calculate the thickness of the reduction gear taper bearing shim from the following formula.

Thickness of reduction gear taper bearing shim =
L3 - L1 + Interference
Standard value: 0.16 - 0.22 mm (0.006 - 0.009 in)
(For reduction gear preload)





4.
CAUTION:
Never reuse the reduction gear taper bearing shim.

Install a selected reduction gear taper bearing shim on the converter housing. Refer to
"SERVICE DATA" for selecting the reduction gear taper bearing shim.





5.
CAUTION:
Never reuse the outer race.

Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the converter housing.





















6.
CAUTION:

- Apply transmission fluid to the bearing so that the interference can be adjusted in a smooth condition.

- Measure the end play at more than two locations and obtain the average of the measurements.

Measure an interference (A) of the differential assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the differential assembly.
(1) Install the differential assembly on the transaxle case.
(2) Set the outer race on the differential side bearing.
(3) Measure distance L1 from the outer race to the end face of the transaxle case.
(4) Measure distance L2 from the end face of the converter housing to the differential taper bearing shim mounting surface of the converter housing.
(5) Calculate the thickness of the differential taper bearing shim from the following formula.

Thickness of differential taper bearing shim =
L2 - L1 + Interference

Standard value: 0.19 - 0.25 mm (0.008 - 0.010 in)
(For differential preload)





7.
CAUTION:
Never reuse the differential taper bearing shim.

Install a selected differential taper bearing shim on the converter housing. Refer to
"SERVICE DATA" for selecting the differential taper bearing shim.









8.
CAUTION:
Never reuse the outer race.

Using the special tool MB991550 [F1CJA] or MB991445 [W1CJA], Install the outer race of the differential side bearing on the converter housing.





9.
CAUTION:

- Never reuse the O-rings.

- Apply transmission fluid to the O-rings before installation.

Install an O-ring on the transaxle case.





10.
CAUTION:
Mounting bolts are Torx E18 bolts.

Install the output gear set. Refer to the following or the exploded view for the tightening torque.





Tightening torque: 41 ± 1 Nm (30 ± 1 ft-lb)





11.
CAUTION:

- Never reuse the D-rings.

- Apply transmission fluid to the D-rings before installation.

Install D-rings on the low-reverse brake piston.





12.
CAUTION:
Apply transmission fluid to the low-reverse brake piston before installation.

Install the low-reverse brake piston on the transaxle case.





13. Install the diaphragm spring.





14. Install the diaphragm spring retainer.





15. Using the special tool MB992195, install the snap ring.

























16.
CAUTION:
Measure the end play at more than two locations and obtain the average of the measurements.

Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to "SERVICE DATA" for the specified low-reverse brake clearance.
(1) While compressing the drive plates, driven plates and retaining plate, measure the thickness L1 of the pack.





NOTE:
If there is no appropriate plate, use the special tool, MD998917

(2) Measure thickness L2 of the one-way clutch.
(3) Measure distance L3 from the end face of the transaxle case to the low-reverse brake piston.
(4) Temporarily assemble the snap ring, one-way clutch and snap ring to the transaxle case.
(5) Measure distance L4 from the end face of the transaxle case to the one-way clutch, while pulling up the one-way clutch.
(6) Remove the temporarily assembled snap ring, one-way clutch and snap ring from the transaxle case.
(7) Calculate the clearance using the following formula.Clearance =
L3 - (L1 +
L2 +
L4)
(8) Select an appropriate retaining plate so that the specified clearance is obtained.
Refer to "SERVICE DATA" for selecting the retaining plate.
Standard value: 1.9 - 2.2 mm (0.07 - 0.09 in)
(For low-reverse brake clearance)





17.
CAUTION:

- Apply vaseline to the needle bearing before installation.

- Ensure that the needle bearing faces the correct direction.

Install the needle bearing.





18.
CAUTION:
Apply vaseline to the bearing race before installation.

Install the bearing race on the RR sun gear on the front side.





19. Install the RR sun gear on the front side.





20.
CAUTION:

- Apply vaseline to the needle bearing before installation.

- Ensure that the needle bearing faces the correct direction.

Install the needle bearing on the RR carrier assembly.





21. Install the RR carrier assembly.





22.
CAUTION:
Ensure that the various plates are installed in the correct order.

Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.





23. Using a flat-head screwdriver or equivalent, install the snap ring.





24. Install the one-way clutch.





25. Using a flat-head screwdriver or equivalent, install the snap ring.