Part 5

DISASSEMBLY AND ASSEMBLY





62.
CAUTION:

- Apply vaseline to the needle bearing before installation.

- Ensure that the needle bearing faces the correct direction.

Install the needle bearing on the 3-5 reverse clutch drum.





63. Install the input shaft.





64.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the transaxle case.





65. Install the magnets on the oil strainer.





66.
CAUTION:

- Never reuse the oil strainer.

- Apply transmission fluid to the O-ring of the oil strainer.

Install the oil strainer on the oil pump assembly. Refer to the following or the exploded view for the tightening torque.





Tightening torque: 9.4 Nm (83 in-lb)






67.
CAUTION:
Apply vaseline to the bearing race before installation.

Install an appropriate bearing race on the oil pump assembly.





68.
CAUTION:

- Never reuse the O-rings.

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

- Apply the transmission fluid as little as possible because too much transmission fluid applied to the O-ring, could cause some confusion over oil leakage.

Install an O-ring on the oil pump.





69. Install the oil pump assembly and oil strainer as one unit. Refer to the following or the exploded view for the tightening torque.





Tightening torque: 21 Nm (15 ft-lb)






70.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the input shaft.





71.
CAUTION:

- Completely degrease the FIPG-applied surface so that water and oil including the old sealant cannot adhere to the surface coated with the sealant. Never touch the degreased surface by hand.

- Make sure the starting point and the ending point are about the middle between the bolts.

- Apply a double bead of sealant in sections A.

Apply the sealant to the transaxle case mounting surface of the converter housing (almost the center line of the surface).
Specified sealant: ThreeBond 1216B











72.
CAUTION:
Mounting bolts are Torx E20 bolts.

Install the converter housing on the transaxle case. Refer to the following or the exploded view for the tightening torque.





Tightening torque: 47 ± 2 Nm (35 ± 1 ft-lb)









73.
CAUTION:

- Never reuse the side oil seal.

- Apply transmission fluid to the side oil seal before installation.

Using the special tools MB992197 and MB992075, install a side oil seal.

CAUTION:

- Ensure that the side oil seal is installed to the specified depth shown in the table below.

- Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm.














74.
CAUTION:

- Never reuse the side oil seal.

- Apply transmission fluid to the side oil seal before installation.

Using the special tools MB992198 and MB992075, install a side oil seal.[F6AJ]

CAUTION:

- Ensure that the side oil seal is installed to the specified depth shown in the table below.

- Measure the installed depth of the seal at four locations diagonally. Any difference between the measurements should be no more than 0.3 mm.










75.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the ATF adjusting bolt.
76. Install the ATF adjusting bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 ± 2.4 Nm (65 ± 21 in-lb)





77.
CAUTION:

- Never reuse the lip seals.

- Apply transmission fluid to the lip seals before installation.

Install the lip seals on the transaxle case.





78. Install the detent spring. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.9 Nm (43 in-lb)






79. Install the bracket on the oil temperature sensor.
80. Install the oil temperature sensor on the control valve. Refer to the following view for the tightening torque.
Tightening torque: 7.9 Nm (70 in-lb)






81.
CAUTION:
Check the oil pressure switch connectors (each indicated with an arrow) for correct fit.

Install the terminal assembly on the control valve.





82.
CAUTION:
Apply transmission fluid to the manual valve before installation.

Install the manual valve on the control valve.





83. Press the terminal body into the transaxle case.









84.
CAUTION:
Ensure that the notch in the manual valve is engaged with the lug on the manual plate.

Install the control valve assembly on the transaxle case.





85.
CAUTION:

- Mounting bolt A is a hexagon head bolt.

- Mounting bolt B is a hexagon socket head bolt.

Install the control valve assembly mounting bolts A and B. Refer to the following or the exploded view for tightening torque.





Tightening torque: 7.9 Nm (70 in-lb)






86.
CAUTION:

- Never reuse the control valve cover gasket.

- Thoroughly clean the control valve cover gasket mounting surface of the transaxle case so that it is completely free of moisture, lubricant and the old gasket.

Install the control valve cover gasket on the transaxle case.





87. Install the control valve cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.





Tightening torque: 9.0 ± 0.9 Nm (80 ± 8 in-lb)





88.
CAUTION:
Never reuse the snap ring.

Install a snap ring on the terminal body.





89.
CAUTION:
Never reuse the copper washers.

Refer to the following or the exploded view for the tightening torque to install the cooler tube (OUT) onto the side cover.
Eye bolt tightening torque: 33 ± 3 Nm (29 ± 2 ft-lb)
Bracket tightening torque: 22 ± 1 Nm (16 ± 1 ft-lb)









90.
CAUTION:
Never reuse the copper washers.

Refer to the following or the exploded view for the tightening torque to install the cooler tube (IN) on the side cover.
Tightening torque: 33 ± 3 Nm (29 ± 2 ft-lb)
CAUTION:
Ensure that the cooler tube (IN) is against the stop on the side cover.





91.
CAUTION:
Ensure that the stud bolts protrude from the case as much as indicated in the table below.





Install stud bolt 1 and 2 on the transaxle case.





92.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the baffle plate.
93. Install the baffle plate on the converter housing. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 6.6 ± 1.0 Nm (58 ± 9 in-lb)





94.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the pressure test port bolt.
95. Install the pressure test port bolt on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.4 Nm (65 in-lb)






96.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the water-cooled transmission fluid cooler.





97. Install the water-cooled transmission fluid cooler on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 4.3 ± 0.6 Nm (38 ± 16 in-lb)













98.
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.)

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. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 22 ± 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 (dia.5 mm) or equivalent through the holes. Now, tighten the bolt to the specified torque shown in the following or in the exploded view. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)






99.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the turbine sensor.
100. Install the turbine sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)






101.
CAUTION:

- Never reuse the O-rings.

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

Install an O-ring on the vehicle speed sensor.
102. Install the vehicle speed sensor on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 5.9 Nm (52 in-lb)






103.
CAUTION:
Measure the end play at more than two locations and obtain the average of the measurements.

Install the torque converter on the transaxle. Ensure that the dimension A is to the specification.





104. Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
105. Install the oil filler tube and oil level gage on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 11 ± 1 Nm (97 ± 8 in-lb)
106. Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
107. Install the corrugate clamp bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft-lb)
108. Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle.
Refer to the following or the exploded view for the tightening torque.
Tightening torque: 90 ± 10 Nm (66 ± 7 ft-lb)
109. Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque. [W6AJ]
Tightening torque: 69 ± 9 Nm (51 ± 6 ft-lb)