Transmission Assembly (1)

ASSEMBLY


Assembly (1)






1. Install the new differential side oil seal into transaxle case using Tool.

Tool number : ST33400001 (J-26082)


CAUTION:
- Do not reuse differential side oil seal.
- Apply ATF to differential side oil seal.

Distance : 3.0 - 4.0 mm (0.118 - 0.157 in)











2. Install counter drive gear sub assembly.






3. Install snap ring using suitable tool.






4. Install new O-rings in 1st and reverse brake piston.

CAUTION:
- Do not reuse O-rings.
- Apply ATF to O-rings.

5. Coat the inner surface of transaxle case with ATF.
6. Install 1st and reverse brake piston in transaxle case.






7. Put return spring on 1st and reverse brake piston.






8. While compressing the return spring by hand, install the snap ring into groove using suitable tool.






9. Put thrust bearing race and thrust bearing on counter drive gear sub assembly.

CAUTION:
Apply petroleum jelly to thrust bearing and thrust bearing race.






10. Install FR planetary ring gear assembly with one-way clutch No.2






11. Install 1st and reverse brake flanges, 1st and reverse brake discs and 1st and reverse brake plates.






12. Install snap ring using suitable tool.






13. Set a dial indicator as shown.
14. Applying compressed air (4Kg/cm2) and measure the 1st and reverse brake piston stroke.

Piston stroke : 1.39 - 2.21 mm (0.0547 - 0.0870 in)

In a case that is out of reference, check the following items:
- Oil pressure leak
- Damage of O-ring
- Wear damage of discs






15. Install thrust bearing.

CAUTION:
Apply petroleum jelly to thrust bearing.






16. Install planetary gear assembly.
17. Install thrust bearing race in planetary gear assembly.

CAUTION:
Apply petroleum jelly to thrust bearing race.






18. Install thrust needle roller bearing and thrust bearing race in RR planetary ring gear assembly.

CAUTION:
Apply petroleum jelly to thrust needle roller bearing and thrust bearing race.

19. Install RR planetary ring gear assembly.






20. Install planetary sun gear sub assembly and thrust needle roller bearings.

CAUTION:
Apply petroleum jelly to thrust needle roller bearings.

21. Install forward and direct clutch assembly.






22. Install thrust bearing race, thrust needle roller bearing and new seal ring in forward and direct clutch assembly.

CAUTION:
- Apply petroleum jelly to thrust needle roller bearing and thrust bearing race.
- Apply ATF to seal ring.
- Do not reuse seal ring.





23. Check the distance of "A".

"A" : 50.850 - 51.825 mm (2.0020 - 2.0404 in)


CAUTION:
If the distance is out of standards, adjust with in standards again.





24. Install transaxle lube apply tube using suitable tool.

CAUTION:
Be careful not to bend and damage transaxle lube apply tube.





25. Tighten tube clamp bolt to specified torque. Refer to Component.
26. Install new governor apply gaskets in transaxle case.






CAUTION:
- Do not reuse governor apply gaskets.
- Apply petroleum jelly to governor apply gaskets.





27. Install transaxle case cover in transaxle case.






28. Tighten transaxle case cover bolts to specified torque. Refer to Component.

CAUTION:
Use old seal bolts for re-installing transaxle case cover when checking and adjusting the end play.
















29. Tighten anchor bolt to specified torque. Refer to Component.






30. Install new O-ring in U/D brake piston assembly.

CAUTION:
- Do not reuse O-ring.
- Apply ATF to O-ring.

31. Coat the inner surface of transaxle case with ATF.
32. Install compression spring and U/D brake piston assembly.






33. Install new O-rings in U/D brake damper assembly.

CAUTION:
- Do not reuse O-rings.
- Apply ATF to O-rings.

34. Install U/D brake damper assembly.






35. Install snap ring using suitable tool.

CAUTION:
If the snap ring is deformed, replace it.





36. Install thrust needle roller bearing, adjust shim and thrust bearing race in U/D RR planetary ring gear sub assembly.

CAUTION:
Apply petroleum jelly to adjust shim, thrust needle roller bearing and thrust bearing race.
37. Install U/D RR planetary ring gear sub assembly.





38. Install U/D RR planetary carrier assembly and thrust bearing races.

CAUTION:
Apply petroleum jelly to thrust bearing races.





39. Install U/D brake band assembly.






40. Install U/D clutch assembly.






41. Measure the U/D brake piston stroke by applying and releasing the compressed air (4Kg/cm2) as shown.

CAUTION:
Measure U/D brake piston stroke after assembling U/D clutch assembly.

Piston Stroke : 5.76 - 6.76 mm (0.2268 - 0.2661 in)











42. If the piston stroke is out of standards, select another U/D brake piston. Refer to Clutch, Gear And Brakes.