Part 1

ASSEMBLY


Assembly (2)

1. Remove transaxle housing and differential gear assembly from transaxle case.





2. Install new seal rings in U/D gear assembly.

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

3. Install U/D gear assembly.





4. Install thrust needle roller bearing and thrust bearing race in U/D gear assembly.
a. Perform the following procedure for adjustment.

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





b. Make sure that measurement (E) is within the specifications.

Specification E : 1.269 - 1.645 mm (0.0500 - 0.0648 in)

NOTE:
(E) is the height between the edge of transaxle case and the roller part of thrust needle roller bearing.











c. If measurement ("E) is outside the specifications, replace (T) with one that has applicable thickness. Refer to Clutch, Gear And Brakes.

CAUTION:
When adjusting (T), use "S) of thickness 0.81mm (0.032in).

d. If all of (T) do not fit (E) within the specifications, replace "S) with one that has applicable thickness. Refer to Clutch, Gear And Brakes.

CAUTION:
When adjusting (S", use (T) of thickness 0.80mm (0.031in).






e. Make sure that measurement (E) is within the specifications.






5. Install new manual valve oil seal into transaxle case until it is flush using Tool.

Tool number : ST33061000 (J-8107-2)

CAUTION:
- Do not reuse manual valve oil seal.
- Apply ATF to manual valve oil seal.






6. Install spring guide sleeve and torsion spring No. 2 in transaxle case.
7. Tighten spring guide sleeve and torsion spring No. 2 torx bolt to specified torque. Refer to Component.






8. Install parking lockpin sub assembly.






9. Install parking lock pawl bracket and parking lock pawl.






10. Install parking lock pawl shaft and torsion spring No. 1.






11. Install manual detent spring sub assembly.






12. Temporarily tighten the bolts.











13. Install parking lock rod sub assembly.






14. Install manual valve lever sub assembly connect parking lock rod sub assembly to it.






15. Connect manual detent spring sub assembly to manual valve lever sub assembly using suitable tool.






16. Tighten manual detent spring sub assembly bolts to specified torque. Refer to Component.






17. Install U/D brake apply tube sub assembly using suitable tool.

CAUTION:
Be careful not to damage U/D brake apply tube sub assembly.






18. Tighten tube clamp bolts to specified torque. Refer to Component.





19. Install oil reservoir plate in transaxle case.
20. Tighten oil reservoir plate bolts to specified torque. Refer to Component.






21. Install oil strainer sub assembly in transaxle case.
22. Tighten oil strainer sub assembly bolt to specified torque. Refer to Component.






23. Install differential gear assembly.






24. Drive new differential side oil seal into transaxle housing using Tool.






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











25. Install new thrust roller bearing in transaxle housing using Tool.

Tool number : ST30720000 (J-25405)

CAUTION:
Do not reuse thrust roller bearing.






26. Install oil cleaner magnets on oil reservoir plate.






27. Install oil reservoir plate in transaxle housing.
28. Tighten oil reservoir plate bolts to specified torque. Refer to Component.






29. install differential gear lube apply tube using suitable tool.

CAUTION:
Be careful not to bend or damage differential gear lube apply tube.






30. Tighten tube clamp bolt to specified torque. Refer to Component.






31. Install new governor apply gasket.

CAUTION:
- Do not reuse governor apply gasket.
- Apply petroleum jelly to governor apply gasket.
32. Install new seal ring.

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






33. Apply silicone RTV to transaxle housing as shown. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Completely remove all moisture, oil and sealant from transaxle housing and transaxle case.
34. Install transaxle housing in transaxle case.






35. Tighten transaxle housing and transaxle case bolts to specified torque. Refer to Component.

CAUTION:
Do not reuse seal bolts.
















36. Install new oil seal into oil pump assembly until it is flush using Tool.

Tool number : ST30720000 (J-25405)

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






37. Install thrust washer and one- way clutch outer race sub assembly in oil pump assembly.

CAUTION:
Apply petroleum jelly to thrust washer.






38. Check the distance of (B).

"(B : 51.09 - 51.71 mm (2.0114 - 2.0358 in)"

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






39. Place oil pump assembly through the input shaft in horizontal position, and align the bolt holes of the oil pump assembly with transaxle case. Lightly press oil pump assembly.

CAUTION:
Be careful not to drop one-way clutch outer race sub assembly.






40. Tighten oil pump assembly bolts to specified torque. Refer to Component.











41. Set a dial indicator as shown, move the input shaft and measure the end play.

End play : 0.188 - 0.570 mm (0.0074 - 0.0224 in)






If the end play is out of standards, select another thrust bearing race. Refer to Clutch, Gear And Brakes.






42. Remove transaxle case cover.
43. Apply silicone RTV to transaxle case cover as shown. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Completely remove all moisture, oil and sealant from transaxle case cover and transaxle.