Assembly (3)

Assembly (3)
1. Remove reverse clutch assembly.





2. Install needle bearing on input shaft assembly (high clutch drum).

CAUTION: Be careful with the direction of needle bearing.

3. Install reverse clutch assembly.

CAUTION: Align teeth of reverse clutch drive plates before installing.





4. Install anchor end pin (2) and lock nut (1) on transaxle case.





5. Place brake band on outside of reverse clutch drum.
6. Tighten anchor end pin just enough so that brake band is evenly fitted on reverse clutch drum.





7. Install bearing race selected in total end play adjustment step on oil pump cover.
8. Install thrust washer selected in reverse clutch end play adjustment step on oil pump cover.
9. Install O-ring to oil pump assembly.

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





10. Install oil pump assembly (1) on transaxle case.
11. Tighten oil pump fitting bolts to the specified torque. Refer to AT-230, "Component". Component





12. Install O-ring to input shaft assembly (high clutch drum).
13. Adjust brake band.





a. Tighten anchor end pin to the specified torque.
Tightening torque: 4.9 Nm (0.50 kg-m, 43 in-lb)





b. Back off anchor end pin two and a half turns.





c. Tighten lock nut while holding anchor end pin. Refer to AT-230, "Component". Component





14. Apply compressed air into oil holes of transaxle case and check operation of brake band.





15. Install final drive assembly on transaxle case.





16. Install differential lubricant tube (1) and clips (2) on converter housing.
<---: Bolt (3)
17. Tighten differential lubricant tube fitting bolts to the 17. Tighten differential lubricant tube fitting bolts to the specified torque. Refer to AT-230, "Component". Component





18. Install O-ring on differential oil port of transaxle case.





19. Apply locking sealant (Loctite #518) to transaxle case as shown in the figure.
<---: Inside of transaxle case
"A": 3 - 5 mm (0.12 - 0.20 in)
"B": 8 mm (0.31 in) R
"C": 1.5 mm (0.059 in) dia.
"D": 4 mm (0.16 in)

CAUTION: Completely remove all moisture, oil and old sealant, etc from the transaxle case and converter housing mating surfaces.

20. Install converter housing on transaxle case.
21. Install bracket on converter housing.








22. Tighten converter housing fitting bolts (1) and (2) to the specified torque. Refer to AT-230, "Component". Component
23. Install plug or speedometer pinion according to the following procedures.





a. With ABS
i. Install O-ring (3) to plug (1).
ii. Install plug (1) to converter housing (2).
<---: Bolt (1)





b. Without ABS
i. Install O-ring (3) to speedometer pinion (1).
ii. Install speedometer pinion (1) to converter housing (2).
<---: Bolt (1)
24. Tighten plug or speedometer pinion fitting bolt to the specified torque
25. Install accumulator pistons.





a. Install O-rings (1) on servo release accumulator piston (2) and N-D accumulator piston (3).





b. Install return springs (1), servo release accumulator piston (2) and N-D accumulator piston (3) into transaxle case (4).





26. Install lip seals (1) for band servo oil holes on transaxle case.
27. Install control valve assembly on transaxle case.
a. Install O-ring on terminal body.

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





b. Insert manual valve into control valve assembly.

CAUTION: Be careful not to drop manual valve.

c. Set manual shaft in "N" position.





d. Install control valve assembly on transaxle case while aligning manual valve (2) with manual plate (1).





e. Install terminal body (2) into transaxle case by pushing it.
f. Install snap ring (1) to terminal body (2).
g. Tighten bolts A, B and C to the specified torque. Refer to AT-230, "Component". Component








28. Install oil pan.
a. Attach magnets on oil pan.





b. Install oil pan gasket on transaxle case.

CAUTION:
^ Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of transaxle case.
^ Do not reuse oil pan gasket.

c. Install oil pan on transaxle case.

CAUTION: Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of oil pan.

d. Tighten oil pan fitting bolts (1) to the specified torque. Refer to AT-230, "Component". Component

CAUTION:
^ Always replace oil pan fitting bolts (1) as they are self-sealing bolts.
^ Tighten four bolts in a criss-cross pattern to prevent dislocation of gasket.

e. Install drain plug gasket and drain plug (2) to oil pan.

CAUTION: Do not reuse drain plug gasket.

f. Tighten drain plug to the specified torque. Refer to AT-230, "Component". Component





29. Install PNP switch (2) on transaxle case.
<---: Bolt (3)
a. Set manual shaft (1) in "P" position.
b. Temporarily install PNP switch (2) on manual shaft (1).
c. Set manual shaft (1) in "N" position.
d. Use a 4 mm (0.16 in) dia. pin for this adjustment.
i: Insert the pin straight into the manual shaft (1) adjustment hole.
ii. Rotate PNP switch (2) until the pin can also be inserted straight into hole in PNP switch (2).
e. Tighten PNP switch fitting bolts to the specified torque. Refer to AT-230, "Component". Component
f. Remove pin from adjustment hole after adjusting PNP switch (2).





30. Install O-ring (3) to turbine revolution sensor (power train revolution sensor) (1).
31. Install turbine revolution sensor (power train revolution sensor) (1) to transaxle case (2).
<---: Bolt (1)
32. Tighten turbine revolution sensor (power train revolution sensor) fitting bolt to the specified torque. Refer to AT-230, "Component". Component





33. Install revolution sensor (1) to transaxle case (2).
34. Tighten revolution sensor fitting bolts to the specified torque. Refer to AT-230, "Component". Component
<---: Bolt (2)





CAUTION: Ensure revolution sensor harness is firmly secured with bolt.

(1): Revolution sensor
<---: Bolt (1)





35. Install torque converter.
a. Pour ATF into torque converter.
^ Approximately 1 liter (11 US qt, 7/8 Imp pt) of fluid is required for a new torque converter.
^ When reusing old torque converter, add the same amount of ATF as was drained.





b. Install torque converter while aligning notches of torque converter with notches of oil pump.





c. Measure distance "A" to make sure that torque converter is in proper position.
Distance "A": 14.4 mm (0.567 in) or more