Part 1

COMPONENT PARTS INSTALLATION
Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended ATF: TYPE Torx equivalent

GENERAL INSTALLATION NOTICE
a. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
b. Before assembling new Clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
c. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
d. Use petroleum jelly to keep small parts in their places.
e. Do not use adhesive cements on gaskets and similar parts.
f. When assembling the transaxle, be sure to use new gaskets and 0-rings.
g. Dry all parts with compressed air-never use shop rags.
h. When working with FIPG material, you must observe the following.
- Using a razor blade and gasket scraper, remove all the FIPG material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.
- Be careful not to drop oil on the contacting surfaces.
i. Be sure to install the thrust bearings and races in the correct direction and position.

DIFFERENTIAL AND DRIVE PINION

INSTALLATION





1. INSTALL COUNTER DRIVEN GEAR BEARING
Using SST and a press, press in a new bearing.
SST 09350-32014 (09351-32090)





2. INSTALL SHAFT BEARING OUTER RACE TO CAGE
Using SST and a press, press the outer race into the cage.
SST 09350-32014 (09351-32111)





3. INSTALL SHAFT BEARING OUTER RACE TO CAGE
Using SST and a press, press in the bearing to the drive pinion shaft.
SST 09350-32014 (09351-32120)
4. INSTALL DRIVE PINION INTO TRANSAXLE CASE





a. Place the bearing cage onto the drive pinion shaft.





b. Using a brass bar and hammer, slightly tap the bearing cage into the transaxle case until the snap ring groove in the bore can be seen.





c. Using SST, install the snap ring into the bore.
SST 09350-32014 (09351-32050)





5. INSTALL DRIVE PINION NO.2 SPACER





6. PLACE OIL SLINGER AND NEW SPACER

HINT: Install the spacer with the small end downward.





7. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST and a press, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)
8. INSTALL COUNTER DRIVE GEAR





a. Place SST bar into the transaxle hole to hold the drive pinion shaft.
SST 09350-32014 (09351-32130, 09351-32150)
b. Using SST and a press, press in the counter driven gear until the counter driven gear bearing almost touches the counter gear.
SST 09350-32014 (09351-32140)
9. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION PRELOAD
a. Install a new lock nut.





b. Using SST to hold the gear, torque the nut.

Torque: 280 Nm (2,855 kgf-cm, 206 ft. lbs.)

SST 09330-00021, 09350-32014 (09351-32032)
c. Turn the gear counterclockwise and clockwise several times.





d. Using a torque wrench, measure the preload of the drive pinion.

Drive pinion preload (at starting):

New bearing
1.0 - 1.6 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)

Reused bearing
0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)

- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less then specified, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) at a time until the specified preload is reached.

Maximum torque: 353 Nm (3,600 kgf-cm 260 ft. lbs.)

If the maximum torque is exceeded while retightening the nut. replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.
e. If the preload is adjusted within specification, make a note of it.





f. Using a chisel and hammer, stake the lock nut.





10. INSTALL 2 APPLY GASKETS





11. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE
Be sure to install the ring gear mount case sleeve and outer race into place.
12. INSTALL CARRIER COVER
a. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case.





b. Apply FIPG to the carrier cover.

FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent





c. Install and torque the 11 bolts.

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 65 mm (2.559 inch)
Bolt B: 75 mm (2.953 inch)
Bolt C: 100 mm (3.937 inch)

Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

13. ADJUST SIDE BEARING PRELOAD
a. Remove any FIPG material on the contacting surfaces of the LH bearing retainer and transaxle case.

HINT: Do not apply FIPG yet.





b. Install the LH bearing retainer and torque the 6 bolts.

Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

c. Snap down the bearings by turning the differential case several times.





d. Using a torque wrench, measure the differential total preload.

Total preload (at starting):

New bearing
Drive pinion preload plus
0.2 - 0.4 Nm (2.3 - 3.7 kgf-cm, 2.0 - 3.2 inch lbs.)

Reused bearing
Drive pinion preload plus
0.1 - 0.2 Nm (1.2 - 1.9 kgf-cm, 1.0 - 1.6 inch lbs.)

If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with one of a different thickness.









Adjusting shim thickness

14. INSTALL LH BEARING RETAINER





a. Remove the 6 bolts and LH bearing retainer.
b. Remove any FIPG material on the contacting surfaces of LH bearing retainer, transaxle case and carrier cover.





c. Apply FIPG to the transaxle case and carrier cover.

FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

d. Install the LH bearing retainer.
e. Coat the threads of bolts with sealer.

Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent

f. Torque the bolts.

Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)

g. Snap down the bearings.
h. Recheck the differential total preload.





15. INSTALL NEW OIL SEAL
Using SST and a hammer, drive in a new oil seal unit its end is flush with surface of the LH bearing retainer.
SST 09223-15020, 09550-10012 (09252-10010)
16. INSTALL DRIVE PINION CAP
a. Install a new O-ring to the cap.





b. Install and torque the drive pinion cap to the transaxle case.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

4-SPEED GEAR UNIT INSTALLATION
1. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.





b. Install the pin into the hole of the case through the spring and pawl.
2. INSTALL MANUAL VALVE SHAFT
a. Coat the oil seal lip with MP grease.





b. Using a plastic hammer, install the manual valve shaft oil seal to the case.





c. Assemble a new collar to the manual valve lever.





d. Install the manual valve shaft to the transaxle case through the manual lever.
e. Install the parking lock rod.





f. Using a pin punch and hammer, drive in the roll pin until its surface is flush with the manual valve lever surface.





g. Match the collar hole to the lever caulking hollow and caulk the collar to the lever.





h. Install the retaining spring.





3. INSTALL PARKING LOCK PAWL BRACKET
Torque the 3 bolts.

Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P position.
5. INSTALL 1ST AND REVERSE BRAKE PISTON TO TRANSAXLE CASE
a. Coat new 2 0-rings with ATF.





b. Using a screwdriver, install the 2 0-rings on the piston.





c. Push the piston into the bore of the case, facing the spring seat upward.
6. INSTALL PISTON RETURN SPRING








a. Place the return spring and snap ring on the piston.
- Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)
- Install the snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the spring retainer claw.
- Remove the SST.





7. INSTALL SNAP RING TO TRANSAXLE CASE
Using a snap ring pliers, install the snap ring.
8. INSTALL OVERDRIVE UNIT





a. Install a new O/D brake apply gasket and a new O/D clutch apply gasket.





b. Install the O/D brake drum to the case.
c. Install a new case gasket to the case.





d. Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 inch).
e. Place a new gasket onto the transaxle case.





f. Install the O/D assembly with 0/D case to the transaxle case.





g. Apply FIPG to a new O/D case protector.

FIPG: THREE BOND 1280 or equivalent

h. Install the O/D case protector.
i. Coat the threads of 23 mm (0.91 inch) bolts with sealer.

Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent





j. Install and torque the 13 bolts.

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 23 mm (0.906 inch)
Bolt B: 38 mm (1.496 inch)
Bolt C: 61 mm (2.402 inch)

Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

9. CHECK INTERMEDIATE SHAFT END PLAY





a. Check the intermediate shaft and play in axial direction.

End play: 0.47 - 1.50 mm (0.0185 - 0.0591 inch)

If the end play is not within specification, check the installation of intermediate shaft.
b. Make sure that the intermediate shaft turns smoothly.
10. INSTALL REAR PLANETARY GEAR





a. Install the rear planetary ring gear.
b. Coat the races and bearing with petroleum jelly, and install them onto the ring gear.





Bearing and races





c. Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear.





d. Install the rear planetary gear.
11. INSTALL DISCS, PLATES AND FLANGE OF 1ST AND REVERSE BRAKE





a. Install the plates and discs.
Install in order:
P = Plate D = Disc
P-D-P-D-P-D-P-D-P-D-P-D
b. Install the flange.

HINT: Facing the flat end downward.





c. Using a screwdriver, install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of the cutouts.

12. CHECK 1ST AND REVERSE BRAKE





a. Check the operation of the 1st and reverse brake piston.
Blow compressed air into the case passage and confirm that the piston moves.





b. Using a filler gauge, check the pack clearance of the 1st and reverse brake.

Clearance: 1.04 - 2.16 mm (0.041 - 0.085 inch)

13. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE





a. Place the No.2 one-way clutch with the shiny side of flange upward.





b. Install the one-way clutch while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If the planetary gear cannot turn clockwise, check the installation of the one-way clutch.





c. Using a screwdriver, install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.





d. Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear.
14. INSTALL 2ND COAST BRAKE BAND GUIDE





15. PLACE NO.1 ONE-WAY CLUTCH ONTO PLANETARY GEAR
16. INSTALL 2ND BRAKE





a. Install the flange.

HINT: Facing the flat end upward.

b. Install the 4 discs and plates.
Install in order:
P=Plate D=Disc
D-P-D-P-D-P-D-P





c. Place the piston return spring into the case.





d. Place the 2nd brake drum into the case.

HINT: Align the groove of the drum with the bolt.

e. Place the snap ring into the case so that the end gap is installed into the groove.





f. While compressing the piston return spring over the drum with hammer handles the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of the cutouts.