Part 2
17. INSTALL NEW 2ND BRAKE GASKET
Install a new gasket until it makes contact with the 2nd brake drum.
18. CHECK OPERATION OF 2ND BRAKE
Blow compressed air into the 2nd brake gasket and confirm that the piston moves.
19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.
b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.
20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT
HINT: After installing the oil seal ring, check that it moves smoothly.
21. INSTALL FRONT PLANETARY GEAR
a. Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear.
Bearing and race A
Bearing and races B
b. Install the planetary gear onto the sun gear.
22. INSTALL FRONT PLANETARY RING GEAR
Coat the race with petroleum jelly and install it onto the tip of the ring gear.
Race outer diameter: 35.7 mm (1.406 inch)
Race inner diameter: 23.0 mm (0.906 inch)
23. INSTALL 2ND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.
24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
a. Coat the race and bearing with petroleum jelly and install it onto the rear side of the forward clutch.
Bearing and race
b. Coat the races and bearing with petroleum jelly and install it onto the front side of the forward clutch.
Bearing and races
HINT: There are 2 different thickness of front races for adjustment of the input shaft thrust play.
Front race thickness
0.8 mm (0.0315 inch)
1.4 mm (0.0551 inch)
c. Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.
d. Mesh the hub of the forward clutch flukes with the direct clutch discs.
HINT: Be careful that the bearing and thrust washer do not get out of place.
e. Install the direct clutch and forward clutch into the case.
HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.
f. Check the distance between the direct clutch drum and the sun gear input drum.
Distance: approximately 3.0 mm (0.120 inch)
25. INSTALL OIL PUMP INTO CASE
a. Coat a new 0-ring with ATF and install it to the oil pump.
b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transaxle case.
NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)
26. MEASURE END PLAY OF INPUT SHAFT
Measure the end play with a dial gauge.
End play: 0.3 - 0.9 mm (0.012 - 0.035 inch)
HINT: There are 2 different thickness of races for the end of the stator shaft. If the end play is out of specification select the other race and recheck the end play.
Race thickness:
0.8 mm (0.031 inch)
1.4 mm (0.055 inch)
27. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
28. INSTALL 2ND COAST BRAKE PISTON
a. Coat new 0-rings with ATF and install it to the cover.
b. Install the outer spring with the piston.
c. Place the cover into the bore.
d. Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351-32050)
e. Check that the front end of the piston rod contacts the center of the 2nd brake band depression.
29. CHECK 2ND COAST BRAKE PISTON STROKE
a. Apply a small amount of paint to the piston rod at the point it meets the case.
b. Using SST, measure the piston stroke while blowing and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 inch)
If the stroke is more than specified, replace the piston rod with a longer one.
Piston rod length:
95.2 mm (3.748 inch)
96.3 mm (3.791 inch)
If the piston stroke is still more than specification, replace the brake band with a new one.
HYDRAULIC CONTROL UNIT
INSTALLATION
1. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Install new 0-rings to the pistons.
b. Install the springs and pistons into the bores.
Spring dimensions
c. Place the cover with a now gasket and gradually torque the 5 bolts a little at a time in sequence.
Torque: 11 Nm (1110 kgf-cm, 8 ft. lbs.)
2. PLACE NEW 2ND BRAKE APPLY GASKET
3. INSTALL SOLENOID WIRE AND THROTTLE CABLE
4. INSTALL VALVE BODY TO TRANSAXLE CASE
a. While holding the cam down with your hand, slip the cable end into the slot.
b. Lower the valve body into place.
NOTICE: Do not entangle the solenoid wire.
c. Install and tighten the 10 bolts.
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 32 mm (1.260 inch)
Bolt C: 43 mm (1.693 inch)
Bolt D: 55 mm (2.165 inch)
HINT: Hand tighten the 10 bolts first, then torque with a torque wrench.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
5. INSTALL B3 APPLY PIPE
NOTICE: Be careful not to bend or damage the pipe.
6. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 39 mm (1.535 inch)
Bolt B: 43 mm (1.693 inch)
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
7. CONNECT 2 SOLENOID CONNECTORS
8. INSTALL 8 OIL PIPES
a. Using a plastic hammer, install the 8 pipes into their position.
NOTICE: Be careful not to bend or damage the pipes.
b. Install and tighten the bolt and retainer.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
9. INSTALL MANUAL VALVE BODY AND DETENT SPRING
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 37 mm (1.457 inch)
a. Align the manual valve with the pin on the manual shaft lever.
b. Lower the manual valve body into place.
c. Hand tighten the 5 bolts first. Then, tighten them with a torque wrench.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
d. Place the detent springs on the manual valve body and hand torque the 2 bolts first. Then. tighten them with a torque wrench.
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 14 mm (0.551 inch)
Bolt B: 37 mm (1.457 inch)
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
e. Check that the manual valve lever is touching the center of the detent spring tip roller.
10. INSTALL PIPE BRACKET AND OIL STRAINER
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 53 mm (2.087 inch)
Torque:
Pipe bracket: 11 Nm (110 kgf-cm, 8 ft. lbs.)
Oil strainer: 11 Nm (110 kgf-cm, 8 ft. lbs.)
11. INSTALL 3 MAGNETS IN PLACE
NOTICE: Make sure that the magnets do not interfere with the oil pipes.
12. INSTALL OIL PAN WITH NEW GASKET
a. Install a new gasket and oil pan.
b. Install and torque 17 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
13. INSTALL THROTTLE CABLE RETAINING BOLT AND PLATE
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
14. INSTALL SOLENOID WIRE RETAINING BOLT AND PLATE
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
15. INSTALL TRANSAXLE CASE UPPER COVER
a. Install a new gasket and transaxle upper cover.
b. Install and torque the 9 bolts.
Torque:
Bolt A: 20 Nm (200 kgf-cm, 14 ft. lbs.)
Bolt B: 10 Nm (100 kgf-cm, 7 ft. lbs.)
HINT: Bolt B length is 20 mm (0.787 inch)
c. Connect the breather hose to filler pipe.
d. Install new 0-rings to the breather pipe unions.
e. Install and tighten the breather pipe unions.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
f. Coat the thread of breather hose union with sealer.
Sealer: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
g. Torque the breather hose union.
Torque: 27 Nm (276 kgf-cm, 20 ft. lbs.)
h. Install the breather pipe.
i. Using SST, torque the 2 nuts.
SST 09631-22020
Torque: 8.0 Nm (85 kgf-cm, 74 inch lbs.)
HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
16. INSTALL VEHICLE SPEED SENSOR
a. Install a new O-ring to the speed sensor.
b. Install the speed sensor to the transaxle case.
c. Torque the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
17. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch to the manual valve shaft.
b. Place a new locking plate and torque the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
c. Stake the nut with locking plate.
d. Install the 2 bolts.
e. Adjust the park/neutral position switch.
HINT: Align the groove and neutral basic line.
f. Torque the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
18. INSTALL UNION AND ELBOW
a. Install new 0-rings to the union and elbow.
b. Install the union and elbow to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
HINT: Install the elbow, as shown in the illustration.
19. INSTALL MANUAL SHAFT LEVER
20. INSTALL DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Install a new snap ring to the shaft groove.
b. Using a plastic hammer, install the shaft.
HINT: Keeping the intermediate shaft on the differential pinion shaft, measure the point in the illustration.
Protrusion length (Reference): 255.5 mm (10.059 inch)
21. INSTALL APPLY GASKET
Install a new apply gasket to the differential carrier cover.
22. INSTALL TRANSFER ASSEMBLY
a. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transfer and transaxle.
b. Apply FIPG to the transaxle.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
c. Coat the threads of bolts with sealer.
Sealer: Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install and torque the 5 nuts and 3 bolts.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
e. Install the breather hose to driven pinion bearing cage and transaxle upper cover.