Part 2
REASSEMBLYNOTICE:
- The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
Recommended ATF: TYPE T-IV
- All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
- Dry all parts with compressed air-never use shop rags.
- When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.
- The recommended automatic transaxle fluid or kerosene should be used for cleaning.
- After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.
- When disassembling a valve body, be sure to match each valve together with the corresponding spring.
- New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.
- All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
- All gaskets and rubber O-rings should be replaced.
- Do not apply adhesive cements to gaskets and similar parts.
- Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
- If a worn bushing is to be replaced, the subassembly containing the bushing must also be replaced.
- Check thrust bearings and races for wear or damage. Replace if necessary.
- Use petroleum jelly to keep parts in place.
- When working with FIPG material, you must observe the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
20. INSTALL U/D BRAKE
a. Install the 3 discs and 3 plates to the transaxle case.
b. Using a screwdriver, install the snap ring.
c. Using a dial indicator, measure the U/D brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Piston stroke: 1.81 - 2.20 mm (0.0713 - 0.0866 inch)
HINT: Select an appropriate flange from the table so that it will meet the specified value.
Flange thickness: mm (inch)
d. Temporarily remove the snap ring and attach the flange. Restore the snap ring.
21. INSTALL ONE-WAY CLUTCH NO. 2
a. Install the outer race retainer to the gangway clutch No. 2.
b. Install the U/D clutch assembly to the gangway clutch. Rotate the U/D clutch assembly to check the rotating direction for the lock or free operation.
22. INSTALL ONE-WAY CLUTCH NO. 2
a. Install the one-way clutch No. 2 to the transaxle case.
NOTICE: Make sure that the mark on the one-way clutch outer race is visible.
b. Using screwdriver, install the snap ring to the transaxle case.
23. INSTALL U/D CLUTCH ASSEMBLY
a. Coat the bearing and bearing race with petroleum jelly and install it onto the U/D clutch.
Race diameter: mm (inch)
b. Install the U/D clutch assembly to the transaxle case.
24. INSTALL U/D PLANETARY GEAR ASSEMBLY AND DIFFERENTIAL ASSEMBLY
a. Install the pawl pin and spring to the parking lock pawl.
b. Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.
c. Install the U/D planetary gear assembly to the transaxle case.
NOTICE: Engage all the discs of U/D clutch and hub spline of the U/D planetary gear assembly firmly and assemble them securely.
d. Install the parking lock pawl shaft.
e. Install the pawl shaft with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
f. Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the U/D planetary gear and contact surface of the transaxle case and housing. (Dimension D)
NOTICE: Note down the dimension D as it is necessary for the following process.
g. As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
NOTICE: Note down the dimension E as it is necessary for the following process.
HINT: Dimension E = Dimension (1) - Dimension (2)
25. INSTALL MULTIPLE DISC CLUTCH HUB
a. Install the bearing race to the transaxle while checking its direction.
Bearings race diameter: mm (inch)
b. Coat the thrust bearing and race with petroleum jelly and install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (inch)
c. Install the bearing to the multiple clutch hub.
Bearing diameter: mm (inch)
d. Install the forward clutch hub to the transaxle case.
e. Install the thrust bearing to the forward clutch.
Bearing diameter: mm (inch)
NOTICE: Install the thrust bearing properly so that the black race will be visible.
f. Install the forward clutch to the multiple clutch hub.
NOTICE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
26. INSTALL 2 NEW APPLY GASKET
27. INSTALL DIFFERENTIAL ASSEMBLY
28. INSTALL TRANSAXLE HOUSING
a. Calculate the end play value using the following formula and values of Dimension D and E that were measured when installing cylindrical roller bearing and U/D planetary gear. Select an appropriate U/D planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 inch)
HINT: End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 inch) - U/D gear thrust bearing race No.2 thickness
Race thickness: mm (inch)
Bearing and bearing race diameter: mm (inch)
b. Install the oil pump and 7 bolts to the transaxle case
Torque: 22 Nm (226 kgf-cm, 16 ft. lbs.)
c. Coat on O-ring of oil pump with ATF.
d. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing.
e. Apply FIPG to the transaxle case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
f. Install the transaxle housing and 16 bolts to the transaxle case.
Torque:
Bolt A: 22 Nm (226 kgf-cm, 16 ft. lbs.)
Bolt B and C: 29 Nm (300 kgf-cm, 22 ft. lbs.)
HINT: Apply seal packing or equivalent to the bolt A.
Seal packing: THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)
NOTICE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.
29. INSPECT INPUT SHAFT END PLAY
Using a dial indicator, measure the input shaft end play.
End play: 0.26 - 1.25 mm (0.0103 - 0.0492 inch)
30. CHECK DIFFERENTIAL PRELOAD
31. PLACE TRANSAXLE HOUSING
32. INSTALL MANUAL VALVE LEVER SHAFT
a. Coat new oil seal with ATF.
b. Install the oil seal to the transaxle case.
c. Install the parking lock rod to the manual valve lever.
d. Install a new spacer and manual valve lever shaft to the transaxle case.
e. Using a pin punch and a hammer, drive in a new pin.
f. Turn the spacer and the lever shaft to alight the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
g. Using a pin punch, stake the spacer through the small hole.
h. Check that the spacer does not turn.
i. Using needle-nose pliers, install the return spring.
j. Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt length: 25 mm (0.984 inch)
k. Install the manual detent spring with the 2 bolts.
NOTICE: Make sure to install the manual detent spring and cover in this order.
Torque:
Bolt A: 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt B: 10 Nm (102 kgf-cm, 7 ft. lbs.)
Bolt length:
Bolt A: 27 mm (1.063 inch)
Bolt B: 16 mm (0.630 inch)
33. INSTALL ACCUMULATOR PISTON AND SPRING
a. Coat new 4 O-rings with ATF and install them to the pistons.
b. Coat the 4 springs and 3 accumulator pistons with ATF, install them to the holes.
Accumulator spring:
34. INSTALL CHECK BALL BODY AND SPRING
35. INSTALL TRANSAXLE SOLENOID WIRE
a. Coat a new O-ring with ATF, install it to the transaxle solenoid wire.
b. Install the solenoid wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
36. INSTALL APPLY GASKET
a. Coat 3 apply gaskets with ATF and install them to the transaxle case.
37. INSTALL VALVE BODY ASSEMBLY
a. Align the groove of the manual valve with the pin of lever.
b. Install the 17 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
NOTICE:
- Push the valve body against the accumulator piston spring and the check ball body to install it.
- Tighten those bolts marked by "STAR" in the illustration first temporarily because they are positioning bolts.
Each bolt length is indicated.
HINT:
Bolt length:
Bolt A: 25 mm (0.984 inch)
Bolt B: 41 mm (1.614 inch)
Bolt C: 45 mm (1.771 inch)
38. INSTALL OIL STRAINER
a. Coat new O-ring with ATF, install it to the oil strainer.
b. Install the oil strainer and 3 bolts to the valve body.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
c. Connect the 5 solenoid connectors.
d. Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 inch lbs.)
39. INSTALL OIL PAN
a. Install the 3 magnets in the oil pan.
b. Apply seal packing or equivalent to new 18 bolts.
Seal packing: THREE BOND 2430 or equivalent
c. Install a new gasket, oil pan and 18 bolts to the transaxle case.
Torque: 7.6 Nm (77 kgf-cm, 67 inch lbs.)
NOTICE: Because the bolts should be seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application.
40. INSTALL SPEED SENSOR
a. Coat 2 new O-rings with ATF, install it to the 2 sensors.
b. Install the 2 sensors with the 2 bolts to the transaxle case.
Torque: 11.3 Nm (115 kgf-cm, 8 inch lbs.)
41. INSTALL UNION AND ELBOW
a. Coat 2 new O-rings with ATF, install them to the union and elbow.
b. Install the union and elbow to the transaxle case.
Torque:
Union: 25 Nm (254 kgf-cm, 18 ft. lbs.)
Elbow: 27 Nm (276 kgf-cm, 20 ft. lbs.)
42. INSTALL TRANSAXLE CASE PLUG NO. 1
a. Coat a new O-ring with ATF, install it to the transaxle case plug No.1.
b. Install the transaxle case plug No.1 to the transaxle case.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
43. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
b. Install a new nut stopper and nut.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
c. Temporarily install control shaft lever.
d. Turn the lever counterclockwise until it stops, them turn it clockwise 2 notches.
e. Remove the control shaft lever.
f. Align the groove with neutral basic line.
g. Tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
h. Using a screwdriver, stake the nut with the nut stopper.
i. Install the control shaft lever, washer and nut.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
44. INSTALL TRANSFER ASSEMBLY
a. Remove any FIPG material and be careful not to get oil on the contacting surfaces of the transaxle case or transfer assembly.
b. Coat new gasket with petroleum jelly and install it to the transfer assembly.
c. As shown in the illustration, apply FIPG to the transfer assembly.
FIPG: Part No. 08826-0090, THREE BOND 1281 or equivalent
NOTICE: Do not apply FIPG to the part where it is not specified.
d. Install the intermediate shaft to the transfer assembly.
e. Install the transfer assembly, 2 bolts and 6 nuts to the transaxle case.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
NOTICE:
- Push the transfer straight up and install it to the transaxle.
- Pull up the transfer case by inserting your fingers into the hole on both sides may cause damage to the oil seal lip. Be careful not to damage it.