Part 1

REASSEMBLY
1. BEARING POSITION

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube, and clamp with the bolt to the transaxle housing.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

NOTICE: Make sure to insert the pipe to the stopper.

3. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
(a) Install a new oil seal ring to the transaxle housing.

4. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, install the U/D cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)

NOTICE: Do not apply excessive pressure to it.

5. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Install 2 new oil seal rings to the transaxle case.

6. INSTALL UNDERDRIVE BRAKE PISTON
(a) Wind vinyl tape around SST at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.).
SST 09950-60010 (09951-00320)

NOTICE: Clean SST to remove deposited oil, before winding vinyl tape.

(b) Using SST and a press, install the needle-roller bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

NOTICE: When the wound vinyl tape contacts the transaxle case, stop press-fitting.

(d) Install the U/D brake piston to the transaxle case.

(e) Using SST, a snap ring expander and a press, install the piston return spring and snap ring to the transaxle case.
SST 09387-00020

NOTICE: Do not apply excessive pressure to it.

7. INSTALL BREATHER PLUG NO. 2 (ATM)

8. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the snap ring to the transaxle case.

9. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, install the 2 bearings outer races to the transaxle case.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)

NOTICE:
^ Press-fit the bearing race until it contacts the snap ring.
^ Do not apply excessive pressure to it.

(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09649-17010

NOTICE:
^ Press-fit the bearing inner race until it contacts the counter drive gear.
^ Do not apply excessive pressure to it.

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09950-70010 (09951-07150), 09950-60020 (09951-00750)

NOTICE: Do not apply excessive pressure to it.

10. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st & reverse brake piston.

11. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Using SST, a press and snap ring expander, install the piston return spring and snap ring to the transaxle case.
SST 09387-00070

NOTICE:
^ Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed.
^ Do not expand the snap ring excessively.

12. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.

13. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear assembly.
SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)

NOTICE: Do not apply excessive pressure to it.

(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 268 N*m (2,732 kgf*cm, 198 ft.*lbf)

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
Torque:
New Bearing 0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 9.0 in.*lbf)
Used Bearing (*) 0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to 4.4 in.*lbf)

HINT:
^ *: Turning torque at 60 rpm:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

(f) Using a chisel and hammer, stake the front planetary gear washer.

14. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assembly.

Bearing and race diameter: mm (in.):

15. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the bearing race with ATF, and install it to the rear planetary gear assembly.

Bearing race diameter: mm (in.):

(b) Install the thrust washer No. 2.

(d) Using a screwdriver, install the snap ring.

16. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.

(b) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case. (Dimension A)
(c) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 1.02 to 1.21 mm (0.0402 to 0.0476 in.)

HINT: Piston stroke = Dimension A - Flange thickness

Flange thickness: mm (in.):

(d) Install the flange.

17. INSTALL 2ND BRAKE PISTON ASSEMBLY
(a) Install the 2nd brake piston assembly to the transaxle case.
(b) Install the snap ring and measure the inside diameter.

NOTICE:
^ Because the taper snap ring has the positioning direction, check it when installing.
^ When the diameter does not satisfy the specified value, replace the snap ring with a new one.

18. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.

NOTICE: Check the positioning direction of the outer sleeve.

19. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the inner race to the 1-way clutch.

NOTICE: Check the direction of the inner race.

(b) Check the rotating direction of the 1-way clutch for the lock or free operation, as shown in the illustration.

Bearing diameter: mm (in.):

NOTICE: Install the thrust bearing properly so that no-colored race will be visible.

20. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the thrust washer No. 1 with petroleum jelly, and install it onto the rear planetary sun gear.

(b) Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

Bearing diameter: mm (in.):

21. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle case.
(b) Temporarily install the snap ring.

(c) Using vernier calipers, measure the distance between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 0.62 to 0.91 mm (0.0244 to 0.0358 in.)

HINT: Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Flange thickness: mm (in.):

(e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

NOTICE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

22. INSTALL DIRECT CLUTCH ASSEMBLY
(a) Install the bearing race to the direct clutch.

Bearing race diameter: mm (in.):

(b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.

NOTICE: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed.

(c) Clean the connector part of the transaxle case and rear cover.
(d) As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers. (Dimension B)

(e) Measure the 2 places of the rear cover as shown in the illustration and calculate a dimension C using the following formula.

HINT: Dimension C = Dimension (1) - Dimension (2)

(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play: 0.198 to 0.936 mm (0.00780 to 0.03685 in.)

NOTICE: Make sure that the colored race side is facing the direct clutch assembly.

HINT: End play = Dimension C - Dimension B

Bearing thickness and diameter: mm (in.):

23. INSTALL GOVERNOR APPLY GASKET NO. 1
(a) Install 2 new governor apply gaskets No. 1.

24. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.

NOTICE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

25. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.

NOTICE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

(b) Install the 2 apply tubes and a bolt to the transaxle case.

NOTICE: Each pipe should be securely inserted until it reaches the stopper.