Part 1

Transmission Assemble

Special Tools
* DT 46451 (DW240-020) Brake Clutch Spring Compressor
* DT 46454 (DW240-050) Overdrive Brake Adapter
* DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut
* DT 46456 (DW240-060-02) Brake Spring Compressor Plate
* DT 46457 DW240-070) 1st/Reverse Brake Adapter
* DT 46458 (DW240-080) 2nd Brake Adapter
* DT 46460 (DW240-100) Counter Drive Gear Installation Adapter
* DT 46461 (DW240-130) Differential Preload Adapter
* DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter
* DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter
* DT 46465 (DW240-170) Adapter Handle
* DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer
* DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket
* DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer

Assembly Procedure




1. Install new O-rings to the bolt plugs.

Caution: Refer to Fastener Caution (Fastener Caution)

2. Install the bolt plugs with the O-rings to the transaxle rear cover and tighten to 7 Nm (62 lb in).




3. Install the seal rings to the transaxle rear cover.




4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.

The standard free length is 18.99 mm (0.7476 in).




5. Coat the new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.





Note: Do not damage the O-rings of the O/D brake piston.

6. Coat the O/D brake piston with ATF. Install the piston to the transaxle rear cover.




7. Using DT 46451 (1), DT 46454 (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover.




8. Using DT 46462 (2) and DT 46465 (1), install a new side bearing outer race into the transaxle housing.




9. Using DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal.

The oil seal depth is 3.1 mm (0.122 in).





Note: Press-fit the outer tapered roller bearing race until the race contacts the transaxle housing.

10. Install a new outer tapered roller bearing race into the transaxle housing.




11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt and tighten to 5 Nm (44 lb in).




13. Install the oil reservoir lock plate to the transaxle housing.
14. Install the oil reservoir lock plate bolts and tighten to 5 Nm (44 lb in).





Note: First install a shim of the same thickness as the original shim.

15. Install the shim to the transaxle case.
16. Install a new bearing outer race into the transaxle case.




17. Using DT 47521 (1) and a hammer, drive in a new transaxle case oil seal.

The oil seal depth is 4.3 mm (0.169 in).





Note: First install a shim of the same thickness as the original shim.

18. Install the shim to the transaxle case.

Note: Press-fit the shim until the shim contacts the transaxle case.

19. Using DT 46464 (2) and DT 46465 (1), press in a new outer tapered roller bearing race into the transaxle case.




20. Install the No. 1 transaxle case plate to the transaxle case.
21. Install the transaxle case plate bolt and tighten to 10 Nm (89 lb in).




22. Install the differential gear to the transaxle case.




23. Install the transaxle housing and hand tighten the bolts of the transaxle housing.
24. Tighten 8 bolts of the transaxle housing completely and tighten to 29 Nm (22 lb ft).




25. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.





Note: Note the measured value.

26. Using DT 46461 and a small torque wrench, measure the preload of the differential gear.




27. Remove the transaxle housing and install the counter driven gear.




28. Install the transaxle housing and hand tighten the bolts of the transaxle housing.
29. Tighten 8 bolts of the transaxle housing completely and tighten to 29 Nm (21 lb ft).




30. Using DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.




31. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. From this value deduct the value measured previously. This new value is the preload of the counter driven gear.

* The preload for a new bearing is 0.33-0.76 Nm (3.21-6.77 lb in).
* The preload for a used bearing is 0.17-0.38 Nm (1.48-3.39 lb in).

Note: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.

32. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the value. Until the value is within the specification, repeat the procedure.




33. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

The standard free length is 18.053 mm (0.7107 in).





Note:
* If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
* Before assembling the new discs, soak the discs in ATF for at least 15 minutes.

34. Inspect the sliding surface of the disc, the plate and the flange of the 1st and reverse brake for wear or burn. Replace if necessary.




35. Coat the new O-rings (1) with ATF and install the O-rings to the 1st and reverse piston.





Note: Do not damage the O-rings of the 1st and reverse brake piston.

36. Install the 1st and reverse brake piston to the transaxle case.




37. Install the return spring to the transaxle case.




38. Install the 4 plates, the 4 discs and the flange in order: 2-1-2-1-2-1-2-1-3, where (2)=Plate, (1)=Disc, and (3)=Flange





Note: Verify that the snap ring is installed correctly in the groove of the transaxle case.

39. Using DT 46457 (2) and DT 46455 (1), install the snap ring.





Note: If the piston stroke is non-standard, inspect the discs, the plates and the flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).

40. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing compressed air (1).





Note: Do not apply excessive force to the transaxle case.

41. Using DT 46460 (3), DT 46455 (2) and DT 46456 (1), install the counter drive gear.




42. Coat a new oil seal with ATF.
43. Install the oil seal to the transaxle case.

The oil seal depth is 0.75-1.25 mm (0.030-0.049 in).




44. Install the parking lock rod to the manual valve lever.




45. Install a new spacer to the manual valve lever.




46. Install the manual valve lever shaft and the manual valve lever.




47. Using a pin punch and hammer, drive in a new pin.




48. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
49. Using a pin punch, stake the spacer through the small hole.
50. Verify that the spacer does not turn.




51. Install the manual detent spring.
52. Install the manual detent spring bolt and tighten to 10 Nm (89 lb in).




53. Install the parking lock shaft, torsion spring, and the parking lock pawl.




54. Verify that the edge of the torsion spring fits into the groove securely.




55. Install the parking lock pawl bracket.
56. Install the parking lock pawl bolts and tighten to 7 Nm (62 lb in).




57. Replace the planetary ring flange of the planetary ring gear.
58. Using DT 46460 (2) and DT 46455 (1), install the planetary ring gear.




59. Fix the counter drive gear with the parking lock pawl.




60. Using DT 46472 (1), install a new nut and tighten to 10 Nm (89 lb in).




61. Using a small torque wrench, turn the counter drive gear 100 turn per minute and measure the preload and tighten to 29 Nm (22 lb ft).

When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 Nm (0.43-3.12 lb in).

62. Stake the nut.