Part 1

ASSEMBLY

CAUTION:
- Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
- Do not use grease other than petroleum jelly (Vaseline).
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- When replacing a bushing, replace the assembly, which it belongs to.
- Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.





1. Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.





2. Tighten the seven mounting bolts (F4A42) and eight mounting bolts (F4A51) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34 ± 2 Nm (25 ± 1 ft. lbs.)
3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
4. Fit a new O-ring into the groove of one-way clutch inner race.





5. Check the placement of the identification notches in the one way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.
6. Put the snap ring on the inner race.





7. Set special tools MD998703 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.

NOTE: This illustration shows F4A51.

8. Install the wave spring onto the low-reverse brake piston.

CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.

9. Install the six brake discs, five brake plates and snap ring as shown in the figure.

NOTE: Do not install the pressure plate at this time.

10. Install special tool MB991631 or MB991632 on the brake disc.
11. Install the reaction plate and the used snap ring.

12. Move special tool MB991631 or MB991632 to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)

13. install the brake discs and brake plates as shown in the figure. Number of brake discs and orates

14. Place special tool MB991631 or MB991632 on top of the brake disc in place of the pressure plate.

15. Install the return spring, second brake piston and snap ring.

16. Move special tool MB991631 or MB991632 and measure its movement.
Standard value of end play (Reference):
0.79 - 1.25 mm (0.0311 - 0.0492 inch)
1.09 - 1.55 mm (0.0429 - 0.0610 inch)
17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.

PRESSURE PLATE FOR F4A42

PRESSURE PLATE FOR F4A51

18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up. Install special tool MD998913 in a dial gauge, and then move special tool MB991631 or MB991632 and measure its movement.
Standard value of end play (Reference): 1.65 - 2~11 mm (0.050 - 0.0831 inch)

19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.

NOTE: This illustration shows F4A51.

PRESSURE PLATE FOR F4A42

PRESSURE PLATE FOR F4A51

20. Remove all parts and special tools that were installed to take the measurements in steps 8 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.

21. Install the snap ring into the groove of transaxle case output shaft bore.
22. Install the thinnest output shaft preload adjustment spacer [thickness 1.88 mm (0.0740 inch); part number MD756579].
23. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.

CAUTION: Do not reuse the bolt, as it has had sealant applied.

24. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Tightening torque:
23 ± 3 Nm (17 ± 2 ft. lbs.)
54 ± 5 Nm (40 ± 4 ft. lbs.)

25. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.

26. Apply ATF to a new jam nut, and use special tools MB990607 and MB991625 to tighten the jam nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Tightening torque: 167 ± 10 Nm (123 ± 7 ft. lbs.)

NOTE: The jam nut is reverse threaded.

27. Move the output shaft to measure the end play and record the measurement value.
28. Remove the parts that were installed in steps 21 to 25.
29. Add 1.88 mm (0.074 inch)* and 0.01 to 0.09 mm (0.0004 to 0.0035 inch)** to the measured value in step 26 and select a spacer of the same thickness. Adjustment spacer sizes are all listed. Select the most suitable one from among those listed.

NOTE: * is the thickness of the spacer installed in step 21. ** is the preload of the output shaft.

30. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 27.
31. Stake the jam nut with a punch (two places).

32. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.

33. Install the parking pawl, spacer, and spring. Then insert the parking pawl shaft.

34. Install the parking roller support, and then insert the two parking roller support shafts.

IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS mm (in)

35. Install the planetary carrier assembly.

36. Install the planetary reverse sun gear.

37. Install the wave spring on the low-reverse brake piston.

38. Install the pressure plate that was selected in step 18. Next, install six brake discs and five brake plates, one on top of the other.

39. Install the snap ring.

40. Install the reaction plate.

41. Install the snap ring that was selected in step 12.

42. Install three brake discs or four brake discs and two brake plates or three brake plates , one on top of the other. Next, install the pressure plate that was selected in step 16.

43. Install the return spring and second brake piston.

44. Install the snap ring.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown.

45. Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.

CAUTION: Use care to install the thrust bearing in the proper direction.

46. Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.
47. Install the reverse and overdrive clutch.

CAUTION: Be sure to install the thrust bearing in the correct direction as shown.

48. Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.

49. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
50. Install the four seal rings in the grooves of the rear cover.
51. Measure the end play of the under drive sun gear by the following procedures:
1) Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch); part number MD707267] on thrust bearing number 7.
2) Install the rear cover on the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 23 ± 3 Nm (17 ± 2 ft. lbs.)
3) Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.

4) Install the under drive clutch hub on the under drive sun gear.
5) Measure end play of the underdrive sun gear and record the measurement value.
Standard value (Reference): 0.25 - 0.45 mm (0.0098 - 0.0177 inch)
6) After taking the measurements in steps (1) to (4), take out the installed parts.