Part 1
CAUTION:- Do not reuse gaskets, oil seals and rubber parts. Use new ones at every reassembly. The oil level dipstick O-ring does not need to be replaced.
- Do not use grease other than petroleum or industrial Vaseline. Apply automatic transaxle fluid to friction element, rotating parts, and sliding parts before installation.
- New clutch disc should be immersed in automatic transaxle fluid for more than two hours before installation. When bushing must be replaced, replace assembly which includes it.
- Do not use shop towels during disassembly and reassembly operations.
- The oil in the cooler should also be replaced.
1. Before assembly of the transaxle, measure the end play of the low-reverse brake, and select a pressure plate to be used so that the end play will be the standard value, as follows:
a. Install the brake reaction plate, brake plate and brake disc into the transaxle case.
CAUTION: If new brake discs are used, be sure to immerse them in Automatic Transmission Fluid (ATF) for two hours or longer.
b. Install the appropriate pressure plate and return spring.
CAUTION: Be sure that the return spring is installed so that it faces in the correct direction.
c. Apply a coating of petroleum grease to the wave spring and attach it to the center support.
d. Install the special tool (09453 - 21310) or equivalent to the center support.
e. Install the snap ring.
f. Install the special tools (09453 - 21400, 09453 - 33100) or equivalents, and a dial indicator at the rear side of the transaxle case.
CAUTION: Install the dial gauge so that it contacts the brake reaction plate at a right angle from the transfer idler shaft hole.
g. Using a manual pump, pump air in from the position shown in the illustration. Read dial gauge, and select the pressure plate that will provide the standard value.
Standard value:
Low reverse brake snap ring clearance: 0.975-1.287 mm (0.039-0.050 inch).
h. After selection pressure plate, remove center support, brake plate, brake disc, brake reaction plate and pressure plate.
2. Using the special tools (09500 - 11000, 09532 - 11500, 09500 - 21000, 09532 - 32000) or equivalents, tap in the bearing outer race.
3. After installing the detent spring assembly and the sprag rod assembly on manual control shaft, insert manual control shaft into transaxle case and push it fully toward manual control lever. At this time, do not install the O-ring (larger one of two Orings) on manual control shaft.
NOTE: If installed before inserting shaft, the O-ring will interface with shaft set screw hole.
4. After installing the new O-ring on manual control shaft, draw shaft back into case, then install set screw and gasket.
5. Install the sprag rod support and tighten two bolts. Install the washer and tighten the bolt of the detent spring assembly.
Tightening torque:
Sprag rod support bolts: 20-27 Nm (15-19 ft. lbs.).
Tightening torque:
Detent sprag assembly bolt: 10-12 Nm (90-100.8 inch lbs.).
6. Press-fit the bearing inner race to the transfer driven gear, and press-fit the bearing outer race to the transaxle end clutch side.
7. Press-fit the bearing inner race to the transfer shaft, and press-fit the bearing outer race to the transaxle case converter housing side.
8. Attach the transfer shaft to the transaxle case.
9. Install the special tool (09455 - 21301) or equivalent to the transaxle case to support the transfer shaft.
10. Insert the thickest 1.80 mm (0.0709 inch) spacer.
11. Attach the transfer driven gear.
12. After removing the special tool, affix the converter housing side of the transfer shaft.
13. Tighten the lock nut to the specified torque.
Tightening torque:
Transfer lock nut: 200-230 Nm (145-166 ft. lbs.).
14. After installing the special tool, measure the transfer shaft end play; then select the spacer(s) needed to obtain the standard value, and refit.
Standard value:
Transfer shaft end play: 0-0.025 mm (0-0.0010 inch).
15. Using a punch, lock the lock nut to prevent rotation.
16. Attach the transfer cover.
17. Insert the assembly of the annular gear, output flange, transfer drive gear and bearing into the case.
18. Install snap ring on output flange rear bearing.
19. Coat petroleum jelly on the spacer and attach it to the transaxle case.
20. Install two taper roller bearings and spacer to transfer idle gear.
21. Place transfer idler gear into the case, then insert the idler shaft from the outer side of the case and screw it in.
22. Tighten the idler shaft using special tool (09454 - 21100) or equivalent.
23. Insert special tool (09458 - 33001) or equivalent, into output flange and measure preload using a low reading torque wrench. Adjust preload by tightening or loosening transfer idler shaft.
Preload: 0.8 Nm (9.6 inch lbs.).
24. After the preload adjustment is completed, eliminate the backlash between the idler shaft and the lock plate by moving the idler shaft in the loosening direction. Attach the lock plate and tighten the lock plate bolt.
Tightening torque:
Lock plate bolt: 48-60 Nm (35-43 ft. lbs.).
25. Install bearing retainer and tighten screws to specified torque. Apply a 5 mm (0.2 inch) width of sealant to the top. Sealant should not stick out of screw head.
Tightening torque:
Screw: 17-22 Nm (13-15 ft. lbs.).
26. Using a punch, lock the flush head screw to prevent rotation.
27. Apply a coating of petroleum to thrust bearing #12 and attach to the planetary carrier.
28. Install the planetary carrier to the case.
29. Assemble the reverse sun gear and the forward sun gear in the following order:
a. Attach the seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in the figure.
b. Attach thrust race #10 to the forward sun gear.
c. Attach thrust bearing #9 to the forward sun gear.
d. Assemble the reverse sun gear, and then the forward sun gear.
30. Install both of the previously assembled sun gears inside the planetary carrier.
31. Install the brake disc and brake plate.
32. Install the selected brake pressure plate.
33. Install the return spring.
34. Apply a coating of petroleum to the wave spring and attach it to the center support.
35. Install the two new O-rings to the center support.