Part 1
CAUTION: Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. O-ring of oil level dipstick need not be replaced. Do not use grease other than petroleum, or industrial Vaseline apply Automatic Transmission Fluid (ATF) to friction element, rotating parts, and sliding parts before installation. New clutch discs should be immersed in automatic transaxle fluid for more than two hours before installation. Do not apply sealer or adhesive to gaskets. If bushings must be replaced, replace the entire assembly. Do not use shop towels during disassembly and reassembly operation. The transaxle oil cooler should be flushed.
1. Using special tool (09431 - 34000) or equivalent, top the drive shaft oil seal into the transaxle.
2. Using special tool (09532 - 32000, 09500 - 11000) or equivalents, press-fit the transfer shaft outer race.
3. Install the transfer shaft.
4. Apply solder [10 mm (0.40 inch) in length and 3 mm (0.118 inch) in diameter] to the locations shown in the illustration.
5. Tighten the transfer shaft cover to the specified torque.
6. Remove the output shaft cover.
7. Remove the crushed solder form the outer race of the deferential bearing.
8. Measure the thickness of the crushed solder using an outside micrometer and select and install a spacer that produces a standard preload.
Standard value: 0.075-0.135 mm (0.003-0.005 inch).
9. Apply the ATF to the new installed O-ring and install the output shaft cover.
10. Insert the annular gear assembly, output flange, transfer drive gear and bearing into the case.
11. Install the snap ring on the output flange rear bearing.
12. Install the bearing retainer, and tighten the screws to the specified torque, apply a 5 mm (0.2 inch) width of sealant around the top. The sealant should not protrude out from under the screw head.
Tightening torque:
Screw: 17-22 Nm (13-15 ft. lbs.).
13. Using a punch, lock the flush head screw to prevent rotation.
14. Apply a coating of petroleum grease to thrust bearing #12 and attach to the planetary carrier.
15. Install the planetary carrier to the case with thrust bearing #12.
16. Assembly 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 #9 to the forward sun gear.
c. Attach thrust race #10 to the forward sun gear.
d. Assemble the reverse sun gear and the forward sun gear.
17. Install both of the previously assembled sun gears inside the planetary carrier.
18. Install the brake disc and brake plate.
19. Install the selected brake pressure plate.
20. Install the return spring.
21. Apply a coating of petroleum grease to the wave spring and attach it to the center support.
22. Install two new O-rings to the center support.
23. After applying a coating of ATF to the O-rings, install the special tool (09453 - 21310) or equivalent to the center support, and install within the case.
NOTE: Be sure that the wave spring is not out of position.
24. Install the snap ring.
25. Measure the thickness of and row and reverse brake end play with thickness gauge.
Standard value: 1.0-1.2 mm (0.04-0.047 inch).
26. Push the air-vent plug and install the plug.
27. Install the anchor rod.
28. Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.
29. Press the kickdown servo and sleeve in by using the special tools (09222 - 28000, 09222 - 28100, 09456 - 21100) or equivalents, and then install the snap ring.