Reassembly
TRANSAXLE REASSEMBLYCAUTION:
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.
- 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 ATF for two hours or longer.
- 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.
- Apply a coating of petroleum grease to the wave spring and attach it to the center support.
- Install the special tool (09453-21310) to the center support.
- Install the snap ring.
- Install the special tools (09453-21400, 09453-33100) and a dial indicator at the rear side of the transaxle case.
CAUTION:
Install the dial gauge so that is contacts the brake reaction plate at a right angle from the transfer idler shaft hole.
- 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)
- 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), 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 O-rings) 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 bolt: 20 - 27 Nm ( 200 - 270 kgf.cm, 15 - 19 ft. lbs.)
Detent sprag assembly bolt: 10 - 12 Nm ( 100 - 120 kgf.cm, 7.5 - 8.4 ft. 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) 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 (2000 - 2300 kgf.cm, 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 the transfer idler gear (assembled in the preceding section) 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).
23. Insert special tool (09458-33001) into output flange and measure preload using a low reading torque wrench. Adjust preload by tightening or loosening transfer idler shaft.
Tightening torque
Preload: 0.8 Nm (8 kgf.cm, 0.59 ft. 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 (480 - 600 kgf.cm, 35 - 43 ft. lbs.)
25. Install bearing retainer and tighten screws to specified torque. Apply a 5 mm (0.2 inch) width of sealant (3M Stud Locking No. 4176) to the top. Sealant should not stick out of screw head.
Tightening torque
Screw: 17 - 22 Nm (170 - 220 kgf.cm, 13 - 15 ft. lbs.)
26. Using a punch, lock the flush head screw to prevent rotation.
Identification of thrust bearings, thrust races and thrust washers (Unit: mm [inch])
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:
1) Attach the seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in the figure.
2) Attach thrust race #10 to the forward sun gear.
3) Attach thrust bearing #9 to the forward sun gear.
4) 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.
36. After applying a coating of ATF to the O-rings, install the special tool (09453-21310) to the center support, and install within the case.
CAUTION: Be sure that the wave spring is not out of position.
37. Install the snap ring.
38. Install the anchor rod.
39. Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston. Install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.
40. Press the kickdown servo and sleeve in using special tools (09222-28000, 09222-28100, 09456-21100), then install the snap ring.
41. Install the kickdown band. Attach the band ends to the end of the anchor rod and servo piston rod.
42. Install kickdown drum with its splines in mesh with the sun gear. Place the kickdown band on the kickdown drum and tighten kickdown servo adjusting screw to keep the band in position.
43. Apply a coating of petroleum to thrust bearing #8, and attach to the kickdown drum.