Part 2

30. Install the kickdown band; attach the ends of the band to the ends of the anchor rod and servo piston rod.





31. Apply a coating of petroleum grease to thrust washer #2 and thrust bearing #4. Attach to the rear clutch assembly.





32. Combine the rear clutch assembly and the front clutch assembly.





33. Attach thrust bearing #6 onto the hub with petroleum grease.





34. Install the clutch hub to the rear clutch.





35. Apply a coating of petroleum grease to thrust race #7, and then attach to the rear clutch hub.





36. Apply a coating of petroleum grease to thrust bearing #8, and then attach to the kickdown drum.





37. Combine the clutch assembly and the kickdown drum.





38. Install the clutch and kickdown drum assembly.
39. If the end play, which was measured and recorded at a disassembly, is not the standard value, adjust to specification by selection thrust race #3.

Standard value: 0.3 - 1.0 mm (0.012 - 0.039 inch)

If the thrust race is replaced with one of different thickness, the #1 thrust washer (located between the oil pump and the front clutch) must also be replaced. Locate the correct pair of thrust races (metal) and thrust washers (fiber) from the following table.





Example: When thick race is selected, thrust washer is one to be parted with it.





40. Attach the reused thrust washer #1, or the one selected in step 38 to the front clutch by using petroleum grease.





41. Install a new oil pump gasket and the oil pump assembly.





42. Using the special tool (09453-21400) check the input shaft end play. Readjust if necessary (see step 38).

Standard value: 0.3 - 1.0 mm (0.012 - 0.039 inch)





43. Install the spacer, idler gear and bearing; then push the idler shaft into the hole.





44. Install the idler shaft lock bolt to the specified torque, then protect the turning with the new lock plate.





45. Install the idler cover with the new gasket.





46. Install the end clutch shaft. Be sure to install the side with the longest splines toward the front as shown.





47. Place the trust washer on the return spring at the end clutch side.





48. Install the end clutch hub to the end clutch.





49. Attach, thrust bearing #12 to the end clutch hub by using petroleum grease.





50. Install the end clutch assembly.





51. Install a new O-ring on the end clutch cover.

NOTE:
1) Apply a sufficient amount of automatic transaxle fluid on the bearing.





52. Attach the end cover and fasten it with four bolts.

CAUTION:
When installing the end cover, be sure the screw hole is correctly aligned. If the end cover is turned (after it is installed) in order to align with the screw hole, the O-ring and/or the D-ring may be twisted as a result.





53. Install the differential assembly.





54. Place two pieces of solder, roughly 10 mm (0.4 inch) long and 3 mm (0.12 inch) in diameter, at the position shown on the differential bearing retainer outer race.





55. Install the differential bearing retainer and tighten the bolt to specified torque.

Tightening torque:
Standard value: 30 - 40 Nm (300 - 400 kgf.cm, 22 - 29 ft. lbs.)





56. Remove the differential bearing retainer.
57. Remove the crushed solder from the outer race of the differential bearing.
58. Using a micrometer, measure the thickness of the crushed solder. Select and install a spacer so that the preload of the differential bearing will be the standard value.

Standard: 0.075 - 0.135 mm (0.03 - 0.053 inch)





59. Apply the ATE to the new installed O-ring and install the differential bearing retainer.





60. Install the differential bearing cap.





61. Install the differential cover with new gasket.





62. Insert the manual control shaft into the transaxle case, after apply the ATF to the new O-ring.
63. Install the set screw and gasket.





64. Install the parking sprag rod to the detent plate (manual control shaft). Install the sprag rod support and tighten the three bolts.

Tightening torque:
Sprag rod support bolts: 20 - 27 Nm (200 - 270 kgf.cm, 15 - 19 ft. lbs.)





65. Insert the oil temperature sensor into the transaxle case.





66. Install the O-ring at the center of the top of the valve body assembly (brake oil pressure passage).
67. Install the valve body assembly to the case, fitting the detent plate (manual control shaft) pin in the slot of the manual valve.





68. Replace the O-ring on the solenoid valve connector.
69. Tilt the solenoid valve connector over from the inner side of the transaxle case to the harness grommet installation hole and install the harness grommet securely. The notch in the harness grommet should be as shown in the illustration.





70. Temporarily attach the valve body; then install the oil temperature sensor from the case hole, and tighten to the specified torque [10 - 12 Nm (100 - 120 kgf.cm, 7.5 - 8.5 ft. lbs.)].
- A bolt: 18 mm (0.709 inch) long
- B bolt: 25 mm (0.984 inch) long
- C bolt: 40 mm (1.575 inch) long





71. Install the oil filter. Tighten the four oil filter mounting bolts to 5 - 7 Nm (50 - 70 kgf.cm, 4 - 5 ft. lbs.).

72. Install the three magnets in the depressions provided on the oil pan.





73. Install a new oil pan gasket on the oil pan and tighten the bolts to 10 - 11.5 Nm (100 - 115 kg cm, 7.5 - 8.5 ft. lbs.).





74. Install the inhibitor switch and manual lever. Adjust the inhibitor switch.





75. Install the pulse generators A and B.





76. Adjust the kickdown servo.





77. After applying automatic transaxle fluid to the outside surface of the oil pump-side of the torque converter, install the torque converter carefully so as not to damage oil seal lip. Make certain that the torque converter is in mesh with the oil pump drive gear. Measure the distance between the ring gear end and the converter housing end. The torque converter has been properly installed when the measurement is about 16.3 mm (0.64 inch).