Part 2
REASSEMBLY16. INSTALL DIRECT CLUTCH ASSEMBLY
a. Install the bearing race to the direct clutch. Bearing race diameter:
Bearing race diameter
b. Install direct clutch assembly and thrust bearing to the rear planetary sun gear assembly.
NOTICE: The disk in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed.
c. Clean the connected part of the transaxle case and rear cover.
d. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers. (Dimension B)
e. Measure the 2 places of the rear cover as shown in the illustration and calculate a dimension C using the formula.
HINT: Dimension C = Dimension (1) - Dimension (2)
f. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play: 0.2 - 0.9 mm (0.008 - 0.035 inch)
NOTICE: Make sure that the black race side is facing the rear cover.
HINT: End play = Dimension C - Dimension B
Bearing thickness and diameter
17. INSTALL 2 NEW APPLY GASKETS
18. INSTALL APPLY TUBE
a. Install the clamp to the apply pipe.
NOTICE: Make sure to install the clamp to the apply pipe before installing the apply tube to the transaxle case. This prevents the apply pipe from being deformed or damaged.
b. Install the 2 apply pipe and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
NOTICE: Each pipe is securely inserted until it reaches the stopper.
19. INSTALL TRANSAXLE REAR COVER
a. Using SST and a press, install the bearing.
SST 09950-60010 (09951-00230, 09951-00350)
Press fit depth: 12.05 - 12.75 mm (0.4744 - 0.5020 inch)
NOTICE:
- Face the inscribed mark side of the bearing race up.
- Repeat the press fit and the measurement until the specified value above is obtained.
b. Coat 2 oil seal rings with ATF, install them to transaxle rear cover.
c. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case.
d. Apply Formed In Place Gasket (FIPG) to the rear cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent.
e. Coat a needle roller bearing with Automatic Transmission Fluid (ATF).
f. Install the transaxle rear cover and 11 bolts to the transaxle case.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
20. INSPECT DISC AND FLANGE OF U/D BRAKE
Check to see if the sliding surface of the disc, plate and flange are worn or burnt if necessary, replace them.
HINT:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.
21. INSTALL U/D BRAKE
a. Install the 4 discs and 4 plates to the transaxle case.
b. Using a screwdriver, install the snap ring.
c. Using a dial indicator, measure the U/D brake piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Piston stroke: 1.81 - 2.07 mm (0.0713 - 0.0815 inch)
HINT: Select an appropriate flange from the table so that it will meet the specified value.
Flange thickness
d. Temporarily remove the snap ring and attach the flange. Restore the snap ring.
22. INSTALL ONE-WAY CLUTCH NO.2
a. Install the outer race retainer to the one-way clutch No.2.
b. Install the U/D clutch assembly to the one-way clutch. Rotate the U/D clutch assembly to check the rotating direction for the lock or free operation.
23. INSTALL ONE-WAY CLUTCH NO.2
a. Install the one-way clutch No.2 to the transaxle case.
NOTICE: Make sure that the mark on the one-way clutch outer race is visible.
b. Using a screwdriver, install the snap ring to the transaxle case.
24. INSTALL U/D CLUTCH ASSEMBLY
a. Coat the bearing and bearing race with petroleum jelly and install it onto the U/D clutch.
Race diameter
b. Install the U/D clutch assembly to the transaxle case.
25. INSTALL U/D PLANETARY GEAR ASSEMBLY AND DIFFERENTIAL ASSEMBLY
a. Install the pawl pin and spring to the parking lock pawl.
b. Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.
c. Install the U/D planetary gear assembly to the transaxle case.
NOTICE: Engage all the discs of U/D clutch and hub spline of the U/D planetary gear assembly firmly and assemble them securely.
d. Install the parking lock pawl shaft.
e. Install the pawl shaft with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
f. Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the U/D planetary gear and contact surface of the transaxle case and housing. (Dimension D)
NOTICE: Note down the dimension D as it is necessary for the following process.
g. As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula.
NOTICE: Note down the dimension E as it is necessary for the following process.
HINT: Dimension E = Dimension (1) - Dimension (2)
26. INSTALL MULTIPLE DISC CLUTCH HUB
a. Install the bearing race to the transaxle while checking its direction.
Bearing race diameter
b. Coat the thrust bearing and race with petroleum jelly and install them onto the multiple disc clutch hub.
Thrust bearing and race diameter
c. Install the bearing to the forward clutch hub.
Bearing diameter
d. Install the forward clutch hub to the transaxle case.
e. Install the thrust bearing to the forward clutch.
Bearing diameter
NOTICE: Install the thrust bearing properly so that the black race will be visible.
f. Install the forward clutch to the multiple clutch hub.
NOTICE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
27. INSTALL 2 NEW APPLY GASKET
28. INSTALL DIFFERENTIAL ASSEMBLY
29. INSTALL TRANSAXLE HOUSING
a. Calculate the end play value using the following formula and values of Dimension D and E that were measured when installing cylindrical roller bearing and U/D planetary gear. Select an appropriate U/D planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install it.
End play: 0.50 - 0.99 mm (0.0197 - 0.0390 inch)
HINT: End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 inch) - U/D gear thrust bearing race No.2 thickness
Race thickness
Bearing and bearing race diameter
b. Install the oil pump and 7 bolts to the transaxle case
Torque: 22 Nm (226 kgf-cm, 16 ft. lbs.)
c. Coat the oil pump O-ring with ATF.
d. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing.
e. Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
f. Install the transaxle housing and 16 bolts to the transaxle case.
Torque:
Bolt A: 22 Nm (226 kgf-cm, 16 ft. lbs.)
Bolt B and C: 29 Nm (300 kgf-cm, 22 ft. lbs.)
HINT: Apply seal packing or equivalent to the bolt A.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)
NOTICE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.
30. INSPECT INPUT SHAFT END PLAY
Using a dial indicator, measure the input shaft end play.
End play: 0.27 - 1.24 mm (0.0106 - 0.0417 inch)
31. CHECK DIFFERENTIAL PRELOAD
32. PLACE TRANSAXLE HOUSING