Part 1

REASSEMBLY

NOTICE: The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended ATF: Type T-IV

All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.

Dry all parts with compressed air-never use shop rags.

When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.

The recommended automatic transaxle fluid or kerosene should be used for cleaning.

After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.

When disassembling a valve body, be sure to match each valve together with the corresponding spring.

New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.

All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.

All gaskets and rubber O-rings should be replaced.

Do not apply adhesive cements to gaskets and similar parts.

Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.

If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.

Check thrust bearings and races for wear or damage. Replace if necessary.

Use petroleum jelly to keep parts in place.

When working with FIPG material, you must observe the following.

Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface.

Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.

Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.









BEARING AND RACES INSTALLATION AND DIRECTION





1. INSTALL TRANSMISSION CASE ON OVERHAUL ATTACHMENT





2. INSTALL REAR PLANETARY RING GEAR





a. Install the assembled bearing & race.





b. Install the rear planetary ring gear.





c. Using SST, install the snap ring. SST 0935-30020 (O9350-07070)





3. INSTALL OUTPUT SHAFT WITH CENTER AND REAR PLANETARY GEAR





a. Install the 2 races and bearing onto the rear planetary ring gear.





b. Install the thrust washer to the output shaft with center & rear planetary gear.





c. Install the output shaft with center & rear planetary gear.





4. INSTALL FRONT PLANETARY GEAR
a. Install the spring to the case.





b. Install the 2nd brake pack (4 plates, 5 discs and flange). Install in order: P = Plate, D = Disc D-P-D-P-D-P-D-P-D





c. Install the front & center planetary sun gear from the case.





d. Coat the thrust washer, with petroleum jelly and install it onto front planetary gear.





e. Install the front planetary gear and 2 washers from the case.





5. INSTALL MULTIPLE DISC BRAKE AND NO.1 ONE-WAY CLUTCH
a. Lay the transmission case over.





b. Install the multiple disc brake to the case.





c. Install the No.1 one-way clutch to the multiple disc brake.





d. Using SST, install the snap ring. SST 09350-30020 (09350-07060)





6. INSTALL BRAKE DRUM GASKET
a. Coat 2 new gaskets with ATF.
b. Install the 2 brake drum gaskets.





7. INSTALL SUN GEAR INPUT DRUM
a. Install the thrust washer.





b. Install the sun gear input drum.









C. Coat the bearing, 2 races with petroleum jelly and install them onto the sun gear input drum.





8. INSTALL 3RD COAST BRAKE BAND
a. Install the 3rd coast brake band to the transmission case.





b. Install the E-ring to the pin.
c. Install the pin through the brake band.





d. Using a needle nose pliers install the E-ring to the pin.









9. INSTALL DIRECT CLUTCH WITH FORWARD CLUTCH
a. Coat the assembled bearing & race, race with petroleum jelly and install them onto the forward clutch hub.









b. Install the assembled bearing & race and thrust washer to the forward clutch.





c. Install the direct clutch and forward clutch hub to the forward clutch.





d. Insert the direct clutch with forward clutch to the case.





e. With the case set upright, using vernier calipers, measure the distance between the sun gear input drum and direct clutch drum.

Height: 4.1 -6.0 mm (0.161 -0.236 in.)

If the height is non-standard, check for improper installation.