Transaxle Unit (Assembly)

TRANSAXLE UNIT (ASSEMBLY)
Preparation





SST

Precaution
1. Select the adjustment shim(s), referring to Bearing Preload.
2. If the drive plates or brake band are replaced with new ones, soak the new part in ATF for at least two hours before installation.
3. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
4. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
5. Use petroleum jelly, not grease, during reassembly.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assembly the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling the transaxle with ATF.





Bearing And Race Locations














Components

Assembly Procedure





1. Install the return spring, parking shaft, parking pawl and parking actuator support into the transaxle case.





2. Install the parking lever and parking rod.





3. Install the required shim(s) and bearing race into the side cover by using the SST.





4. Install the selected shim(s) and bearing race into the transaxle case by using the SST.





5. Press in the idler gear and reduction gear by using the SST.





6. Remove any grease or oil from the idler gear/locknut surface.
7. Align the parking pawl with the parking gear, and tighten the locknut.
8. Verify that the idler gear rotates smoothly.





9. Stake the locknut.





10. Install the accumulator piston.
1. Install the N-D accumulator return spring.

Spring free length: 45.5 mm (1.772 inch)

2. Apply ATF to the new O-ring and install it to the accumulator piston.
3. Apply ATF to the accumulator piston and install it shown in the figure.





11. Install the drum support.

Tightening torque: 16 - 21 Nm (11.6 - 2.1 kgf-m, 12 - 15 ft. lbs.)





12. Install the forward clutch assembly.
1. Apply petroleum jelly to the thrust bearing and install it to the forward clutch drum.
2. Install the forward clutch drum into the transaxle case.





3. Verify that the forward clutch drum turns smoothly.





13. Install the overrunning clutch hub.
1. Apply petroleum jelly to the thrust washer and bearing race.
2. Install the thrust washer and bearing race to the overrunning clutch hub.
3. Install the overrunning clutch hub into the forward clutch drum.





14. Install the rear internal gear and forward clutch hub into the forward clutch drum as an assembly.





15. Install the rear planetary carrier.
1. Apply petroleum jelly to the thrust bearing and install it to the rear planetary carrier.
2. Install the rear planetary carrier into the rear internal gear.





16. Install the rear sun gear into the rear planetary carrier shown in the figure.





17. Install the low and reverse brake piston and front planetary carrier.
1. Apply petroleum jelly to the two thrust bearings and install them to the front planetary carrier.
2. Install the front planetary carrier to the rear planetary carrier.
3. Install the low and reverse brake return spring and retainer into the transaxle case.





CAUTION: Align the oil holes in the low and reverse brake piston with the oil holes in the transaxle case.

4. Insert the piston into the transaxle case, and align the springs and piston pins by rotating the spring retainer.





5. Install the snap ring by using the SST.
6. Remove the SST.





18. Install the low one-way clutch.
1. Install the one-way clutch so that the retaining clips are facing up.
2. Install the snap ring.





19. Install the band servo.
1. Apply ATF to the O-rings of the band servo.
2. Install the band servo assembly to the transaxle case.
3. Compress the band servo piston retainer by using the SST and install the snap ring.
4. Remove the SST.





20. Install the reverse clutch, high clutch and front sun gear.
1. Apply petroleum jelly to the thrust bearings and bearing race.
2. Install the thrust bearings and bearing race to the reverse clutch, high clutch, high clutch hub and front sun gear.
3. Install the reverse clutch, high clutch, high clutch hub and front sun gear into the transaxle case as an assembly.





21. Install the brake band into the transaxle case.





22. Install the new anchor end bolt and loosely tighten it by hand.





23. Use the following procedure to adjust the total end play.
1. Install the new oil pump gasket to the transaxle case.





2. Measure height A by using vernier calipers and a straightedge.





3. Measure height B.





4. Apply petroleum jelly to the bearing and install it on the oil pump.

Bearing outer diameter: 50.6 mm (1.992 inch)





5. Measure height C.





6. Measure height D.

7. Calculate the total end play by using the formula below.

Formula: T1 = A - B - (C - D) - 0.1 mm (0.0039 inch)





T1: Total end play
A: Distance between front of transaxle case and bearing race on the high clutch drum
B: Distance between front of transaxle case and oil pump gasket
C: Distance between upper surface of oil pump and oil pump gasket contact surface.
D: Distance between upper surface of oil pump and upper surface of oil pump bearing.
0.1 mm (0.0039 inch): Amount of compression of new oil pump gasket

Total end play: 0.25 - 0.55 mm (0.010 - 0.022 inch)





8. If the total end play is not within specification, adjust it by selecting and installing the proper bearing race.





24. Adjust the reverse clutch end play.
1. Measure height E by using vernier calipers and a straightedge.





2. Measure height B.





3. Measure height C.





4. Measure height F.





5. Calculate the reverse clutch end play by using the formula below.

Formula: T2 = E - B - (C - F) - 0.1 mm (0.0039 inch)

T2: Reverse clutch end play
B: Distance between front of transaxle case and oil pump gasket.
C: Distance between upper surface of oil pump and oil pump gasket contact surface.
E: Distance between front of transaxle case and the reverse clutch drum
F: Distance between reverse clutch contact surface of oil pump and upper surface of oil pump
0.1 mm (0.0039 inch): Amount of compression of new oil pump gasket

Reverse clutch end play: 0.55 - 0.90 mm (0.022 - 0.035 inch)





6. If the reverse clutch end play is not within specification, adjust it by selecting and installing the proper thrust washer.





25. Install the oil pump onto the transaxle case, and tighten the bolts evenly and gradually.

Tightening torque: 24 - 27 Nm (2.4 - 2.8 kgf.m, 18 - 20 ft. lbs.)





26. Apply ATF to the new O-ring and install it to the input shaft.
27. Apply ATF to the new O-ring and install it to the differential lubrication hole of transaxle case.





28. Adjust the brake band.
1. Tighten the anchor end bolt.

Tightening torque: 4.0 - 5.8 Nm (40 - 60 kgf-cm, 35 - 52 inch lbs.)





2. Loosen the anchor end bolt 2.5 turns.
3. Install the locknut.
4. Hold the anchor end bolt and tighten the locknut.

Tightening torque: 31 - 42 Nm (3.2 - 4.3 kgf.m, 24 - 31 ft. lbs.)





29. Install the differential.
30. Hold the side gear of differential by using the SST.





31. Install the bearing race into the converter housing by using the SST.





32. Apply a light coat of silicone sealant to the contact surfaces of the converter housing and the transaxle case.





33. Install the transaxle case on the converter housing, and tighten the bolts evenly and gradually.

Tightening torque: 27 - 30 Nm (2.8 - 3.1 kgf-m, 21 - 22 ft. lbs.)





34. Apply ATF to the O-rings and low and reverse brake sleeve and install them shown in the figure.





35. Install the 2-3 accumulator return spring shown in the figure.

Spring free length: 52.5 mm (2.055 inch)





36. Align the manual valve with the pin on the manual plate.





37. Install the control valve body into the transaxle case and tighten the bolts evenly and gradually shown in the figure.

Tightening torque: 6.9 - 8.8 Nm (70 - 90 kgf-cm, 61 - 78 inch lbs.)





38. Install the clip.





CAUTION:
- Clean all bolt holes thoroughly.
- Make sure there is no grease or oil in the bolt holes.

39. Apply sealant to the oil pan.
40. Install the oil pan and tighten the new bolts evenly and gradually.

Tightening torque: 6.9 - 8.8 Nm (70 - 90 kgf-cm, 61 - 78 inch lbs.)





41. Install and adjust the transmission range sensor.
1. Verify that the manual shaft is positioned at the L position (fully forward).
2. Install the transmission range sensor and install new bolts.





3. Turn the manual shaft fully rearward, then return it 2 notches (neutral position).
4. Insert a 4.0 mm (0.16 inch) outer diameter pin through the holes of the transmission range sensor and the manual shaft lever.
5. Tighten the transmission range sensor retaining bolts.

Tightening torque: 2.5 - 3.9 Nm (25 - 40 kgf-cm, 22 - 34 inch lbs.)

6. Remove the pin.





42. Apply petroleum jelly to the thrust bearing and install it into the transaxle case.
43. Apply petroleum jelly to the seal rings of the output gear and install it into the transaxle case.





44. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and side cover.





45. Install the side cover on the transaxle case, and tighten the bolts evenly and gradually.

Tightening torque: 19 - 22 Nm (1.9 - 2.2 kgf-m, 14 - 15 ft. lbs.)





46. Install the output speed sensor.
1. Apply ATF to the new O-ring and install it onto the output speed sensor.
2. Install the output speed sensor into the side cover.

Tightening torque: 5.0 - 6.8 Nm (50 - 70 kgf-cm, 44 - 60 inch lbs.)





47. Install the vehicle speedometer sensor.
1. Apply ATF to the new O-ring and install it onto the vehicle speedometer sensor.
2. Install the vehicle speedometer sensor into the transaxle case.

Tightening torque: 7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95 inch lbs.)





48. Install the bracket onto the transaxle case, and tighten the bolts evenly and gradually.

Tightening torque: 6.9 - 9.8 Nm (70 - 100 kgf-cm, 61 - 86 inch lbs.)

49. Install the shift control rod onto the manual shaft.

Tightening torque: 16 - 22 Nm (1.6 - 2.3 kgf-m, 12 - 16 ft. lbs.)





50. Remove the transaxle from the SST.
51. If the torque converter has been drained and washed, hold the torque converter in an upright position and fill it with new ATF.

ATF type: M - III or Dexron II

52. Carefully install the converter to the torque converter housing. Rotate the torque converter to align the splines.





53. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the face of the converter housing.

Distance A: 14.0 mm (0.551 inch)