Transaxle Unit (Assembly)
TRANSAXLE UNIT (ASSEMBLY)Preparation
SST
Precaution
1. If the drive plates or the 2-4 brake band are replaced with new ones, soak the new part in ATF for at least two hours before installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
4. Use petroleum jelly, not grease, during reassembly.
5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
6. Assemble the housing within 10 minutes after applying sealant, and allow it to cure at least 30 minutes after assembly before filling the transaxle with ATF.
Bearing and race locations
Note: The bearing and race at locations 2, 3, 4, 6, and 7 are one-piece units.
Outer diameter of bearing and race
Components
Transaxle Unit (Assembly) (Part 1):
Transaxle Unit (Assembly) (Part 2):
Transaxle Unit (Assembly) (Part 3):
Transaxle Unit (Assembly) (Part 4):
Assembly Procedure
1. Align the bearing cover with guide bolts as shown, and press the bearing cover in. Tighten the new bolts.
Tightening torque:
10.8 - 13.7 Nm (110 - 140 kgf-cm, 95.5 - 121 in-lbf)
2. Press the bearing race into the converter housing.
3. Assemble the SSTs.
4. Install the idler gear and output gear assembly by tapping it in with a plastic hammer.
5. Install the bearing housing.
Note: Tighten the bolts evenly and gradually.
1) Mount the bearing housing on the converter housing.
Tightening torque:
19 - 25 Nm (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
2) Align the holes on the idler shaft with the mark on the bearing housing.
3) Tap a new roll pin in with a pin punch and a hammer.
6. Install the differential assembly.
7. Install the parking pawl.
1) Install the parking pawl and shaft.
Caution: Do not deform the snap ring when installing it.
2) Install the spring and snap ring.
3) Move the manual shaft and verify that the parking pawl operates.
8. Install the actuator support with new bolts.
Tightening torque:
15 - 17 Nm (1.5 - 1.8 kgf-m, 11 - 13 ft-lbf)
9. Install the detent lever and return spring.
10. Install the parking assist lever.
11. Install the lever holder and bolt.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95.4 in-lbf)
12. Install the manual shaft and manual plate.
1) Install the manual plate, washer, and nut.
2) Tighten the nut to the specified torque.
Tightening torque:
42 - 54 Nm (4.2 - 5.6 kgf-m, 31 - 40 ft-lbf)
13. Install the output shell to the output gear, and set the thrust bearing onto the output shell.
Thrust bearing outer diameter:
72.1 mm (2.84 in)
14. Apply a thin coat of silicone sealant to the contact surfaces of the converter housing and transaxle case.
Note: Do not damage the O-ring when installing it.
15. Install new O-rings.
Note: Tighten the bolts evenly and gradually.
16. Mount the transaxle case to the converter housing.
Tightening torque:
38 - 51 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft-lbf)
17. Install engine mount No. 1.
Tightening torque:
58 - 66 Nm (5.9 - 6.8 kgf-m, 43 - 49 ft-lbf)
18. Install the SST to hold the turbine shaft.
19. Install the turbine shaft and 3-4 clutch assembly.
1) Assemble the turbine shaft and 3-4 clutch assembly.
2) Verify that the thrust bearing is properly installed.
3) Install the turbine shaft and 3-4 clutch assembly into the transaxle case.
20. Install the internal gear.
1) Install the internal gear to the output shell.
Caution: Do not deform the snap ring when installing it.
2) Install the snap ring.
21. Install the carrier hub assembly.
1) Verify that the thrust bearing and bearing race are properly installed.
2) Hold the turbine shaft with one hand to prevent it from rotating.
3) Install the carrier hub assembly into the 3-4 clutch drum by rotating it.
Caution: Installation order: Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive
22. Install the drive and driven plates.
23. Install the retaining plate.
Caution: Do not deform the snap ring when installing it.
24. Install the snap ring.
25. Install the friction plate.
26. Install one-way clutch 2.
1) Hold one-way clutch 2 horizontally.
2) Install it by turning the carrier hub assembly counterclockwise.
Caution: Do not deform the snap ring when installing it.
3) Install the snap ring.
27. Install the band servo into the transaxle case.
1) Install the return spring and band servo assembly.
Caution: Do not deform the snap ring when installing it.
2) Install the snap ring.
28. Install the anchor strut.
Note: Interlock the 2-4 brake band and anchor strut as shown.
29. Install the 2-4 brake band in the transaxle case.
30. Install the small sun gear and one-way clutch 1.
1) Verify that the thrust bearing and bearing race are installed in the correct positions.
2) Install the small sun gear and one-way clutch 1 while rotating it.
31. Install the clutch assembly.
1) Verify that the thrust bearing is installed in the correct position.
2) Install the clutch assembly while rotating it.
Note: Measure the height difference between the reverse and forward drum and the transaxle case.
Height difference: 0.9 mm (0.035 in) max.
Caution: Do not deform the snap ring when installing it.
32. Install the snap ring into the bottom ring groove of the turbine shaft.
33. Use the following procedure to adjust the total end play and select a suitable bearing race.
1) Set the thrust bearing onto the clutch assembly.
2) Remove the previously used race and gasket.
3) Set the thickest bearing race (2.2 mm (0.087 in)) onto the oil pump.
4) Set the oil pump onto the clutch assembly.
Note: Make several measurements and calculate the average value.
5) Measure clearance A between the transaxle case and the oil pump.
6) Select a suitable bearing race from the chart below.
7) Remove the oil pump.
8) Place the selected bearing race and a new gasket onto the oil pump.
Note:
^ Tighten the bolts evenly and gradually.
^ If the bolts are difficult to tighten, the gasket may be out of place. Remove the oil pump and reset the gasket.
9) Install the oil pump onto the clutch assembly.
10) Install the oil pipe.
Tightening torque:
19 - 25 Nm (1.9 - 2.6 kgf-m, 14 - 18 ft-lbf)
34. Install a new O-ring on the bracket; then feed the throttle cable through the transaxle case and connect it to the throttle lever.
35. Install the throttle cable bracket with new bolts.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95 in-lbf)
36. Install the solenoid connector and a new O-ring in the transaxle case.
37. Install the solenoid connector.
Note: Tighten the bolts evenly and gradually.
38. Align the manual valve with the pin on the manual plate, and install the control valve body.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95.4 in-lbf)
Bolt length (measured from below the head)
(A) 30 mm (1.18 in)
(C) 50 mm (1.97 in)
Caution: Apply a thin coat of silicone sealant to each side of the new gasket.
Note:
^ Tighten the bolts evenly and gradually.
^ If the bolts are difficult to tighten, the gasket may be out of place. Remove the oil pan and reset the gasket.
39. Install a new gasket and the oil pan.
Tightening torque:
8.4 - 10.7 Nm (85 - 110 kgf-cm, 74 - 95.4 in-lbf)
40. Install the input / turbine speed sensor.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95.4 in-lbf)
41. Install the transaxle range switch.
1) Rotate the manual shaft to the N position.
2) Turn the transaxle range switch so that the neutral mark is in line with the flat, straight surfaces on either side of the manual shaft.
3) Loosely tighten the transaxle range switch.
4) Tighten the transaxle range switch mounting bolts.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95 in-lbf)
5) Install the lever and spring washer.
6) Tighten the manual shaft nut.
Tightening torque:
32 - 46 Nm (3.2 - 4.7 kgf-m, 24 - 33 ft-lbf)
42. Remove the transaxle from the SST.
43. Install a new O-ring and install the oil dipstick and oil filler tube to the transaxle case.
Tightening torque:
7.9 - 10.7 Nm (80 - 110 kgf-cm, 70 - 95 in-lbf)
44. Install the oil pump shaft.
Caution: Do not damage the O-ring when installing it.
45. Install a new O-ring onto the turbine shaft.
O-ring inner diameter:
20 mm (0.787 in)
46. If the torque converter has been drained and washed, fill it with ATF.
ATF type: Dexron II or M-III
Caution:
^ Hold the torque converter in an erect position when filling it With ATF. Do not allow the ATF to overflow.
^ If the torque converter does not fit in easily, do not try to force it; install carefully.
47. Install the torque converter in the converter housing while rotating it to align the splines.
48. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing.
(A): 13.6 mm (0.535 in)