Assembly procedure

Assembly procedure





1. Using the SSTs and a hammer, install the reduction gear outer race.
2. Install the oil pipe to converter housing.
1) Check the oil pipe and seal surface for dents or damage.
^ Replace the parts if necessary.





2) Install the oil pipe.

Tightening torque:
4.9-6.9 Nm (0.5-0.7 kgf-m, 3.6-5.1 ft.lbf.)

3. Install the baffle plate to the converter housing.





4. Install the output gear.
1) Set the installation bolts on the control valve body to the transaxle case and the output gear.





2) Set the SSTs to the output gear, and install the output gear using a press.





5. Apply petroleum jelly to new seal rings, and then install them onto the one-way clutch inner race.
6. Apply a coat of ATF to new O-rings, and then attach them in two bolts.
7. Install the one-way clutch inner race.





8. Install the bolts which secure the one-way clutch inner race.

Tightening torque:
32.4-38.3 Nm (3.30-3.90 kgf-m, 23.9-28.2 ft.lbf.)





9. Install the low and reverse brake.
1) Install the low one-way clutch with the groove facing upward.

Note: The snap ring opening must be positioned as shown in the figure.





2) Install the snap ring.
3) Install the retaining plate, drive plates, driven plates, and dished plate as a unit.
4) Install the spring retainer and return spring.

Caution: Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the retainer component edges.





5) Install the SSTs in the transaxle case as shown in the figure.

Note: The snap ring opening must be positioned as shown in the figure.





6) Install the snap ring.
7) Remove the SSTs.





10. Install the 2-4 brake.
1) Install the retaining plate.
2) Install the drive plate and driven plate.
3) Install the retaining plates.
4) Install the snap ring.





11. Apply petroleum jelly to the needle bearing, then install it to the low clutch component.
12. Install the low clutch component.





13. Apply petroleum jelly to the needle bearing, then install it to the rear internal gear.
14. Install the rear internal gear.





15. Apply petroleum jelly to the needle bearing and bearing race, then install it to the rear planetary carrier component.

Note: The race bearing must be installed with the black surface towards the front planetary carrier.

16. Install the front planetary carrier component.





17. Apply petroleum jelly to the race bearing and bearing race, and then install it to the low clutch hub with the black surface towards the low clutch hub.
18. Install the low clutch hub.





19. Apply petroleum jelly to the race bearing, and then install it to the high clutch hub with the black surface towards the high clutch hub.
20. Install the high clutch hub.





21. Apply petroleum jelly to the needle bearing, and then install it to the reverse and high clutch component.
22. Install the reverse clutch and high clutch component.





23. Install the return spring and spring retainer.





24. Install the input/turbine speed sensor.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

25. Connect the input/turbine speed sensor connector.





26. Install the oil pipes in the order of A, B, and C.
27. Install the direct clutch accumulator.
1) Measure the free length of the springs and inspect for deformation.
^ If not within the specification, replace the spring.

Specification





2) Install the direct clutch accumulator large spring and direct clutch accumulator small spring.





3) Apply coat of ATF to a new O-rings, then assemble them to the direct clutch accumulator piston.
4) Install the direct clutch accumulator piston.





5) Install the snap ring.
28. Install the 2-4 brake accumulator.
1) Measure the free length of the spring and inspect for deformation.
^ If not within the specification, replace the spring.

Specification








2) Apply coat of ATF to a new O-ring, and then install it to the 2-4 brake accumulator cover.
3) Install the 2-4 brake accumulator cover and spring.
4) Install the snap ring which secures the 2-4 brake accumulator onto the end cover.





29. Check the end play using a dial depth gauge and the SST.

Note: When measuring the end play, do not install the needle bearing on the reverse clutch and high clutch component.

1) Measure dimension A as shown in the figure.

Note: When measuring the end play, do not install the needle bearing on the surface of the end cover where it contacts the needle bearing.





2) Measure dimension B as shown in the figure.

Note: When measuring the end play, do not install the needle bearing on the reverse clutch and high clutch component.

3) Measure the bearing race thickness C.
4) Measure the SSTs height D.
5) Calculate the end play using the following formula.

End play = (A-D)-(D-B)-C
Specification: 0.25-0.55 mm (0.01-0.02 in)

6) If the end play is out of specification, select a suitable bearing race.

Bearing race sizes





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





31. Assemble a new O-ring to two bolts.

Caution: Do not hammer the end cover.





32. Install the end cover.

Tightening torque:
19-22 Nm (1.9-2.2 kgf-m, 14-16 ft.lbf.)





33. Apply petroleum jelly to the needle bearing, bearing race, and then install them to the one-way clutch inner race.





34. Install the direct clutch component.





35. Install the reduction brake band.
1) Apply a coat of ATF to a new O-ring, then install it to the reduction brake band piston.
2) Install the spring, band servo piston, and spacer.





3) Pushing the piston stem using a wood stick, install the snap ring.





36. Apply a coat of ATF to the friction surface of reduction brake band, then install it to the direct clutch component.

Note:
^ Do not reuse the anchor end bolt.
^ The tip of anchor end bolt must be inserted to the band groove.





37. Install a new anchor end bolt.

Tightening torque:
64-94 Nm (6.5-9.5 kgf-m, 47-69 ft.lbf.)





38. Adjust the brake band.
1) Set the SST to prevent the brake band piston from turning.
2) Tighten the piston stem.

Tightening torque:
4.0-6.0 Nm (0.40-0.60 kgf-m, 2.9-4.3 ft.lbf.)

3) Loosen the piston stem 5 rotations.
4) Tighten the lock nut while preventing the piston stem from turning.

Tightening torque:
39-50 Nm (4.1-5.2 kgf-m, 40-51 ft.lbf.)





39. Position the reduction brake band servo.
40. Install the snap ring which secures the reduction brake band servo.





41. Install the sun gear on the reduction gear.





42. Install the reduction gear component.





43. Apply petroleum jelly to new seal rings, then assemble them to the input shaft.
44. Install the input shaft.

Caution: If the oil pump gasket is bent or scratched, do not reuse it.





45. Position the oil pump gasket.
46. Install the oil pump component and tighten bolts.

Tightening torque:
19-22 Nm (1.9-2.2 kgf-m, 14-16 ft.lbf.)

47. Apply a coat of ATF to a new O-ring, then install it to the input shaft.





48. Install the vehicle speedometer sensor (VSS).

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

49. Connect the VSS connector.
50. Install the harness bracket.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)





51. Install the intermediate sensor.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

52. Connect the intermediate sensor connector.





53. Install the magnets.
54. Install the transaxle fluid temperature (TFT) sensor.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

55. Install the oil strainer.

Tightening torque:
19-22 Nm (1.9-2.2 kgf-m, 14-16 ft.lbf.)





56. Install the differential component.





57. Install the converter housing.

Tightening torque:
27-30 Nm (2.8-3.1 kgf-m, 20-22 in.lbf.)

Caution: Be careful not to scratch the mating surface of the converter housing and transaxle case.





58. Install the terminal component.
59. Install the bracket to the coupling connector.

Note: If the seal ring is misplaced or scratched, do not reuse it.

60. Apply a coat of ATF to new seal rings, then install them to the transaxle case.





61. Install the control valve body to the transaxle case.
1) Position the manual valve so that it protrudes from the control valve body end by 3.0 mm.
2) Install the control valve body while holding the manual valve in the position.





62. Tighten the bolts which secure the control valve body to the transaxle case.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

63. Tighten the bracket on the coupling connector.





64. Connect the coupling connectors between the solenoid valves and terminal component.
65. Apply a light coat of silicone sealant to the contact surfaces of the control valve body cover and transaxle case.





66. Install the control valve body cover.

Tightening torque:
6.9-8.8 Nm (0.70-0.90 kgf-m, 5.1-6.5 ft.lbf.)

67. Remove the transaxle from the transaxle stand.





68. Install the transaxle range (TR) switch.
1) Rotate the manual shaft to the right fully, then return 2 notches to set the N position.
2) Loosen the TR switch mounting bolts.

Caution: Improper adjustment of the TR switch will cause abnormal operation of the automatic transaxle. Be sure to use the SST to adjust the TR switch correctly.





3) Using the SST and by turning the TR switch, adjust the positions of the manual shaft and the TR switch neutral hole.
4) Tighten the TR switch mounting bolts.

Tightening torque:
4.9-6.9 Nm (50.0-70.4 kgf-cm, 43.4-61.1 in.lbf.)

5) Remove the SST.





69. Install the torque converter.

Note: Ensure that the torque converter is inserted at least 18.0 mm as shown by "A" in the figure.