Part 1
AUTOMATIC TRANSAXLE ASSEMBLYPrecaution
General notes
1. Select the adjustment shims, referring to Bearing Preload.
2. If the drive plates or 2-4 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, when assembling again.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assemble 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.
Warning: Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.
Assembly
Bearing and race locations
Note: The bearing and race at locations 2, 3, 4, 5, and 6 are one-piece units.
Outer diameter of bearing and race
Components
Assembly procedure
1. Measure the bushing of the front sun gear.
Bushing inner diameter
Standard: 18.000 - 18.018 mm (0.70866 - 0.70936 inch)
Maximum: 18.038 mm (0.71016 inch)
2. If not as specified, replace the front sun gear.
3. Measure the bushing of the end cover.
Bushing inner diameter
Standard: 23.600 - 23.621 mm (0.92913 - 0.92995 inch)
Maximum: 23.641 mm (0.93075 inch)
4. If not as specified, replace the end cover.
5. Assemble the SST.
6. Lift the transaxle case and mount it on the SST.
7. Install the oil pipe.
8. Install a new funnel and bearing race.
9. Install the bearing race, then tighten torx screws.
Tightening torque 10.8 - 13.7 Nm (110 - 140 kgf-cm, 95.5 - 121 inch lbs.)
10. Install the bearing race to the transaxle case.
11. Install the locknut.
(1) Set the primary gear.
(2) Set the distance piece and bearing.
(3) Loosely tighten the locknut.
(4) Set the SSTs in the order shown.
(5) Tighten the locknut from the end cover side to adjust the preload within the specification.
Preload 0.50 - 0.90 Nm (5.10 - 9.17 kgf-cm, 4.42 - 7.96 inch lbs.)
(6) Stake the locknut.
(7) Remove the SST
12. Install the front internal gear and one-way clutch.
13. Apply petroleum jelly to the bearing, and secure it to the front planetary gear component.
14. Install the front planetary gear component.
15. Apply petroleum jelly to the bearing, and secure it to the front sun gear.
16. Install the front sun gear.
17. Install the rear planetary gear.
Note: Rotate the engine stand so that the oil pan faces downward. Pull the front internal gear and one-way clutch component a little until the groove for the snap ring appears, then install the snap ring.
18. Install the snap ring.
19. Rotate the engine stand so that the end cover faces upward, and verify that the snap ring is installed accurately.
20. Install the band servo component.
(1) Install the servo return spring and servo piston.
(2) Apply ATF to the O-ring, and install it to the transaxle case.
(3) Install the servo retainer.
Tightening torque 10.8 - 13.7 Nm (110 - 140 kgf-cm, 95.5 - 121 inch lbs.)
21. Install the 2-4 brake band.
22. Apply petroleum jelly to the bearing, and secure it to the clutch component.
23. Install the clutch component.
24. Select the band strut. (1) Find an appropriate bolt (under head length: 60 - 70 mm (2.36 - 2.75 inch)), and tighten the 2-4 brake band with the bolt.
Tightening torque 4.9 Nm (50 kgf-cm, 43 inch lbs.)
(2) Measure the dimension A shown in the figure.
(3) Remove the bolt.
(4) Measure the dimension B shown in the figure.
(5) Calculate according to the formula below.
B - A = C (The middle of the under head length)
C - 4 = D (The lower limit of under head length)
C - 4.7 = E (The upper limit of under head length)
(6) Select a band strut whose length should be between D and E.
Band strut length
(7) Install the selected band strut.
Tightening torque 37 - 52 Nm (3.8 - 5.3 kgf-m, 28 - 38 ft. lbs.)
25. Use the following procedure to adjust the total end play.
(1) Install the thickest bearing race (2.6 mm (0.102 inch)) to the end cover.
(2) Install the end cover to the clutch component.
(3) Measure the clearance A between transaxle case and end cover.
(4) Calculate according to the formulas below. Select an appropriate bearing race whose bearing thickness matches the calculated limits.
A - 2.6 mm (0.102) (Bearing thickness) = B
B - 0.25 = C (The lower limit of bearing thickness)
B - 0.50 = D (The upper limit of bearing thickness)
(5) Select a bearing race whose thickness is between D mm (in) and C mm (in).
Bearing race sizes
Caution: The bearing race and end cover may be damaged if the end cover is not installed correctly to the transaxle case. Align the projection of the bearing race within the area of the arrows shown in the figure, and then install the end cover to the transaxle case.
(6) Remove the end cover, apply petroleum jelly to the selected bearing race, then install it to the end cover.
26. Apply ATF to new seal ring, and install it to the end cover.
Seal ring inner diameter
A: 47.1 mm (1.854 inch)
B: 55.8 mm (2.197 inch)
27. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the end cover.
28. Apply ATF to the O-ring and install it to the transaxle case.