48 - 96

Transmission Assemble Continued





49. Install the manual detent spring with the bolt.

Tighten the bolt to 9.8 Nm (87 inch lbs.).





50. Install the parking lock shaft, the torsion spring and the parking lock pawl.





51. Verify that the edge of the torsion spring fits into the groove securely.





52. Install the parking lock pawl bracket with the 2 bolts.

Tighten the bolts to 7.4 Nm (65 inch lbs.).





53. Replace the planetary ring flange of the planetary ring gear.
54. Using DT 46460 (2) and DT 46455 (1), install the planetary ring gear.





55. Fix the counter drive gear with the parking lock pawl.





56. Using DT 46472 (1), install a new nut.

Tighten the nut to 9.8 Nm (87 inch lbs.).





57. Using a small torque wrench, turn the counter drive gear 100 turn per minute and measure the preload.

Tighten the nut to 29 Nm (22 ft. lbs.) or less.

When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05 - 0.35 Nm (0.43 - 3.12 inch lbs.).
58. Stake the nut.





59. Install the planetary gear to the transaxle case.





60. Coat the planetary carrier thrust washer with petroleum jelly and install the washer onto the planetary gear.





61. Install the No. 2 one-way clutch to the transaxle case.





62. Verify that the planetary gear turns freely counterclockwise and locks clockwise.





63. Install the anti-rattle clip in the space between the No. 2 one-way clutch outer race and transaxle case. Push the anti-rattle clip in place until you hear the click.





64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

The standard free length is 15.85 mm (0.6240 inch).





65. Important:
^ If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
^ Before assembling the new discs, soak the discs in ATF for at least 15 minutes.

If the sliding surface of the disc, the plate and the flange of 2nd brake are worn or burnt, replace the parts.





66. Important:
Install the snap ring in the groove of the transaxle case correctly.

Install the flange, 2 discs and 2 plates in order: 2-1-3-1-3, where (1)=Disc, (2)=Flange, and (3)=Plate.
67. Install the 2nd brake return spring.





68. Coat 2 new O-rings (1) with ATF and install the O-rings to the 2nd brake piston.





69. Important:
Do not damage the O-rings.

Install the 2nd brake piston into the 2nd brake clutch cylinder.





70. Install the 2nd brake clutch cylinder to the transaxle case.





71. Using DT 46455 (1) and DT 46458 (2), compress the 2nd brake piston return spring.

72. Important:
Install the snap ring in the groove of the transaxle case correctly.

Using the screwdriver, install the snap ring.





73. Coat the thrust bearing race with petroleum jelly and install the race onto the front planetary sun gear.
^ The race inner diameter is 19.3 mm (0.760 inch).
^ The race outer diameter is 29.0 mm (1.142 inch).





74. Install the front planetary sun gear to the transaxle case.





75. Install the thrust washer and the one-way clutch assembly to the rear planetary sun gear.





76. Important:
Verify the direction of the bearing.

Coat the thrust bearing race with petroleum jelly and install the race onto the rear planetary sun gear and the one-way clutch assembly.
^ The bearing inner diameter is 42.5 mm (1.673 inch).
^ The bearing outer diameter is 57.5 mm (2.264 inch).





77. Install the rear planetary sun gear and the one-way clutch assembly to the transaxle case.





78. Important:
Verify the direction of the race.

Coat the thrust bearing race with petroleum jelly and install the race onto the transaxle case.
^ The race inner diameter is 34.95 mm (1.3760 inch).
^ The race outer diameter is 45.50 mm (1.7913 inch).





79. Important:
Verify the direction of the bearing.

Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward clutch hub.
^ The bearing inner diameter is 33.3 mm (1.311 inch).
^ The bearing outer diameter is 46.5 mm (1.831 inch).





80. Install the forward clutch hub to the transaxle case.





81. Coat the thrust bearing race with petroleum jelly and install the race onto the forward clutch hub.
^ The race inner diameter is 19.3 mm (0.760 inch).
^ The race outer diameter is 30.6 mm (1.205 inch).





82. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.
^ The race inner diameter is 18.1 mm (0.713 inch).
^ The race outer diameter is 28.2 mm (1.110 inch).
^ The bearing inner diameter is 18.1 mm (0.713 inch).
^ The bearing outer diameter is 29.6 mm (1.165 inch).





83. Install the forward and reverse clutch assembly to the transaxle case.





84. Important:
^ If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.
^ Before assembling new discs, soak the discs in ATF for at least 15 minutes.

If the sliding surface of the disc, the plate and the flange of 2nd coast and O/D brake are worn or burnt, replace the components.





85. Important:
Install the snap ring in the groove of the transaxle case correctly.

Using a screwdriver, install the snap ring to the transaxle case.





86. Install the flange, 2 discs and 2 plates to the transaxle case in the following order: 3-2-3-2-1, where (3)=Plate, (2)=-Disc, and (1)=Flange.
87. Clean the connected part the transaxle case and the transaxle rear cover.





88. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and the O/D brake flange and the straight edge using vernier calipers (a).





89. Place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
90. Calculate the piston stroke value using the following formula. Select and install a flange which satisfies the piston stroke value.





91. Install 4 new apply gaskets to the transaxle rear cover.





92. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward and reverse clutch assembly.
^ The bearing inner diameter is 43.2 mm (1.701 inch).
^ The bearing outer diameter is 62.0 mm (2.441 inch).
93. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or transaxle case.





94. Apply a formed in place gasket (FIPG) to the transaxle rear cover.

The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 inch).





95. Install the transaxle rear cover to the transaxle case with 9 bolts.

Tighten the bolts to 25 Nm (18 ft. lbs.).





96. Install the counter driven gear assembly to the transaxle case.





97. Install the differential gear assembly to the transaxle case.





98. Install the direct clutch hub to the transaxle case.