Part 5

OVERHAUL
106. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY [34360/98-4]

a. Install the outer race retainer to the 1-way clutch.

b. Install the 1-way clutch to the transaxle case.

NOTICE: Make sure that the mark on the 1-way clutch outer race is visible.

c. Using screwdriver, install the snap ring to the transaxle case.
107. INSTALL UNDERDRIVE CLUTCH ASSY

a. Coat the bearing and bearing race with petroleum jelly, install them onto the U/D clutch.

Race diameter: mm (in.)

b. Install the U/D clutch assy to the transaxle case.
108. INSTALL UNDERDRIVE PLANETARY GEAR ASSY

a. Install the pawl pin and spring to the parking lock pawl.

b. Temporarily install the parking lock pawl, shaft and spring to the transaxle case as shown in the illustration.

c. Install the U/D planetary gear assy to the transaxle case.

NOTICE: Engage all the discs of U/D clutch and hub splines of the U/D planetary gear assy firmly and assemble them securely.

d. Install the parking lock pawl shaft.

e. Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)

f. Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the U/D planetary gear and contact surface of the transaxle case and housing. (Dimension D)

NOTICE: Note down the dimension D as it is necessary for the following process.

g. As shown in the illustration, measure the 2 places of the transaxle housing, Calculate the dimension E using the formula.

NOTICE: Note down the dimension E as it is necessary for the following process.

HINT: Dimension E = Dimension (1)- Dimension (2)

109. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB [35631/98-5]

a. Install the bearing race to the transaxle while checking its direction.

Bearing race diameter: mm (in.)

b. Coat the thrust bearing and race with petroleum jelly, install them onto the multiple disc clutch hub.

Thrust bearing and race diameter: mm (in.)

c. Install the bearing to the multiple clutch hub.

Bearing diameter: mm (in.)

d. Install the forward clutch hub to the transaxle case.
110. INSTALL FORWARD CLUTCH ASSY

a. Install the thrust bearing to the forward clutch.

Bearing diameter: mm (in.)

NOTICE: Install the thrust bearing properly so that the black race or blue ink jet race will be visible.

b. Install the forward clutch to the multiple clutch hub.

NOTICE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

111. INSTALL OVERDRIVE BRAKE GASKET [35179/98-3]
a. Install 2 new O/D brake gaskets.

112. INSTALL DIFFERENTIAL GEAR ASSEMBLY
a. Install the differential gear assy to the transaxle case.

113. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2 [34736A/98-4]
a. Install the thrust bearing race to the U/D planetary gear assy.

114. INSTALL THRUST NEEDLE ROLLER BEARING [34736B/98-4]
a. Calculate the end play value using the following formula and values of Dimension D and E that ware measured when installing cylindrical roller bearing and U/D planetary gear, Select an appropriate U/D planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 inch)

HINT: End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 inch) - U/D thrust bearing race No. 2 thickness.

Race thickness: mm (in.)

Bearing and bearing race diameter: mm (in.)

115. INSTALL OIL PUMP ASSY

a. Install the oil pump and 7 bolts to the transaxle case.
Torque: 22 Nm (226 kgf-cm, 16 ft. lbs.)

b. Coat the O-ring of oil pump with ATF.
116. INSTALL TRANSAXLE HOUSING [35111C/98-14]

a. Remove any parking material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing.
b. Apply FIPG to the transaxle case.
FIPG:
Part No. 08826 00090, THREE BOND 1281 or equivalent

c. Install the transaxle housing and 16 bolts to the transaxle case.
Torque:
Bolt A: 22.1 Nm (225 kgf-cm, 16.3 ft. lbs.)
Bolt B and C: 29.4 Nm (300 kgf-cm, 21.7 ft. lbs.)

HINT: Apply seal packing or equivalent to the bolt A.
- Seal packing:
- THREE BOND 2403 or equivalent
- Bolt length:
- Bolt A: 50 mm (1.969 inch)
- Bolt B: 50 mm (1.969 inch)
- Bolt C: 42 mm (1.654 inch)

NOTICE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.

117. INSTALL TRANSAXLE CASE NO.1 PLUG [35104Q/98-3]
a. Install 2 new O-rings to the 2 transaxle case No.1 plugs.
b. Install the 2 transaxle case No 1 plugs to the transaxle housing.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)

118. INSPECT INPUT SHAFT ENDPLAY
a. Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0103 - 0.0492 inch)

119. FIX AUTOMATIC TRANSAXLE ASSY [30500/98-1]

120. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL [35506F/98-11]
a. Coat a new oil seal with ATF.
b. Install the oil seal to the transaxle case.

121. INSTALL PARKING LOCK ROD SUB-ASSY [35501/98-11]
a. Install the parking lock rod to the manual valve lever.
122. INSTALL MANUAL VALVE LEVER SUB-ASSY [35505/98-11]

a. Install a new spacer and manual valve lever shaft to the transaxle case.

b. Using a pin punch and a hammer, drive in a new pin.

c. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
d. Using a pin punch, stake the spacer through the small hole.
e. Check that the spacer does not turn.

123. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING [35506J/98-11]
a. Using needle-nose pliers, install the retainer spring.

124. INSTALL PARKING LOCK PAWL BRACKET [35595/98-11]
a. Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt length: 25 mm (0.984 inch)

125. INSTALL MANUAL DETENT SPRING SUB-ASSY [35409/98-9]
a. Install the manual detent spring with the 2 bolts.

NOTICE: Make sure to install the manual detent spring and cover in this order.

Torque:
Bolt A: 20 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt B: 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt length:
Bolt A: 27 mm (1.063 inch)
Bolt B: 16 mm (0.630 inch)
126. INSTALL B-3 ACCUMULATOR PISTON [35427K/98-9]