Part 4

OVERHAUL
91. INSTALL REAR PLANETARY GEAR ASSY [35760/98-8]





a. Coat a bearing race with AFT, install it to the rear planetary gear assy.





Bearing race diameter: mm (in.)





b. Install the thrust washer No. 2.





c. Install the rear planetary gear to the rear planetary ring gear.





d. Using a screwdriver, install the snap ring.
92. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC [35677A/98-7]





a. 1MZ-FE:
Install the 7 plates and 7 discs.
b. 2AZ-FE
Install the 5 plates and 5 discs.





c. Using vernier calipers,measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case.(Dimension A)
d. Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance:
1MZ-FE:
1.10 - 1.29 mm (0.0433 - 0.0508 inch)
2AZ-FE:
1.02 - 1.21 mm (0.0402 - 0.0476 inch)

HINT: Piston stroke = Dimension A -Flange thickness





Flange thickness: mm (in.)





e. Install the flange.





93. INSTALL SECOND BRAKE PISTON ASSY
a. Install the 2nd brake piston assy to the transaxle case.
b. Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 inch)

NOTICE:
- Because the taper snap ring has the positioning direction, check it when installing.
- When the diameter does not satisfy the specified value, replace the snap ring with new one.





94. INSTALL 1 WAY CLUTCH SLEEVE OUTER [35798A/98-6]
a. Install the 1-way clutch outer sleeve to the 2nd brake cylinder assy.

NOTICE: Check the positioning direction of the outer sleeve.

95. INSTALL 1 WAY CLUTCH ASSY [35790/98-6]





a. Install the inner race to the 1-way clutch.

NOTICE: Check the direction of the inner race.





b. Check the rotating direction of 1-way clutch for the lock or free operation, as shown in illustration.





c. Install the 1-way clutch and bearing to the 1-way clutch sleeve outer.





Bearing diameter: mm (in.)

NOTICE: Install the thrust bearing properly so that no colored race will be visible.





96. INSTALL REAR PLANETARY SUN GEAR ASSY [35730/98-8]
a. Coat the thrust washer No. 1 with petroleum jelly, install it onto the rear planetary sun gear.





b. Coat the bearing with petroleum jelly, install it onto the rear planetary sun gear.





Bearing diameter: mm (in.)





c. Install the rear planetary sun gear assy to the rear planetary gear.
97. INSTALL 2ND BRAKE CLUTCH DISC [35677/98-6]





a. 1MZ-FE:
Install the 4 discs and 4 plates to the transaxle case.
b. 2AZ-FE:
Install the 3 discs and 3 plates to the transaxle case.
c. Temporarily install the snap ring.





d. Using vernier calipers, measure the distance between the disc surface and snap ring surface.
e. Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 inch)

HINT: Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 inch)





Flange thickness: mm (in.)





f. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

NOTICE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

98. INSTALL DIRECT CLUTCH ASSY





a. Install the bearing race to the direct clutch.





Bearing race diameter: mm (in.)





b. Install direct clutch assy and thrust bearing to the rear planetary sun gear assy.

NOTICE: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed.





c. Clean the connector part of the transaxle case and rear cover.

d. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers. (Dimension B)





e. Measure the 2 places of the rear cover as shown in the illustration and calculate a dimension C using the following formula.

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

f. Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value and install it.
End play: 0.198 - 0.936 mm (0.00800 - 0.03685 inch)

NOTICE: Make sure that the colored race side is facing the direct clutch assy.

HINT: End play = Dimension C - Dimension B





Bearing thickness and diameter: mm (in.)





99. INSTALL GOVERNOR APPLY GASKET NO.1 [35148/98-3]
a. Install 2 new governor apply gaskets No 1.





100. INSTALL FRONT CLUTCH APPLY TUBE [35895/98-9]
a. Install the clamp to the front clutch apply tube.

NOTICE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.

101. INSTALL BRAKE APPLY TUBE [35666D/98-9]





a. Install the clamp to the brake apply tube.

NOTICE: Make sure to install the clamp to the apply pipe before installing the apply pipe to the transaxle case. This prevents the apply pipe from being deformed or damaged.





b. Install the 2 apply tubes and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Each pipe should be securely inserted until it reaches the stopper.





102. 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 2 transaxle case No. 1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
103. INSTALL TRANSAXLE REAR COVER SUB-ASSY [35102/98-3]





a. Using SST and a press, install the bearing.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 12.05 - 12.75 mm (0.4744 - 0.5020 inch)

NOTICE:
- Face the inscribed mark side of the bearing race up.
- Repeat the press fit until the specified value is obtained.

b. Apply liquid sealer to the 2 screws.
Sealant:
Part No. 08833 00080, THREE BOND 2430 or equivalent.





c. Using a torx socket wrench (T30), install the transaxle rear cover plate with the 2 screws.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)





d. Coat 2 new oil seal rings with AFT, install them to the transaxle rear cover.





e. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case.
f. Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent.
g. Coat a needle roller bearing with ATF.





h. Apply liquid sealer to the "A" bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
i. Install the 11 bolts.
Torque:
Bolt A: 18.6 Nm (190 kgf-cm, 14 ft. lbs.)
Other bolt: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
SST 09950-60010 (09951-00230, 09952-06010)
104. INSTALL UNDERDRIVE CLUTCH DISC NO.2 [34262/98-4]





a. 1MZ-FE:
Install the 4 discs and 4 plates to the transaxle case.
b. 2AZ-FE:
Install the 3 discs and 3 plates to the transaxle case.
c. Using a screwdriver, install the snap ring.





d. Using a dial indicator, measure the U/D brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 inch)

HINT: Select an appropriate flange from the table so that it will meet the specified value.





Flange thickness: mm (in.)

e. Temporally remove the snap ring and attach the flange. Restore the snap ring.





105. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY [34360/98-4]
a. Install the U/D clutch assy to the 1-way clutch. Rotate the U/D clutch assy to check the rotating direction for the lock or free operation.