Part 2

REASSEMBLY(continued)





22. INSTALL DIRECT CLUTCH ASSEMBLY
a. Install the bearing race to the direct clutch.

Bearing Race Diameter:

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

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 to 0.936 mm (0.00800 to 0.03685 inch)

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

HINT: End play = Dimension C - Dimension B

Bearing Thickness And Diameter: mm (inch):

23. INSTALL GOVERNOR APPLY GASKET NO.1
a. Install 2 new governor apply gaskets No. 1.





24. INSTALL FRONT CLUTCH APPLY TUBE
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.





25. INSTALL BRAKE APPLY TUBE
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.

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





26. INSTALL TRANSAXLE CASE NO.1 PLUG
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.)





27. INSTALL TRANSAXLE REAR COVER SUB ASSEMBLY
a. Using SST and a press, install the bearing.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 12.05 to 12.75 mm (0.4744 to 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 ATF, 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.)





28. INSTALL UNDERDRIVE CLUTCH DISC NO.2
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. Using a screwdriver, install the snap ring.
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 to 2.20 mm (0.0713 to 0.0866 inch)

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

Flange Thickness: mm (inch):

e. Temporally remove the snap ring and attach the flange. Restore the snap ring.
29. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY





30. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
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.





31. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Coat the bearing and bearing race with petroleum jelly, install them onto the U/D clutch.

Race Diameter: mm (inch):

b. Install the U/D clutch assembly to the transaxle case.





32. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
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 assembly to the transaxle case.

NOTICE: Engage all the discs of U/D clutch and hub splines of the U/D planetary gear assembly 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 NG using the formula.

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

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





33. INSTALL MULTIPLE DISC CLUTCH HUB
a. Install the bearing race to the transaxle while checking its direction.

Bearing Race Diameter: mm (inch):

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

Thrust Bearing And Race Diameter: mm (inch):

c. Install the bearing to the multiple clutch hub.

Bearing Diameter: mm (inch):

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





34. INSTALL FORWARD CLUTCH ASSEMBLY
a. Install the thrust bearing to the forward clutch.

Bearing Diameter: mm (inch):

NOTICE: Install the thrust bearing properly so that the race B 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.





35. INSTALL OVERDRIVE BRAKE GASKET
a. Install 2 new O/D brake gaskets.





36. INSTALL DIFFERENTIAL GEAR ASSEMBLY
a. Install the differential gear assembly to the transaxle case.





37. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2
a. Install the thrust bearing race to the U/D planetary gear assembly.





38. INSTALL THRUST NEEDLE ROLLER BEARING
a. Calculate the end play value using the following formula and values of Dimension D and NG 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 to 0.993 mm (0.01961 to 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 (inch):

Bearing And Bearing Race Diameter: mm (inch):

39. INSTALL OIL PUMP ASSEMBLY
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.





40. INSTALL TRANSAXLE HOUSING
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.





41. INSTALL TRANSAXLE CASE NO.1 PLUG
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.)
42. INSPECT INPUT SHAFT END PLAY





43. FIX AUTOMATIC TRANSAXLE ASSEMBLY
a. Fix the automatic transaxle assembly.