Part 1

Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly.

If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.

Recommended ATF: DEXRON(R) II

GENERAL INSTALLATION NOTES:

1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least two hours
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.

INSTALL AND ADJUSTMENT OF DRIVE PINION SHAFT




1. INSTALL NEW O-ring ONTO BEARING CAGE




2. INSTALL DRIVE PINION SHAFT INTO CASE
Slightly tap the cage into the case until the groove with the bore can be seen.

HINT: Drive in the bearing cage until the surface of the bearing cage passes through the groove with the bore.

3. INSTALL SNAP RING INTO CASE




a. Using SST, install the snap ring into the groove.
SST 09350-32014 (09351-32050)




b. Slightly tap the drive pinion to fit the snap ring into the groove.




4. INSTALL OIL SLINGER
Install the oil slinger, facing the lip outward.




5. INSTALL OUTER RACE
Using SST, drive the outer race into the case.
SST 09350-32014 (09351-32100, 09351-32140)

CAUTION: Drive in the outer race with the narrower diameter end toward you




6. INSTALL NEW SPACER
Always use a new spacer.
Install the spacer with the small end first.

7. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT




a. Place a bar at the drive pinion side and position the other end of the bar against a vise or such.




b. Using SST, driven gear onto the shaft until the nut can be installed on the threads of the shaft.

NOTE: Be careful not to cause an impact to the transmission case.

SST 09350-32014 (09351-32140)

8. ADJUST DRIVE PINION PRELOAD




a. Coat the threads and surface of the nut with MP grease.
b. Using SST to hold the gear, tighten the nut.

Torque: 1,750 kg-cm (127 ft-lb, 172 N.m)

SST 09330-00021,09350-32014 (09351-32032)




c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.

Preload (at starting):

New bearing 10 - 16kg-cm (8.7 - 13.9 in.-lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg-cm (4.3 - 6.g in.-lb, 0.5 - 0.8 N.m)

- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less than specified, retighten the nut 130 kg-cm (9 ft-lb, 1 3 N.m) at a time until the specified preload is reached.

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.

Do not back off the nut to reduce the preload.

Maximum torque: 2,950 kg-cm (213 ft-lb, 289 N.m)

e. If the preload is adjusted within specification, make a note of it.

INSTALLATION OF DIFFERENTIAL




1. PLACE OUTER RACE AND SELECTED ADJUSTING SHIM ONTO RH SIDE BEARING




2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim into place.




3. INSTALL LH BEARING RETAINER

a. Install a new O-ring.
b. While holding the differential case centered with the retainer, tap in the retainer.




c. Clean the threads of the bolts and case with white gasoline.
d. Coat the threads of the bolts with sealant.

Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent

e. Temporarily tighten the bolts evenly and gradually while turning the ring gear.




4. INSTALL RH SIDE BEARING CAP

Tighten the bolts evenly and gradually while turning the ring gear.

Torque: 500 kg-cm (36 ft-lb, 49 N.m)




5. TIGHTEN LH BEARING RETAINER

Torque: 195 kg-cm (14 ft-lb, 19 N.m)




6. MEASURE TOTAL PRELOAD

Using a torque meter, measure the total preload of the drive pinion shaft.

Total pre load (at starting):

Add drive pinion preload

New bearing 2.9 - 4.0 kg-cm (2.5 - 3.5 in.-lb, 0.3 - 0.4 N.m)
Reused bearing 1.5 - 2.0 kg-cm (1.3 - 1.7 in.-lb, 0.1 - 0.2 N.m)

If the preload is not within specification, disassemble and readjust.




7. STAKE COUNTER DRIVEN GEAR NUT




8. INSTALL DRIVE PINION CAP




9. INSTALL CARRIER COVER
a. Clean the threads of the bolts and case with white gasoline.
b. Coat the threads of the bolts with sealant.

Sealant: Part No.08833-00070, THREE BOND 1324 or equivalent

c. Install the carrier cover over the gasket.

Torque: 250 kg-cm (18 ft-lb, 25 N.m)

INSTALLATION OF 3-SPEED GEAR UNIT




1. INSTALL GOVERNOR PRESSURE ADAPTOR
a. Install the governor pressure adaptor into the case.
b. Align the hole of adaptor with the hole of the case and install the torsion spring.
c. Check that the adaptor does not slide or the spring fall Out when pulled by hand.

2. INSTALL MANUAL VALVE SHAFT




a. Install the manual valve shaft oil seal to the case.




b. Assemble a new collar to the manual valve lever.
c. Install the manual valve shaft to the transmission case through the manual valve lever.




d. Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface.




e. Match the collar hole to the lever calking hollow and calk the collar to the lever.




f. Install the retaining spring.




g. Make sure that the lever moves smoothly.




3. INSTALL PARKING LOCK PAWL

a. Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and pawl.




4. INSTALL PARKING LOCK ROD




5. INSTALL PARKING LOCK PAWL BRACKET

Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)




6. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P range.

7. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE




a. Coat the new O-rings with ATF.
b. Install the two O-rings on the piston.




c. Push the piston into the bore of the case facing the spring seat upward.




8. INSTALL PISTON RETURN SPRING

a. Place the return spring and snap ring on the piston.
b. Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)




c. Install snap ring. Visually check to make sure it is fully seated and centered by the three lugs on the spring retainer.

Be sure the end gap of snap ring is not aligned with the spring retainer claw.

d. Remove SST.




9. INSTALL SNAP RING
Using SST, install the snap ring.
SST 09350-32014 (09351-32050)




10. INSTALL INTERMEDIATE SHAFT AND TRANSAXLE REAR COVER
a. Install the intermediate shaft to the case.
b. Install the new gasket and rear cover.

Torque: 250 kg-cm (18 ft-lb 25 N.m)




11. CHECK INTERMEDIATE SHAFT END PLAY
Make sure that the intermediate shaft has thrust play in axial direction.

Thrust play: 0.49 - 1.51 mm (0.0193 - 0.0594 in.) If the thrust play is not within specification, check the installation of intermediate shaft.




12. INSTALL FIRST AND REVERSE BRAKE IN CASE
a. Install the inner flange, facing the flat end toward the oil pump side.
b. Install the discs and plates.

Install in order: P=Plate D=Disc

Flange-D-P-D-P-D-P-D-P-D-Flange

c. Install the outer flange, facing the flat end toward the piston side.




13. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of cutouts.




14. CHECK OPERATION OF FIRST AND REVERSE BRAKE
Apply compressed air into the oil passage with the case and be sure that the piston moves.

15. INSTALL RING GEAR INTO CASE




a. Coat the races and bearing with petroleum jelly and install them onto the ring gear.







b. Install the ring gear into the case.




16. INSTALL REAR PLANETARY GEAR INTO CASE
a. Align the flukes of the discs in the first and reverse brake.




b. Coat the thrust washer with petroleum jelly. Align the tab of the washer with the hollow of the carrier.
c. Align the spline of the planetary carrier with either of the flukes of the discs, and install the planetary gear into the first and reverse brake discs.




17. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD

a. Place the one-way clutch with the shiny side upward.
b. Install the one-way clutch onto the inner race while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)




c. Coat the thrust washer with petroleum jelly and install it onto the planetary gear.




18. CHECK OPERATION OF NO.2 ONE-WAY CLUTCH
Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise.




19. INSTALL SNAP RING
Be sure the end gap of the snap ring is not aligned with one of the cutouts.




20. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the two band guides so that its tip touches the case.




21. INSTALL SECOND BRAKE INTO CASE
a. Install the flange, facing the flat end toward the oil pump side.
b. Install the discs and plates.

Install in order: P=Plate D=Disc
Flange - D - P - P - D - P - P




22. INSTALL PISTON RETURN SPRING
Each spring end is installed onto the protrusion with the case.




23. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.




24. INSTALL SNAP RING
a. Place the snap ring into the case so that the end gap is installed into the groove.
b. While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove.
c. Be sure the end gap of the snap ring is not aligned with one of the cutouts.




25. INSTALL SECOND BRAKE DRUM GASKET
Install a new gasket until it makes contact with the second brake drum.




26. CHECK OPERATION OF SECOND BRAKE
Blow compressed air into the oil passage with the case, and be sure that the piston moves.




27. INSTALL NO.1 ONE-WAY CLUTCH AND SECOND BRAKE HUB
a. Align the flukes of the discs in the 2nd brake.
b. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.




c. Check the distance between the surfaces of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)




28. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.

HINT: Check that the thrust washer is on the sun gear input drum.

29. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR







a. Coat the races and bearing with petroleum jelly, and install them onto the ring gear.







b. Coat the race and bearing with petroleum jelly, and install them onto the planetary gear.




c. Install the planetary gear onto the ring gear.

30. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR




a. If the planetary gear and other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.




b. Coat the race with petroleum jelly and install it onto the tip of ring gear flange.

Race:
Outer diameter 35.7 mm (1.406 in.)
Inner diameter 23.0 mm (0.906 in.)