Part 2

REASSEMBLY

NOTICE:
^ The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection repair and reassembly of other component groups.
Recommended ATF: D-II or DEXRON(R)III (DEXRON(R)II)
^ All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
^ Dry all parts with compressed air-never use shop rags.
^ When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.
^ The recommended automatic transaxle fluid or kerosene should be used for cleaning.
^ After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.
^ When disassembling a valve body, be sure to match each valve together with the corresponding spring.
^ New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.
^ All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
^ All gaskets and rubber O-rings should be replaced.
^ Do not apply adhesive cements to gaskets and similar parts.
^ Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
^ If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.
^ Check thrust bearings and races for wear or damage. Replace if necessary.
^ Use petroleum jelly to keep parts in place.
^ When working with Formed In Place Gasket (FIPG) material, you must observe the following.
Using a razor blade and a gasket scraper, remove all the old packing Formed In Place Gasket (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing Formed In Place Gasket (FIPG) material must be removed and reapplied.

27. INSTALL NO. 2 ONE-WAY CLUTCH INTO CASE





a. Place the No. 2 one-way clutch with the shiny side of flange upward.





b. Install the No. 2 one-way clutch while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If the planetary gear cannot turn clockwise, check the installation of the No. 2 one-way clutch.





c. Using a screwdriver, install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.





28. INSTALL 2ND COAST BRAKE BAND GUIDE
Install the 2nd coast brake hand guide with the bolt.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
29. PLACE NO. 1 ONE-WAY CLUTCH





a. Coat the thrust washer with petroleum jelly and install it on the No. 1 one-way clutch.





b. Place the No. 1 one-way clutch onto the rear planetary gear.





30. INSTALL 2ND BRAKE
a. Install the flange, facing the flat end upward.
b. Install the 3 discs and plates.
Install in order:
P = Plate D = Disc
D - P - D - P - D - P





c. Place the piston return spring into the case.





d. Place the 2nd brake drum into the case.

HINT: Align the groove of the drum with the bolt.





e. Place the snap ring into the case so that end gap is installed into the groove.
f. While compressing the piston return spring over the drum with a screwdriver, install the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of cutouts.





31. INSTALL NEW 2ND BRAKE DRUM GASKET
Install a new gasket until it makes contact with the 2nd brake drum.





32. CHECK OPERATION OF 2ND BRAKE
Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) into the 2nd brake gasket and confirm that the piston moves.
If the piston does not move, disassemble and inspect it.
33. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM





a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.





b. While turning the sun gear clockwise, install it into the No. 1 one-way clutch.





34. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

HINT: After installing the oil seal ring, that it moves smoothly.

35. INSTALL FRONT PLANETARY GEAR





a. Coat the bearings with petroleum jelly, and install them onto the both side of the front planetary gear.





Bearing diameter:





b. Install the front planetary gear onto the sun gear.





36. INSTALL FRONT PLANETARY RING GEAR





37. INSTALL 2ND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.
38. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH





a. Coat the bearing and race with petroleum jelly and install it onto rear side of the forward clutch.





Bearing diameter:





b. Coat the bearing with petroleum jelly and install it onto the front side of the forward clutch.

HINT There are 2 differential thickness bearings for adjustment of the input shaft thrust play.





Bearing thickness:





c. Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.





d. Mesh the hub of the forward clutch flukes with the direct clutch discs.

HINT: Be careful that the bearing and thrust washer do not get out of place.





e. Install the direct clutch and forward clutch into the case.

HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.

39. INSTALL OIL PUMP INTO CASE





a. Coat a new O-ring with ATF and install it to the oil pump.





b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.

c. Install the 7 bolts.
Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)





40. MEASURE END PLAY OF INPUT SHAFT
Measure the end play with a dial gauge.
End play: 0.25 - 0.90 mm (0.0098 - 0.0354 inch)

HINT: There are 2 different thickness bearings for end of stature shaft. If the end play is in excess of standard, select one of them.

Bearing thickness:
3.60 mm (0.1417 inch)
4.19 mm (0.1650 inch)
41. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.
42. INSTALL 2ND COAST BRAKE PISTON





a. Coat 2 new O-rings with ATF and install them to the cover.
b. Install the spring with the piston.
c. Place the cover into the bore.





d. Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351-32050)
e. Check that the front end of the piston rod contacts the center of the 2nd brake band depression.
43. CHECK 2ND COAST BRAKE PISTON STROKE





a. Using a water proof pen, place a mark on the 2nd coast brake piston rod at the point it meets the case, as shown in the illustration.





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 inch)
If the piston stroke non-standard, replace the piston rod with a longer one.
Piston rod length:
95.2 mm (3.748 inch)
96.3 mm (3.791 inch)
If the still more than standard value, replace the brake band with a new one.





44. INSTALL ACCUMULATOR PISTON AND SPRING
a. Install new O-rings to each pistons.
b. Coat the O-ring with ATF.
c. Install the springs and pistons into the bores.








Spring dimensions:

d. Place the cover with a new gasket and gradually install the 4 bolts a little at a time in sequence.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





45. PLACE NEW 2ND BRAKE APPLY GASKET





46. INSTALL SOLENOID WIRE
a. Install a new O-ring to the solenoid wire.
b. Coat the O-ring with ATF.
c. Install the solenoid wire with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)





47. INSTALL THROTTLE CABLE
a. Coat a new O-ring with ATF.
b. Install the O-ring to the throttle cable.
c. Install the throttle cable to the transaxle case.
48. INSTALL VALVE BODY





a. While holding the cam down with your hand, slip the cable end into the slot.
b. Lower the valve body into place.

NOTICE: Do not entangle the solenoid wire.





c. Install the 9 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT:
^ Each bolt length is indicated.
^ Hand tighten the 9 bolts first, then torque with a torque wrench.

Bolt length:
Bolt A: 30 mm (1.181 inch)
Bolt B: 43 mm (1.693 inch)
Bolt C: 48 mm (1.890 inch)
Bolt D: 52 mm (2.047 inch)





49. INSTALL B3 APPLY PIPE

NOTICE: Be careful not to bend or damage the pipe.





50. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
a. Install the connector clamp with the bolt.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
b. Install the pipe retainer with the bolt.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT: Each bolt length is indicated.

Bolt length:
Bolt A: 48 mm (1.890 inch)
Bolt B: 39 mm (1.535 inch)





51. CONNECT 3 SOLENOID CONNECTORS





52. INSTALL OIL PIPE
Using a plastic hammer, install the 6 pipes into the positions.

NOTICE: Be careful not to bend or damage the pipes.

53. INSTALL MANUAL VALVE BODY AND DETENT SPRING





a. Align the manual valve with the pin on the manual shaft lever.
b. Lower the manual valve body into place.
c. Hand tighten the 5 bolts first. Then, tighten them with a torque wrench.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT: Each bolt length is indicated.

Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 37 mm (1.457 inch)





d. Place the detent springs on the manual valve body and hand tighten the 2 bolt first.
Then, tighten them with a torque wrench.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT: Each bolt length is indicated.

Bolt length:
Bolt A: 14 mm (0.551 inch)
Bolt B: 37 mm (1.457 inch)
e. Check that the manual valve lever is touching the center of the detent spring tip roller.





54. INSTALL PIPE BRACKET AND OIL STRAINER
a. Install the oil pipe bracket with the 3 bolts.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
b. Place a new gasket to the oil strainer.
c. Install the oil strainer with the 3 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
d. Each bolt length is indicated.
Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 53 mm (2.087 inch)





55. INSTALL 3 MAGNETS IN PLACE

NOTICE: Make sure that the magnets do not interfere with the oil pipes.





56. INSTALL OIL PAN WITH NEW GASKET
a. Install a new gasket and oil pan.
b. Install the 17 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





57. INSTALL THROTTLE CABLE RETAINING PLATE
Install the throttle cable retaining plate with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





58. INSTALL TRANSAXLE UPPER COVER
a. Place a new gasket.
b. Install the transaxle upper cover with the 9 bolts.
Torque:
Bolt A: 19.6 Nm (200 kgf-cm, 14 ft. lbs.)
Bolt B: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)





59. INSTALL DIRECT CLUTCH SPEED SENSOR
a. Coat a new O-ring with ATF.
b. Install the O-ring to the direct clutch speed sensor.
c. Install the direct clutch speed sensor with the bolt.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
60. INSTALL PARK/NEUTRAL POSITION SWITCH





a. Install the park/neutral position switch to the manual valve shaft.
b. Place a new locking plate and install the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
c. Stake the nut with the locking plate.
d. Temporarily install the 2 bolts.





e. Adjust the park/neutral position switch.

HINT: Alight the groove and neutral basic line.

f. Tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





61. INSTALL UNION AND ELBOW
a. Install 2 new O-rings to the union and elbow.
b. Install the union and elbow to the transaxle case.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)





HINT: Install the elbow, as shown in the illustration.





62. INSTALL MANUAL SHAFT LEVER
Install the manual shaft lever and washer with the nut.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)





63. INSTALL SHIFT CONTROL CABLE BRACKET