Part 1

REASSEMBLY
1. BEARING POSITION

2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)

NOTICE: Make sure to insert the pipe to the stopper.

3. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 2 new O-rings to the 2 transaxle case No.1 plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)

4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
(a) Coat the new oil seal ring with ATF and install it to the transaxle housing.

5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)

NOTICE: Do not apply excessive pressure to it.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new oil seal rings with ATF, install them to the transaxle rear cover.

NOTICE:
^ Do not expand the gap of the oil seal ring too much.
^ Fix the hooks certainly. Confirm the smooth rotation.

7. INSTALL NEEDLE ROLLER BEARING
(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157 inch) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).

NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.

(b) Coat the needle roller bearing with ATF.

(c) Using SST and a press, install the needle-roller bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

NOTICE: When the wound vinyl tape contacts the transaxle case, stop press-fitting.

8. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF, install them to the underdrive brake piston.

NOTICE:
^ Assemble the O-ring carefully not to have a twist and a pinching.
^ Apply enough ATF to the O-ring prior to assembling.

(b) Coat the underdrive brake piston with ATF.

9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUBASSEMBLY
(a) Place SST on the return spring and compress the return spring with a press.
(b) Using a snap ring expander, install the snap ring to the transaxle case.

NOTICE:
^ Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, to prevent the spring sheet from deforming.
^ Do not expand the snap ring excessively.
^ Installing the spring subassembly, check all of the springs are fit in the piston correctly.
^ The snap ring should be fixed surely in the groove of the transaxle case.

10. INSTALL BREATHER PLUG NO.2 (ATM)

11. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counter drive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010

NOTICE:
^ Do not apply excessive pressure to it.
^ Press-fit the bearing outer race until it contacts the transaxle case.

12. INSTALL COUNTER DRIVE GEAR
(a) Coat the counter drive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010

NOTICE: Do not apply excessive pressure to it.

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09223-15030

NOTICE: Do not apply excessive pressure to it.

13. INSTALL 1ST & REVERSE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st & reverse brake piston.

NOTICE:
^ Assemble the O-ring carefully not to have a twist and a pinching.
^ Apply enough ATF to the O-ring prior to assembling.

(c) Coat a 1st & reverse brake piston with ATF, install it to the transaxle case.

NOTICE: Be careful not to damage the O-ring.

14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUBASSEMBLY
(a) Place SST on the return spring and compress the return spring with a press.
SST 09387-00070
(b) Using a snap ring expander, install the snap ring to the transaxle case.

NOTICE:
^ Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
^ Do not expand the snap ring excessively.
^ Installing the spring subassembly, check all of the springs are fit in the piston correctly.
^ The snap ring should be fixed surely in the groove of the cylinder.
^ Fix the snap ring to the inside of the claw of the spring seat surely.

15. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.

NOTICE: Confirm the snap ring is fixed in the groove of the brake hub correctly.

16. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear assembly to the brake hub.

(b) Using SST and a press, press-fit the front planetary gear assembly.
SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)

NOTICE:
^ Do not apply excessive pressure to it.
^ Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right).

(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 210 - 350 Nm (2141 - 3569 kgf-cm, 155 - 258 ft. lbs.)

NOTICE: Assemble the washer after pressing each part, then tighten the nut to minimum tightening torque.

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
OK: Turning torque at 60 rpm
Bearing:
New Bearing: 0.51 - 1.02 Nm (5.1 - 10.0 kgf-cm, 4.4 - 8.7 inch lbs.)
Used Bearing: 0.26 - 0.51 Nm (2.7 - 5.2 kgf-cm, 2.3 - 4.5 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 inch).

(f) Tighten the nut gradually until the specified rotation torque of tapered roller bearing is measured.
Torque: 350 Nm (3569 kgf-cm, 258 ft. lbs.)

(g) Using a chisel and hammer, stake the front lock washer.

17. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assembly.

NOTICE:
^ Install the bearing race on the side of the front planetary carrier. Be careful about the orientation of the race.
^ Installing thrust bearing and front sun gears, be careful about the orientation of the parts.
^ Install the bearing race on the side of the front sun gear. Be careful about the orientation of the race.
^ Install the thrust bearing and the race after holding the parts on the rear planetary carrier by applying grease. Be sure the assembling order.

Thrust bearing and bearing race diameter: mm (inch):

18. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the rear planetary gear assembly to the rear planetary ring gear.

(b) Using a screwdriver, install the snap ring.

NOTICE: Confirm the snap ring is fixed in the groove of the 1st & reverse brake hub correctly.

19. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.

NOTICE: Be careful about the order of discs, plates and flange assembly.

20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
(a) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
(b) Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 inch)

HINT: Piston stroke = Dimension A - Flange thickness

Flange thickness: mm (inch):

21. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Install the second brake piston assembly 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 meet the specified value, replace the snap ring with new one.
^ After assembling, confirm that there is no clearance between the second brake cylinder and the fitting surface of the cylinder in the transaxle case.

22. INSTALL ONE-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.

NOTICE: Check the positioning direction of the outer sleeve.

23. INSTALL ONE-WAY CLUTCH ASSEMBLY
(a) Install the 1-way clutch inner race to the 1-way clutch.

NOTICE:
^ Check the direction of the inner race.
^ Confirm that the discrimination mark can be seen by the worker.

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

Bearing diameter: mm (inch):

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

24. INSTALL PLANETARY CARRIER THRUST WASHER NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, install it onto the planetary sun gear assembly.

NOTICE: After assembling, confirm that the projection should be fixed surely in the hole of the planetary sun gear assembly.

25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer No. 2 with yellow petrolatum, install it onto the rear planetary sun gear.

(b) Coat the bearing with yellow petrolatum, install it onto the rear planetary sun gear.

Bearing diameter: mm (inch):

(c) Install the rear planetary sun gear assembly to the rear planetary gear.

NOTICE: Installing the rear planetary sun gear assembly, confirm that the B1 discs engage.