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 places.
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 ASSEMBLY




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. (A140E) INSTALL ROTOR SENSOR
Install the rotor sensor, facing the magnet outward.




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




6. INSTALL OUTER RACE
Using SST, drive the outer race into the case.

SST 09350-32014 (09351-32100, 09351-32140)




7. INSTALL NEW SPACER
Always use new spacer.

Install the spacer with the small end first.

8. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT




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




b. Using SST, driven in 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)

9. 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 (09351-32031)




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 - 16 kg-cm
(8.7 - 13.9 in-lb, 1.0 - 1.6 N.m)

Reused bearing 5 - 8 kg-cm
(4.3 - 6.9 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, 13 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. Position the retainer by tapping it while holding the differential case center with the retainer.
c. Clean the threads of the bolts and case with white gasoline.




d. Coat the threads of the bolts with sealer.

Sealer: 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: 730 kg-cm (53 ft-lb, 72 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 preload (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, redisassemble 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 sealer.

Sealer: 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 4-SPEED GEAR UNIT




1. (A140L)
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 dose not slide or the spring fall out when puller by hand.

2. INSTALL MANUAL VALVE SHAFT




a. Coat the oil seal lip with MP grease.
b. Install the manual valve shaft oil seal to the case.




c. Assemble a new collar to the manual valve lever.




d. Install the manual valve lever shaft to the transmission case through the manual valve lever.




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




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




g. Install the retaining spring.




h. 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 OVERDRIVE UNIT




a. Install the overdrive brake apply gasket and overdrive clutch apply gasket.




b. Install the overdrive brake drum to the case.
c. Install the new case gasket to the case.




d. Make sure that the length from the top surface of the case to the counter driven gear top surface should be about 24 mm (0.94 in.).




e. Install the overdrive unit with overdrive case to the transaxle case.
f. Install and tighten the bolts.

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




10. CHECK INTERMEDIATE SHAFT END PLAY
a. Make sure that the intermediate shaft has thrust Play.

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.

b. Make sure that the intermediate shaft turns smoothly.




11. 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
D-P-D-P-D-P-D-P-D-P-D

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




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




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

14. 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.