Part 1
CAUTION:Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. O-ring of oil level dipstick need not be replaced.
Do not use grease other than petrolatum or industrial Vaseline.
Apply automatic transmission fluid to friction element, rotating parts, and sliding parts before installation. Use specified automatic transmission fluid.
New clutch disc should be immersed in automatic transmission fluid for more than two hours before installation. Do not apply sealer or adhesive to gaskets. When bushing must be replaced, replace assembly which includes it.
Do not use shop towels during disassembly and reassembly operation.
1. Before reassembling the transaxle, measure the end play in the low-reverse brake and select a pressure plate to obtain the specified end play. Use the following procedure.
a. Install the brake reaction plate, brake plates and brake discs in the transaxle case.
CAUTION: Blow off automatic transmission fluid from the plates and discs with low-pressure compressed air.
b. Install the pressure plate and mount the return spring.
c. Apply petrolatum jelly to the wave spring and attach the wave spring on the low-reverse brake piston.
d. Install the two O-rings removed during disassembly and coat them with automatic transaxle fluid.
e. Attach the special tool to the center support and install the support in the transaxle case.
CAUTION:
1. Install the center support, taking care that the waved spring is not out of position.
2. Install the two O-rings in alignment with the oil holes provided in the transaxle case.
f. Remove the special tool.
g. Install the snap ring.
h. Mount the special tool and dial indicator on the rear side of the transaxle case.
Make sure that the dial indicator rod (MD998913) is inserted into the transfer idler shaft hole, contacting the brake reaction plate at a right angle.
i. Using a hand pump, feed air through the location shown and, at the same time, read the dial indicator and select a pressure plate to obtain the specified end play.
Standard value: 0.8-1.0 mm (0.031 -0.039 in.)
j. After a pressure plate of the appropriate thickness has been selected, remove all the mounted parts.
2. Place the transaxle case on the workbench with the oil pan mounting surface up.
3. Insert the output flange in position (with two ball bearings and transfer drive gear attached) from the inside of the transaxle case.
4. Install the snap ring in the groove of the output flange bearing.
5. Apply petrolatum jelly to the spacer and attach the spacer to the case.
6. Install the bearing outer race and inner races in the transfer idler gear.
7. Install a new O-ring in the groove of the idler shaft, and apply a very thin coat of automatic transaxle fluid to the O-ring.
8. Place the transfer idler gear in the case, and insert and screw the idler shaft into position.
9. Screw in and tighten the idler shaft by using the special tool.
1O. Insert the special tool into the output flange and measure the preload using a low reading torque wrench.
Adjust the preload to the standard value by tightening or loosening the transfer idler shaft.
Standard value: 0.8 Nm (0.6 ft.Lbs.)
11. After completing the preload adjustment, install the idler shaft lock plate. The clearance between the idler shaft and the lock plate should be closed in the direction that will prevent idler shaft looseness, and then tighten the lock plate bolt to specified torque.
Tightening torque: 24 Nm (18 ft.lbs.)
12. Install a new O-ring in the groove of the transaxle case, and then install the bearing retainer.
13. Insert the transfer shaft in the case.
14. Mount the special tool on the transaxle case to support the transfer shaft.
15. Use the special tool to install the bearing inner race on the transfer shaft.
16. Install the tapered roller bearing outer race, and then the snap ring.
17. Use the special tool to install the transfer driven gear on the transfer shaft.
18. Install the snap ring on the end of the transfer shaft.
19. Coat thrust race # 13 with petrolatum jelly and attach it to the output flange.
IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS
20. Apply petrolatum jelly to thrust bearing # 12 and secure the bearing on the planetary carrier.
21. Mount the planetary carrier on the case.
22. Attach thrust race # 10 and thrust bearing # 9 to the forward sun gear. Then, assemble the reverse sun gear.
23. Install the sun gear assembly assembled in step 22 in the planetary carrier.
24. Put the brake disc and brake plate in position.
25. Install the brake pressure plate which was selected in Step 1.
26. Install the return spring.
27. Apply petrolatum jelly to the wave spring and attach the wave spring to the center support.
28. Install the two new O-rings on the oil pressure holes of the center support.
Coat the O-rings with automatic transaxle fluid.
29. Attach the special tool to the center support and install the support in the transaxle case.
CAUTION:
1. Install the center support, taking care that the waved spring is not out of position.
2. Install the two O-rings in alignment with the oil holes provided in the transaxle case.
30. Remove the special tool from center support.
31. Install the snap ring for the center support.
32. Install the anchor rod, in the transaxle case.
33. Install new seal rings in the grooves of the kickdown servo piston and coat the rings with automatic transaxle fluid.
34. Insert the kickdown servo spring and piston in the transaxle case.
35. Install a new O-ring and D-ring on the kickdown servo sleeve, and apply a very thin coat of automatic transaxle fluid to the rings.
36. Insert the kickdown servo sleeve in the transaxle case and install the snap ring.
37. Install the kickdown band; attach the ends of the band to the ends of the anchor rod and servo piston rod.
38. When putting the kickdown drum in the kickdown band, engage the splines of the kickdown drum with those of the reverse sun gear.