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 plate, and brake disc in the transaxle case.
CAUTION: Blow off automatic transmission fluid from the plates and discs with low-pressure compressed air.
b. Install the appropriate pressure plate and mount the return spring.
CAUTION: Make sure that the return spring is mounted in the correct direction.
c. Apply petrolatum jelly to the wave spring and attach the wave spring on the center support.
d. Install the two O-rings removed during disassembly and coat them with automatic transmission 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: 1.0-1.2 mm (0.039-0.047 in.)
j. After a pressure plate of the appropriate thickness has been selected, remove all the mounted parts.
2. Using the special tools, drive the transfer shaft bearing outer races into position.
3. Insert the transfer shaft in the case.
4. Mount the special tool on the transaxle case to support the transfer shaft.
5. Install the thickest spacer, 1.80 mm (.071 in.).
6. Install the transfer driven gear on the transfer shaft.
7. Remove the special tool and secure the transfer shaft in position.
8. Put on the lock nut and tighten it to specified torque.
CAUTION: The lock nut is a left-handed screw.
Tightening torque: 215 Nm (156 ft.lbs.)
9. Measure the end play while sliding the transfer shaft in and out, and select a spacer to obtain the specified end play.
Standard value: 0-0.025 mm (0-0.001 in.)
1O. Bend the locking tab of the lock nut.
11. Place the transaxle case on the workbench with the oil pan mounting surface down.
12. Insert the output flange in position (with two ball bearings and transfer drive gear attached) from the inside of the transaxle case.
13. Install the snap ring in the groove of the output flange bearing.
14. Apply petrolatum jelly to the spacer and attach the spacer to the case.
15. Install the bearing outer race and inner races in the transfer idler gear.
16. Place the transfer idler gear in the case, and insert and screw the idler shaft into position.
17. Screw in and tighten the idler shaft by using the special tool.
18. 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.)
19. 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 the specified torque.
Tightening torque: 54 Nm (40 ft.lbs.)
20. Install the bearing retainer.
21. Tighten the screw to specified torque.
CAUTION: The screw should not be reused.
Tightening torque: 20 Nm (15 ft.lbs.)
22. Lock the screw head in place using a chisel.
23. Apply petrolatum jelly to thrust bearing # 12 and secure the bearing on the planetary carrier.
24. Mount the planetary carrier on the case.
25. Attach thrust race # 10 and thrust bearing # 9 to the forward sun gear. Then, assemble the reverse sun gear.
26. Install the sun gear assembly assembled in step 25 in the planetary carrier.
Identification Of Thrust Bearings, Thrust Races, And Thrust Washers
27. Put the brake disc and brake plate in position.
28. Install the pressure plate which was selected in Step 1.
29. Install the return spring.
30. Apply petrolatum jelly to the wave spring and attach the wave spring to the center support.
31. Install the two new O-rings on the oil pressure holes of the center support.
Apply automatic transmission fluid to the O-rings.
32. Attach the special tool to the center support. Install the center support slowly in the transaxle case, grasping the special tool.
CAUTION:
1. During installation, take care not to let the wave spring drop which was applied in Step 30.
2. Install the two O-rings in alignment with the oil holes provided in the transaxle case.
33. Remove the special tool from the center support.
34. Install the snap ring to secure the center support. The snap ring ends should not interfere with the pulse generator mounting hole.
35. Install the anchor rod, in the transaxle case.
36. Install a new teflon seal ring and a new O-ring in the grooves of the kickdown servo piston, and apply automatic transaxle fluid to the rings.
37. Install a new O-ring to the groove of kickdown servo sleeve, and apply automatic transaxle fluid to the ring.
38. Assemble the kickdown servo piston with the sleeve.
39. Put the spring on the kickdown servo piston and sleeve assembly, and insert them together in the transaxle case, making sure that the end gap of the teflon seal ring of the kickdown servo piston does not interlace with the fluid apply hole provided in the servo bore of the transaxle case.