Part 1

1. Using the special tool, press-fit the drive shaft oil seal.

CAUTION: Align with the case positioning boss and assemble so the oil seal flange pieces are on top when put in the car.




2. Using the special tool, install the rear output shaft oil seal.




3. Using the special tool, press-fit the outer race in the transaxle case.




4. Install the front output shaft assembly.




5. Position the solder approx. 10 mm (0.39 in.) long by 1.6 mm (0.063 in.) in diameter in the front bearing retainer in the position shown in the figure and then install the outer race.




6. Install tile front bearing retainer and tighten the bolt with the specified torque.

Front bearing retainer mounting bolts: 49 Nm (35 ft.lbs.)

7. Loosen the bolts and remove the front bearing retainer.

8. Remove the outer race from the front bearing retainer and remove the solder. If the solder does not break, perform the work in steps 5-8 with large diameter solder. Measure the thickness of the crushed solder with a micrometer and select a spacer with the correct thickness so the preload reaches the standard value.

Standard value: 0.055 - 0.115 mm (0.00217 - 0.00453 in.)




9. Install the spacer selected in the previous step and the outer race in the Front bearing retainer.

10. First install the front bearing retainer and apply sealant to the bolts and then tighten with the specified torque.

Specified sealant: 3M Stud Locking Part No.4170 or equivalent.

Front bearing retainer mounting bolts: 49 Nm (35 ft.lbs.)




11. Using a bearing puller, support the viscous coupling and insert in the case. Then, install the stopper ring.




12. Using the special tool, install the outer race in the center bearing retainer.




13. Install the center bearing retainer stopper bolt.

Center bearing retainer stopper bolt: 5.0 Nm (3.5 ft.lbs.)




14. Install the center bearing retainer so the protection of the stopper bolt fits in the groove of the center bearing retainer.




15. Install the special tool in the center differential and install the center differential in the transaxle case.




16. Position solder approx. 10 mm (0.39 in.) in length and 1.6 mm (0.063 in.) in diameter in the output bearing retainer as shown in the figure and then install the outer race.




17. Install the output bearing retainer and tighten the bolts with the specified torque.

Output bearing retainer mounting bolts: 24 Nm (17 ft.lbs.)

18. Loosen the bolts and remove the output bearing retainer.




19. remove the e outer race from the output bearing retainer and remove the solder. If the solder does not break, perform the work in steps 16-19 with large diameter solder. Measure the thickness of the crushed solder with a micrometer and select a spacer with the correct thickness so that the preload reaches the standard value.

Standard value: 0.075 - 0.135 mm (0.00295 - 0.00531 in.)

20. Install the spacer and the outer race selected in the previous step in the output bearing retainer.








21. Install a new O-ring in the outer circumference of the output bearing retainer.
22. Apply ATF to the O-ring, install the output bearing retainer and tighten the bolts with the specified torque.

Output bearing retainer mounting bolts: 24 Nm (17 ft.lbs.)




23. Insert the output flange in the case and install the snap ring on the outside circumference of the bearing.




24. Use new bolts when installing the bearing retainer.

Bearing retainer mounting bolts: 20 Nm (14 ft.lbs.)




25. Caulk the bolt heads.

26. Apply petrolatum to thrust bearing # 10 and stick in the planetary carrier.




27. Install the planetary carrier.




Identification Of Thrust Bearings, Thrust Races, Thrust Washers




28. Assemble the forward sun gear, thrust bearing # 9, thrust race # 8 and reverse sun gear.




29. Install the two sun gears assembled in the previous step in the planetary carrier




30. Install the reaction plate, brake disc and brake plate.

CAUTION: When using a new brake disc, first soak it for over 2 hours in ATF.




31. Install the pressure plate used during disassembly and then install the return spring.

CAUTION: Be sure to install the return spring in the correct direction.




32. Apply a coating of petrolatum to the waved spring and attach it to the center support.




33. Install the special tool on the center support, install new O-rings (2 locations) pressing them into the transaxle case.

CAUTION:

1. Apply ATF to the O-ring and align the oil hole.
2. Install so the waved spring is aligned.




34. Install the snap ring.




35. Measure the end play of the low reverse brake with a thickness gauge and select and adjust the pressure plate so it is within the standard value.

Standard value: 1.0 - 1.2 mm (0.039 - 0.047 in.)




36. Install the air exhaust plug and then install the plug.

Air exhaust plug: 33 Nm (24 ft.lbs.)




37. Install the anchor rod.




38. Install the kickdown servo spring, piston and sleeve.

CAUTION: The kickdown servo piston seal ring end should not coincide with the oil supply ports (arrows in figure on left).




39. Using the special tool, press in the kickdown servo piston and sleeve and install the snap ring.




40. Install the kickdown band.

CAUTION: Install so the direction indicated by the arrow is to the front.




41. Install thrust bearing # 4 and thrust washer # 2 in the rear clutch.




42. Assemble the rear clutch and front clutch.




43. Install thrust bearing # 5 in the rear clutch hub.




44. Install the rear clutch hub in the rear clutch.