Part 3

Automatic Transaxle Assembly (Continued)

37. Assemble a new D-ring and new seal rings to the turbine shaft using the following procedure:

CAUTION:
- If a D-ring is reused it could cause ATF leakage, therefore use a new D-ring.
- If a seal ring is reused it could cause ATF leakage, therefore use a new seal ring.

1. Apply ATF (ATF FZ) to the new D-ring and new seal rings.

2. Assemble the new D-ring and new seal rings to the turbine shaft using the procedure shown in the figure:.

38. Assemble together the clutch component, turbine shaft, high clutch hub, low clutch hub, and thrust needle bearing using the following procedure:

1. Assemble the parts using the procedure shown in the figure:

NOTE: For the high clutch hub and low clutch hub assembly, assembly is easier if the work is performed using the following procedure:

- High clutch hub

1. Place the assembled parts on the workbench with the clutch component situated sideways.

2. While rotating the high clutch hub, engage the splines of each of the high clutch drive plates one by one, and assemble.

- Low clutch hub

1. Place the assembled parts on the workbench with the clutch component situated sideways.

2. While rotating the low clutch hub, engage the splines of each of the low clutch drive plates one by one, and assemble.

2. To verify that the parts are securely assembled together, measure the distance shown in the figure.

NOTE: Recommended measuring instrument: Vernier caliper

Specification
63.9-66.0 mm {2.52-2.59 in}

- If not within the specification, disassemble the assembled parts and reassemble.

39. Assemble the parts which were assembled together in Step 38 using the following procedure:

1. Assemble the parts assembled together in Step 38.

2. To verify that the parts are securely assembled, measure the distance shown in the figure.

A : Transaxle case end (alignment surface with converter housing)
B : Clutch component end

NOTE: Recommended measuring instrument: Depth gauge, straight edge ruler

Specification
11.6-14.8 mm {0.457-0.582 in}

- If not within the specification, remove the parts and perform re-assembly from Step 38.

NOTE: Measurement method

1. Set two straight edge rulers along the alignment surface of the transaxle case with the converter housing as shown in the figure.

A : Straight edge ruler

2. Measure the positions (2 locations) shown in the figure using a depth gauge and calculate the average value.
3. Subtract the thickness of the straight edge ruler from the average value.

40. Assemble the thrust needle bearing.

NOTE: Thrust needle bearing size: Outer diameter approx. 72.7 mm {2.86 in}

41. Assemble the oil pump using the following procedure:.

1. Assemble the oil pump.

2. Assemble and tighten the bolts shown in the figure.

NOTE: Bolt size: M8x1.25 bolt, length to approx. 31 mm {1.2 in}

Tightening torque
19-25 N.m {2.0-2.5 kgf.m, 15-18 ft.lbf}

42. Assemble the baffle plate.

43. Assemble the converter housing using the following procedure:

1. Assemble new O-rings using the following procedure:

CAUTION: If an O-ring is reused it could cause ATF leakage, therefore use a new O-ring.

1. Apply ATF (ATF FZ) to the new O-rings.
2. Assemble the new O-rings in the order shown in the figure.

2. Remove any remaining old sealant on the contact surfaces of the transaxle case and converter housing, and degrease the contact surfaces.

CAUTION: When degreasing and if degreaser is used, use a rag saturated with degreaser and be careful not to allow degreaser to penetrate the interior of the transaxle.
In addition, after degreasing, visually verify that there is no foreign matter (such as old sealant, cloth fibers) which has penetrated the interior of the transaxle.

3. Apply sealant (silicone sealant TB1217E) to the transaxle case.

CAUTION: If sealant is applied excessively or applied to a part other than the indicated part, the O-ring could deform and the sealant could penetrate the oil passage. Apply an appropriate amount of sealant to the indicated part.

NOTE: Sealant application amount (bead thickness): dia. 1.8-2.5 mm {0.071-0.098 in}

4. Assemble the converter housing before the applied sealant starts to harden.

5. Assemble and temporarily tighten the bolts to the positions shown in the figure.

NOTE: Bolt size: M8x1.25 bolt, length to approx. 28 mm {1.1 in}

6. Assemble and temporarily tighten the new bolts to the positions shown in the figure.

CAUTION: The bolts for the assembly are applied with sealant. If the bolts are reused it could cause ATF leakage, therefore use new bolts.

NOTE: Bolt size: M8x1.25 bolt, length to approx. 28 mm {1.1 in} (with sealant applied)

7. Tighten the bolts shown in the figure.

Tightening torque
19-25 N.m {2.0-2.5 kgf.m, 15-18 ft.lbf}

44. Assemble the front sun gear.

45. Assemble the rear sun gear.
46. Assemble the rear planetary gear using the following procedure:

1. Assemble the rear planetary gear.

NOTE: If the rear planetary gear assembly is difficult, assembly is easier if the work is performed using the following procedure:

1. Rotate and adjust the rotation handle of the engine stand so that the end cover side is situated sideways.

2. While rotating the rear planetary gear, engage the splines of each drive plate of the low and reverse brake one by one, and assemble.

2. To verify that the rear planetary gear is securely assembled, measure the distance shown in the figure.

A : Transaxle case end (alignment surface with end cover)
B : Rear planetary gear end

NOTE: Recommended measuring instrument: Depth gauge, straight edge ruler

Specification
32.8-35.1 mm {1.30-1.38 in}

- If not within the specification, remove the rear planetary gear and reassemble.

NOTE: Measurement method

1. Set two straight edge rulers along the alignment surface of the transaxle case with the end cover as shown in the figure.

A : Straight edge ruler

2. Measure the positions (2 locations) shown in the figure using a depth gauge and calculate the average value.
3. Subtract the thickness of the straight edge ruler from the average value.

47. Assemble the thrust needle bearing.

NOTE: Thrust needle bearing size: Outer diameter approx. 44 mm {1.7 in}

48. Assemble the reduction sun gear.

49. Assemble the thrust needle bearing.

NOTE: Thrust needle bearing size: Outer diameter approx. 61.5 mm {2.42 in}

50. Assemble the shim using the following procedure:

NOTE: Shim size: Outer diameter approx. 59.5 mm {2.34 in}

1. Measure the total end play and select the appropriate shim. (See TOTAL END PLAY MEASUREMENT/ADJUSTMENT.)

CAUTION: The total end play is the play (gap) in the axial direction of each planetary gear. If the total end play adjustment is not performed, it may cause damage to the thrust needle bearing between each planetary gear or other parts.

2. Assemble the selected shim in Step (1).

A : Selection

51. Assemble the end cover component using the following procedure:

1. Assemble new O-rings using the following procedure:

CAUTION: If an O-ring is reused it could cause ATF leakage, therefore use a new O-ring.

NOTE: O-ring size: Outer diameter approx. 15.6 mm {0.614 in}, thickness approx. 2.4 mm {0.094 in}

1. Apply ATF (ATF FZ) to the new O-rings.
2. Assemble the new O-rings.

2. Remove any remaining old sealant on the contact surfaces of the transaxle case and end cover, and degrease the contact surfaces.

CAUTION: When degreasing and if degreaser is used, use a rag saturated with degreaser and be careful not to allow degreaser to penetrate the interior of the transaxle.
In addition, after degreasing, visually verify that there is no foreign matter (such as old sealant, cloth fibers) which has penetrated the interior of the transaxle.

4. Assemble the end cover component before the applied sealant starts to harden.

NOTE: Adjust the oil pipe and assemble the end cover component so that the oil pipe is assembled to the end cover oil passage.

A : End cover oil passage
B : Oil pipe

5. Assemble and temporarily tighten the bolts to the positions shown in the figure.

NOTE: Bolt size: M8x1.25 bolt, length to approx. 21 mm {0.83 in}

7. Tighten the bolts shown in the figure.

Tightening torque
19-25 N.m {2.0-2.5 kgf.m, 15-18 ft.lbf}

52. Assemble the control valve body using the following procedure:.

CAUTION: Do not drop or apply an impact to the control valve body. Replace the control valve body with a new one if it was dropped or received an impact.

1. Assemble new gaskets using the following procedure:

CAUTION: If a gasket is reused it could cause ATF leakage, therefore use a new gasket.

1. Apply ATF (ATF FZ) to the new gaskets.
2. Assemble the new gaskets.

2. Assemble the dowel pins.

CAUTION: Do not assemble the dowel pin using a tool such as a hammer to prevent damaging the part. For the dowel pin assembly, only insert the dowel pin to the transaxle case assembly hole by hand.

3. Assemble the control valve body.

CAUTION:
- Assemble the control valve body at a straight angle so that force is not applied to the control valve body connector in the lateral direction.
- Assemble the control valve body so that the TCM, turbine/input shaft speed sensor, and the output shaft speed sensor do not contact the transaxle case.

A : Control valve body connector
B : TCM
C : Output shaft speed sensor
D : Turbine/input shaft speed sensor

CAUTION: Adjust the manual valve and assemble the control valve body so that the parking assist lever component end is engaged with the manual valve.

A : Parking assist lever component
B : Manual valve

4. Assemble and tighten the bolts shown in the figure.

NOTE: Bolt size: M6x1.0 bolt, length to approx. 30 mm {1.2 in}

Tightening torque
9-10 N.m {92-101 kgf.cm, 80-88 in.lbf}

5. Move the manual valve in the direction shown in the figure and verify that the manual valve is engaged with the parking assist lever component end.

A : Manual valve

NOTE: If the manual valve is only moved for excessive play on both surfaces of the parking assist lever component and the manual valve, the manual valve is correctly connected to the parking assist lever component.

- If there is a malfunction, remove the control valve body and reassemble.