Part 2

51. INSTALL SECOND COAST BRAKE BAND GUIDE
Install the band guide so that its tip touches the case.

52. INSTALL SECOND BRAKE INTO CASE




a. Install the flange, facing the flat end upward.




b. Install in order: Disc - plate - disc - plate - disc - plate




53. INSTALL PISTON RETURN SPRING ASSEMBLY
Install each of the springs over the protrusions in the case.




54. INSTALL SECOND BRAKE DRUM INTO CASE
Align the groove of the drum with the bolt and place it into the case.




55. INSTALL SNAP RING
a. Place the snap ring into the case so that the end gap is installed into the groove.
b. While compressing the piston return springs over the drum with hammer handles, install the snap ring. Be sure the end gap of the snap ring is not aligned with one of the cutouts.




56. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the oil passage of the case, and be sure that the piston moves.




57. INSTALL SECOND BRAKE DRUM GASKET
Install a new drum gasket until it makes contact with the 2nd brake drum.




58. INSTALL NO.1 ONE-WAY CLUTCH AND SECOND BRAKE HUB
a. Align the flukes of the discs in the 2nd brake.
b. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.




59. CHECK SECOND BRAKE HUB INSTALLATION DISTANCE
Check the distance between the surface of the 2nd brake hub and rear planetary gear.

Distance: Approx. 5 mm (0.20 in.)




60. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
While turning the sun gear clockwise, install it into the one-way clutch.




61. INSTALL RACE AND BEARING
Coat the race and the bearing with petroleum jelly and install them onto the planetary gear.




62. INSTALL FRONT PLANETARY GEAR




63. INSTALL RACES AND BEARING
Coat the races and the bearing with petroleum jelly and install them onto the planetary gear.

64. INSTALL FRONT PLANETARY RING GEAR




a. If the planetary gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.




b. Coat the race with petroleum jelly and install it onto the tip of ring gear flange.




c. Coat the race and bearing with petroleum jelly and install them.




65. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.

66. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH




a. Coat the race and bearing with petroleum jelly, and install them onto the forward clutch drum.
b. Coat the clutch drum thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.
c. Align the flukes of discs in the direct clutch.




d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.
e. If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch.




f. Place the direct clutch and forward clutch into the case.
g. While rotate the forward clutch to mesh the front planetary ring gear and discs.




h. Check the distance between the A and B as shown in the illustration.

Distance: Approx. 3 mm (0.118 in.)




67. INSTALL DIFFERENTIAL

68. INSTALL TRANSAXLE HOUSING




a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transmission case.
b. Apply seal packing to the transaxle housing as shown.

Seal packing: Part No. 08833-00090, THREE BOND 1131, LOCTITE 518 or equivalent




c. Install and tighten the eighteen bolts.

Torque: 300 kg.cm (22 ft.lb, 29 N.m)

NOTE: Each bolt length (mm) is indicated in the image.

69. CHECK PRE LOAD OF DIFFERENTIAL SIDE BEARING Service and Repair




70. INSTALL OIL PUMP INTO CASE
a. Coat the O-ring with ATF.
b. Install the O-ring around the pump body.
c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.

e. Install the six bolts.

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




71. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play in axial direction.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)

NOTE: There are two different thicknesses of races for the end of the stator shaft. If necessary, select one of them.

Race thicknesses:
0.8 mm (0.031 in.)
1.4 mm (0.055 in.)

72. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.




73. INSTALL SECOND COAST BRAKE PISTON
a. Install the outer spring with the piston.
b. Place the cover into the bore.
c. Using SST, install the snap ring while pressing the cover.

SST 09350-32013 (09351-32050)

d. Check that the front end of the piston rod contacts the center of the second brake band depression.

74. CHECK SECOND COAST BRAKE PISTON STROKE




a. Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.




b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

SST 09240-00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

If the stroke is more than standard value, replace the piston rod with a longer one.

Piston rod length:
72.9 mm (2.870 in.)
71.4 mm (2.811 in.)

Re-measure the stroke. If it is still more than standard value, replace the brake band with a new one.

75. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Coat new O-rings with ATF, install them to the pistons.







b. Install the pistons and springs.




c. install a new gasket and accumulator cover.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)




76. INSTALL SECOND BRAKE APPLY GASKET




77. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to damage the O-ring. Check for full seating.

CAUTION: In subsequent work, do not roll the case over the cable to avoid breaking the cable fitting.

78. INSTALL SOLENOID WIRE IN CASE

79. PLACE VALVE BODY ON TRANSMISSION




a. While holding the cam down with your hand, slip the cable end into the slot.




b. Connect the connecting rod to the manual valve lever.
c. Lower the valve body into place.




80. INSTALL THE TWELVE BOLTS IN VALVE BODY

NOTE: Each bolt length (mm) is indicated in the image.

Hand tighten all the bolts first. Then, tighten them with a torque wrench.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)




81. CONNECT SOLENOID CONNECTORS




82. INSTALL DETENT SPRING
a. Hand tighten all the bolts first. Then, tighten them with a torque wrench.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)

b. Check that the manual valve-lever is in contact with the center of the roller at the tip of the detent spring.




83. INSTALL OIL TUBES
a. Tap the tubes with a plastic hammer to install them into the positions indicated in the image.

CAUTION: Be careful not to bend or damage the tubes.

b. Install the oil tube clamp.




84. INSTALL OIL STRAINER

NOTE: Each bolt length (mm) is indicated in the image.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)




85. INSTALL OIL TUBE BRACKET
Each bolt length (mm) is indicated in the image.

Torque: 100 kg.cm (7 ft.lb, 10 N.m)




86. INSTALL MAGNETS IN PLACE AS SHOWN

CAUTION: Make sure that the magnet does not interfere with the oil tubes.




87. INSTALL OIL PAN WITH NEW GASKET

Torque: 50 kg.cm (43 in.lb, 4.9 N.m)

88. INSTALL SPEED SENSOR




a. Install a new gasket.
b. Install the sensor rotor adaptor.




c. Install the sensor rotor.




d. Install the sensor cover.
e. Install the speed sensor.




89. INSTALL THROTTLE CABLE RETAINING PLATE




90. INSTALL SOLENOID WIRE RETAINING PLATE
91. INSTALL NEUTRAL START SWITCH
Tighten the nut and stake it with the lock washer.

Torque: 70 kg.cm (61 in.lb, 6.9 N.m)




92. ADJUST NEUTRAL START SWITCH Neutral Start Switch
93. INSTALL MANUAL SHIFT LEVER
94. INSTALL THE OIL COOLER PIPES

Torque: 350 kg.cm (25 ft.lb, 34 N.m)