Part 2

13. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE




a. Place the No.2 one-way clutch with the shiny side of flange upward.




b. Install the one-way clutch while turning the planetary gear clockwise with SST.
SST 09350 - 32014 (09351 - 32050)

If can not turn the planetary gear clockwise, check the installation of the one-way clutch.




c. Install the snap ring.

HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.

d. Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear.




14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO.1 ONE-WAY CLUTCH




a. Coat the thrust washer with petroleum jelly and install it on the No.1 one-way clutch.




b. Place the No.1 one-way clutch onto the rear planetary gear.

16. INSTALL SECOND BRAKE




a. Install the flange, facing the flat end upward.
b. Install the three discs and plates.

Install in order: P = Plate D = Disc
D-P - D - P - D - P




c. Place the piston return spring into the case.

d. Place the second brake drum into the case. HINT: Align the groove of the drum with the bolt.




e. Place the snap ring into the case so that end gap is installed into the groove.




f. While compressing the piston return spring over the drum with hammer handles, install the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of cutouts.




17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the second brake drum.




18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and confirm that the piston moves.

19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM




a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.




b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.




20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

HINT: After installing the oil seal ring, check that it moves smoothly.

21. INSTALL FRONT PLANETARY GEAR




a. Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear.

Bearing outer diameter: 45.5 mm (1.791 in.)
Bearing inner diameter: 30.1 mm (1.185 in.)




b. Install the planetary gear onto the sun gear.




22. INSTALL FRONT PLANETARY RING GEAR




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

24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH




a. Coat the bearing with petroleum jelly and install it onto rear side of the forward clutch.

Bearing outer diameter:
47.6 mm (1.874 in.)

Bearing inner diameter:
31.4 mm (1.236 in.)




b. Coat the bearing with petroleum jelly and install it onto front side of the forward clutch.






HINT: There are two different - thick bearings for adjustment of the input shaft thrust play.




c. Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.




d. Mesh the hub of the forward clutch flukes of the direct clutch discs.

HINT: Be careful that the bearing and thrust washer do not get out of place.

e. Install the direct clutch and forward clutch into the case.






HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.




f. Check the distance between the direct clutch drum and the sun gear input drum.

Distance:
Approx. 3 mm (0.12 in.)

25. INSTALL OIL PUMP INTO CASE




a. Coat a new O-ring with ATF and install it to the oil pump.







b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

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

Torque: 22 N.m (225 kg.cm, 16 ft.lb)

26. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.

Thrust play:
0.25 - 0.90 mm (0.0098 - 0.0354 in.)

HINT: There are two different-thick bearings for end of stator shaft. If the thrust play is in excess of standard, select one of them.

Bearing thickness:
3.60 mm (0.1417 in.)
4.19 mm (0.1650 in.)

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

28. INSTALL SECOND COAST BRAKE PISTON




a. Coat the new O-ring with ATF and install it to the cover.
b. Install the outer spring with the piston.
c. Place the cover into the bore.




d. Using SST, install the snap ring while pressing the cover.

SST 09350 - 32014 (09351 - 32050)

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

29. CHECK SECOND COAST BRAKE PISTON STROKE




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




b. Using SST, measure the piston stroke applying and releasing the compressed air (392 - 785 kPa, 4 - 8 kg/sq.cm, 57 - 11 4 psi) a shown.

SST 09240 - 00020

Piston stroke:
2.0 - 3.5 mm (0.079 - 0.138 in.)

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

Piston rod length:
9.52 mm (3.748 in.)
96.3 mm (3.791 in.)

If the still more than standard value, replace the brake band with a new one.

HYDRAULIC CONTROL UNIT INSTALLATION

1. INSTALL ACCUMULATOR PISTONS AND SPRINGS







a. Install the new O-ring to the pistons.
b. Install the springs and pistons into the bores.




c. Place the cover with a new gasket and gradually tighten the bolts a little a time in sequence.

HINT: Each bolt length (mm, in.) is indicated in the figure.

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




2. PLACE NEW SECOND BRAKE APPLY GASKET




3. INSTALL SOLENOID WIRE




4. INSTALL THROTTLE CABLE

5. INSTALL VALVE BODY TO TRANSAXLE CASE

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




b. Lower the valve body into place.

NOTE: Do not entangle the solenoid wire.




c. Install and tighten the ten bolts.

HINT:
- Each bolt length mm, in.) is indicated in the figure.
- Hand tighten the ten bolts first, then torque with a torque wrench.

Torque: 11 N.m (110 kg.cm, 8 ft.lb)




6. INSTALL B3 APPLY TUBE

NOTE: Be careful not to bend or damage the tube.




7. INSTALL CONNECTOR CLAMP AND TUBE RETAINER

HINT: Each bolt length (mm, in.) is indicated in the figure.

Torque: 11 N.m (110 kg.cm, 8 ft.lb)




8. CONNECT SOLENOID CONNECTORS




9. INSTALL OIL TUBES
a. Using a plastic hammer, install the tubes into the positions indicated in the figure.
b. Install the bolt.

Torque: 5.4 N.m (55 kg.cm, 48 ft.lb)

HINT: Each bolt length (mm, in.) is indicated in the figure.

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

10. INSTALL MANUAL VALVE BODY AND DETENT SPRING






HINT: Each bolt length mm. in.) is indicated in the figure.

a. Align the manual valve with the pin on the manual shaft lever.
b. Lower the manual valve body into place.
c. Hand tighten the five bolts first. Then, tighten them with a torque wrench.

Torque: 11 N.m (110 kg.cm, 8 ft.lb)




d. Place the detent springs on the manual valve body and hand tighten the two bolts first.
Then, tighten them with a torque wrench.

Torque: 11 N.m (110 kg.cm, 8 ft.lb)

HINT: Each bolt length mm, in.) is indicated in the figure.

e. Check that the manual valve lever is touching the center of the detent spring tip roller.




11. INSTALL TUBE BRACKET AND OIL STRAINER
Each bolt length (mm. in.) is indicated in the figure.

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

Oil strainer
Torque: 11 N.m (110 kg.cm, 8 ft.lb)




12. INSTALL MAGNETS IN PLACE AS SHOWN

NOTE: Make sure that the magnets do not interfere with the oil tubes.




13. INSTALL OIL PAN WITH NEW GASKET
a. Install a new gasket and oil pan.
b. Install and torque new seventeen bolts.

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




14. INSTALL SPEED SENSOR
a. Install a new O-ring to the speed sensor.
b. Install the speed sensor to the transaxle case.
c. Tighten the bolt.
d. Connect the sensor connector.




15. INSTALL THROTTLE CABLE RETAINING PLAT

16. INSTALL NEUTRAL START SWITCH




a. Install the neutral start switch to the manual valve shaft.
b. Place the new locking plate and tighten the nut.
c. Stake the nut with locking plate.
d. Install the two bolts.




e. Adjust the neutral start switch.

HINT: Align the groove and neutral basic line.

f. Tighten the two bolts.

17. INSTALL UNION AND ELBOW




a. Install the new O-ring to the union and elbow.
b. Install the union elbow to the transaxle case.

Torque: 27 N.m (275 kg.cm, 20 ft.lb)






HINT: Install the elbow as shown in the illustration.




18. INSTALL MANUAL SHAFT LEVER