Part 1 of 2
COMPONENT PARTS INSTALLATIONDisassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure again that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended Automatic Transmission Fluid (ATF): DEXRON(R)II
General Notice:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage and affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
3. Apply automatic transaxle fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keeps small parts in their place.
5. Do not apply adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, make sure to use new gaskets and O-rings.
7. Dry all parts with compressed air-never use shop rags.
8. Be sure to install the thrush bearings and races in the correct direction and position.
U/D Gear Unit Installation
1. INSTALL BEARING TO TRANSAXLE HOUSING
a) Using SST and a press, press the bearing in the transaxle housing.
SST 09350-32014 (09351-32140)
b) Install the bearing stopper with a bolt.
2. INSTALL NEW GASKET AND OIL PIPE APPLY COVER
Install a new gasket and oil pipe apply cover, and tighten the 3 bolts.
3. INSTALL OIL PIPES
a) Using a plastic hammer, install the oil pipes.
NOTICE: Take care not to bend or damage the pipes.
b) Install the 4 pipe clamps with bolts.
4. INSTALL BEARING TO TRANSAXLE CASE
Using SST and a press, press the bearing into the transaxle case.
SST 09350-32014 (09351-32090)
5. INSTALL B4 ACCUMULATOR PISTON AND SPRING
6. INSTALL OIL GALLERY COVER AND GASKET
a) Clean the threads of the screws and case with white gasoline.
b) Install a new gasket and oil gallery cover in place.
c) Install and tighten the 3 bolts.
d) Apply sealant to the 6 screws.
Sealant: Part No. 08833-00070, THREE BOND 1324 or equivalent
e) Using a torx wrench, install and tighten the 3 screws.
7. INSTALL MANUAL VALVE SHAFT AND LEVER
a) Install the parking lock rod to the manual valve lever.
b) Slide in the shaft and install the washer, a new spacer and the manual lever.
c) Install the retaining spring.
HINT: Make sure there is a washer between the retaining spring and case.
8. INSTALL PIN
a) Using a pin punch and hammer, drive in the pin.
b) Position the spacer and stake it.
9. INSTALL CAM GUIDE BRACKET
Install the cam guide bracket and then install the parking lock rod into the guide bracket.
10. INSTALL PARKING LOCK SLEEVE
Install the parking lock sleeve protruding portion upward.
11. PLACE STOPPER PLATE
Place the stopper plate on the protruding portion of lock sleeve.
12. INSTALL GUIDE SLEEVE AND SPRINGS
13. INSTALL PARKING LOCK PAWL, PAWL SHAFT AND SHAFT CLAMP
a) Install the parking lock pawl.
b) Insert the parking lock pawl shaft and install the shaft clamp.
14. INSTALL FIRST AND REVERSE BRAKE PISTON
a) Coat the O-rings with ATF.
b) Install 2 new O-rings to the piston.
c) Place the piston into the bore of the case, facing the spring seats upward.
d) Using SST, press in the piston.
SST 09350-32014 (09351-32040)
NOTICE: Be careful not to damage the O-rings.
e) Remove the SST.
15. INSTALL PISTON RETURN SPRING AND SNAP RING
a) install the piston return spring assembly and snap ring in place.
b) Set SST, and tighten the bolt gradually to compress the springs.
SST 09350-32014 (09351-32040)
NOTICE: Avoid bending the spring retainer by over tightening the bolt.
c) Using snap ring pliers, install the snap ring.
HINT: Visually check to make sure it is fully seated and centered by the three tugs on the spring retainer.
Make sure the end gap of snap ring is not aligned with the spring retainer claw.
d) Remove the SST.
16. INSTALL UNDERDRIVE BRAKE PISTON
a) Coat new O-rings with ATF.
b) Install the 2 new O-rings to the piston.
c) Place the piston into the case with the cup side up, being careful not to damage the O-rings.
17. INSTALL RETURN SPRING
18. INSTALL PLATES. DISCS AND FLANGE
a) Install the plates, discs and flange in order.
D = Disc P = Plate F = Flange
P-D-P-D-P-D-F
HINT: Install the flange with the flat end facing downward.
b) Place SST on the flange, and compress the flange with a press.
SST 09350-32014 (09351-32070)
c) Using a screwdriver, install the snap ring.
HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.
19. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES
Using compressed air (392 - 785 kPa, 4 - 8 kg-cm2, 57 - 114 psi), confirm that the underdrive brake piston moves smoothly.
20. INSTALL OIL SEAL RINGS TO TRANSAXLE CASE
Install the 2 oil seals to the transaxle case.
21. INSTALL UNDERDRIVE ONE-WAY CLUTCH
22. INSTALL ANTI-RATTLE CLIP
In the place shown in the illustration (the space between the one-way clutch outer race and case), push the anti-rattle clip in until you hear the "click".
23. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a) Align the flukes of discs in the underdrive brake.
b) Install the clutch assembly.
c) Turn the clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clock wise.
24. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the inner race.
Height: 17.3 - 18.2 mm (0.681 - 0.717 inch)
25. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH
a) Set a dial indicator and measuring terminal (SST) together.
SST 09350-32014 (09351-32190)
b) While applying and releasing the compressed air (392 - 785 kPa, 4 - 8 kg-cm2, 57 - 114 psi), measure the underdrive clutch piston stroke.
Piston stroke: 1.21 - 1.55 mm (0.0476 - 0.0610 inch)
If the piston stroke is less than limit, parts may have been misassembled. Check them.
If the piston stroke is non-standard, select another flange.
HINT: There are 3 different thicknesses for the flange.
Flange thickness:
2.30 mm (0.0906 inch)
2.50 mm (0.0984 inch)
2.70 mm (0.1063 inch)
26. INSTALL BEARING WITH CASE
Install the thrust bearing with race, with bearing facing upward.
27. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.
28. INSTALL COUNTER SHAFT ASSEMBLY
a) Align the flukes of the discs in the underdrive clutch.
b) Install the counter shaft assembly.
29. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.
Height: 33.3 - 35.5 mm (1.311 - 1.398 inch)
30. INSTALL THRUST NEEDLE BEARING
31. INSTALL COUNTER DRIVEN GEAR
Using SST and a press, press in driven gear.
SST 09350-31014 (09351-32100, 09351-32140)
32. TIGHTEN NEW LOCK NUT
a) Using SST to hold the driven gear, tighten a new lock nut.
SST 09330-00021, 09350-32014 (09351-32032)
Torque: 157 Nm (1,600 kg-cm, 116 ft. lbs.)
b) Remove the SST.
33. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.
End play: 0.23 - 0.89 mm (0.0091 - 0.0350 inch)
34. STAKE LOCK NUT
Using a pin punch and hammer, stake the lock nut.
35. INSTALL SNAP RING TO TRANSAXLE CASE
Using snap ring pliers, install the snap ring to the transaxle case.