Part 1 of 3
COMPONENT PARTS INSTALLATIONBefore 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 ATF: DEXRON II
General Notes:
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 keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be 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 thrust bearings and races in the correct direction and position.
Transaxle Bearing Diameters
U/D Gear Unit Installation
1. INSTALL BEARING TO TRANSAXLE HOUSING
a. Using SST and a press, install the bearing into the transaxle housing.
SST 09350-32014 (09351-32140)
b. Install the bearing stopper with the bolt.
Torque: 17 Nm (170 kgf -cm, 12 ft. lbs.)
2. INSTALL OIL TUBES
a. Using a plastic hammer, install the 2 oil tubes.
NOTICE: Be careful not to bond or damage the tubes.
b. Install the 3 tube clamps.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
3. INSTALL BEARING TO TRANSAXLE CASE
Using SST and a press, install the bearing into the transaxle case.
SST 09350-32014 (09351-32090)
4. INSTALL B4ACCUMULATOR PISTON AND SPRING
5. 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 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
d. Apply seal packing or equivalent to the 6 screws.
Seal packing: Part No. 08833-00070, THREE BOND 1324 or equivalent
e. Using a torx wrench, install and tighten the 6 screws.
Torque: 7.0 Nm (75 kgf-cm, 65 inch lbs.)
6. 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 manual lever.
c. Install the retaining spring.
HINT: Make sure there is a washer between the retaining spring and case.
d. Using a punch and hammer, drive in the pin.
e. Position the spacer and stake it.
7. INSTALL PARKING LOCK PAWL
a. Install the cam guide bracket and then insert the parking lock rod into the guide bracket.
b. Install the parking lock sleeve protruding portion upward.
c. Place the stopper plate on the protruding portion of lock sleeve.
d. Install the guide sleeve and spring.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
e. Install the parking lock pawl.
f. Install the parking lock pawl shaft and install the shaft clamp.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
8. INSTALL FIRST AND REVERSE BRAKE
a. Install 2 new O-rings to the piston.
b. Coat the O-rings with ATF.
c. Place the piston into the bore of the case, facing the spring seats upward.
HINT: Be careful not to damage the O-rings.
d. Install the piston return spring assembly and snap ring in place.
e. Place SST on the return spring, and compress the return spring with a press.
SST 09350-32014 (09351-32040)
f. Using snap ring pliers, install the snap ring.
HINT: Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw.
9. INSTALL UNDERDRIVE BRAKE
a. Coat 2 new 0- rings with ATF.
b. Install the 2 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.
d. Install the return spring.
e. 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.
f. Place SST on the flange, and compress the flange with a press.
SST 09350-32014 (09351-32070)
g. 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.
10. CHECK PACK CLEARANCE OF UNDERDRIVE BRAKE
Using a dial indicator, measure the underdrive brake pack clearance.
Pack clearance (reference): 1.15 - 1.97 mm (0.0453 - 0.0776 inch)
If the pack clearance is non-standard, parts have been misassembled. Check them.
11. INSTALL OIL SEAL RINGS TO TRANSAXLE CASE
Install the 2 oil seal rings to the transaxle case.
12. INSTALL COUNTER DRIVE GEAR
a. Install the front bearing and spacer.
b. Using SST and a press, install the counter drive gear, front bearing, and a new spacer.
SST 09350-32014 (09351-32130, 09351-32150)
13. INSTALL INTERMEDIATE SHAFT
a. Install the intermediate shaft.
b. Using SST, install the lock nut.
SST 09960-10010 (09962-01000, 09963-01000)
14. CHECK DRIVE GEAR PRELOAD
Using a torque wrench, measure the starting torque of the counter drive gear.
Starting torque:
New bearing: 0.3 - 0.7 Nm (3.1 - 7.1 kgf-cm, 2.6 - 6.1 inch lbs.)
Reused bearing: 0.2 - 0.4 Nm (2.0 - 4.1 kgf-cm, 1.7 - 3.5 inch lbs.)
If the torque is exceeded, replace the spacer.
15. STAKE LOCK NUT
Using pin punch and hammer, stake the lock nut.
16. INSTALL UNDERDRIVE ONE-WAY CLUTCH
17. 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".
18. 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 clockwise.
19. 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)
20. 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 compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi), measure the underdrive clutch piston stroke.
Piston stroke: 1.50 - 1.90 mm (0.0591 - 0.0748 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 4 different thicknesses for the flange.
Flange thickness:
2.04 mm (0.0803 inch)
2.20 mm (0.0866 inch)
2.40 mm (0.0945 inch)
2.50 mm (0.0984 inch)
21. INSTALL BEARING WITH RACE
Install the thrust bearing with race, with the bearing facing upward.
Bearing:
Outer diameter 43.9 mm (1.728 inch)
Inner diameter 31.0 mm (1.220 inch)