Part 3 of 3

16. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
a. Coat the races and bearing with petroleum jelly, and install them onto the forward clutch drum.

Bearing:
Inner diameter 30.7 mm (1.209 inch)
Outer diameter 46.0 mm (1.811 inch)





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





c. Using a screwdriver, align the flukes of the discs in the direct clutch.





d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.

HINT: If the flukes of the discs are meshed correctly, the end of the bushing with the direct clutch will be flush with the surfaces of the forward clutch.





e. Place the direct clutch and forward clutch into the case.
f. While rotating the forward clutch to mesh the front planetary ring gear and discs, install them.





g. Check the distance between A and B.

Distance: Approx. 3 mm (0.118 inch)





17. INSTALL SECOND COAST BRAKE PISTON
a. Install 2 new O-rings to the cover.

HINT: Coat the O-rings with ATF before installing.





b. Install the spring, piston and cover into the bore.





c. Using SST, install the snap ring.
SST 09350-32014 (09351-32050)





18. MEASURE PISTON STROKE OF SECOND COAST BRAKE
a. Apply a small amount of paint to the piston rod at the point it meets the case.





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm, 57 - 114 psi).
SST 09240-00020

Piston stroke: 1.5 - 3.0 Nm (0.059 - 0.118 inch)

If the piston stroke exceeds the limit, select a new piston rod.





19. INSTALL APPLY GASKET





20. INSTALL DIFFERENTIAL





21. INSTALL APPLY TUBE
a. Using a plastic hammer, install the apply tube.

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





b. Install the apply tube bracket.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





22. INSTALL TRANSAXLE HOUSING
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle housing or transaxle case.
b. Apply seal packing to the transaxle housing.

Seal packing: Part No. 08826-00090, THREE BOND 1131 or equivalent





c. Apply sealant to the 35 mm bolt threads.

Sealant: Part No. 08826-00090, adhesive 1281, or equivalent

d. Install and tighten the bolts.

Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

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

Bolt length:
30 mm (1.18 inch)
35 mm (1.38 inch)





23. CHECK PRELOAD OF DIFFERENTIAL SIDE BEARING
24. INSTALL OIL PUMP INTO CASE
a. Coat a new O-ring with ATF, and install it to pump body.





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

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





d. Install and tighten the 6 bolts.

Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





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

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 inch)

If the play is not as specified, select and replace the race for the end of the stator shaft.

HINT: There are 2 different thicknesses of races. If necessary, select one of them.

Race thickness:
0.8 mm (0.031 inch)
1.4 mm (0.055 inch)





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





27. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Coat new O-rings with ATF, and install them to the pistons.
b. Install the pistons and springs to the case.

A245E





A246E









28. INSTALL SECOND BRAKE APPLY GASKET





29. INSTALL CHECK BALL BODY
Install the check ball body and spring.





30. INSTALL THROTTLE CABLE





31. INSTALL SOLENOID WIRE





32. INSTALL VALVE BODY
a. Install the connecting rod to the manual valve.
b. Install the E-ring to the connecting rod.





c. Install the manual valve to the valve body.





d. Connect the connecting rod to the manual valve lever.





e. Connect the throttle cable to the cam.





f. Install the 17 bolts.

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

Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
Bolt length:
20 mm (0.79 inch)
28 mm (1.10 inch)
50 mm (1.97 inch)





g. Install the wire retainer.

Torque: 6.4 Nm (65 kgf-cm, 56 inch lbs.)





33. INSTALL MANUAL DETENT SPRING

Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





34. CONNECT SOLENOID CONNECTOR





35. INSTALL OIL STRAINER
a. Install a new gasket to the oil strainer.





b. Install the oil strainer with the 3 bolts.

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

Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
Bolt length:
12 mm (0.47 inch)
20 mm (0.79 inch)





36. INSTALL 2 MAGNETS IN [1][2]OIL PAN





37. INSTALL [1][2]OIL PAN
a. Install a new gasket to the oil pan and install them to the transaxle.
b. Tighten the 18 bolts.

Torque: 5.2 Nm (54 kgf-cm, 47 inch lbs.)





38. INSTALL THROTTLE CABLE RETAINING BOLT

Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)

39. INSTALL SOLENOID WIRE RETAINING BOLT

Torque: 6.5 Nm (56 kgf-cm, 49 inch lbs.)





40. INSTALL UNIONS
a. Install new O-rings to each union.
b. Install the unions to the transaxle case.

Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





41. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch to the manual valve shaft.
b. Place a new locking plate and tighten the nut.

Torque: 12 Nm (125 kgf-cm, 9 ft. lbs.)

c. Temporarily install the 2 bolts.








d. Temporarily install the manual shift lever.
e. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
f. Remove the manual shift lever.





g. Align the groove and neutral basic line.
h. Install and tighten the 2 bolts.

Torque: 5.3 Nm (54 kgf-cm, 49 ft. lbs.)





i. Using a screwdriver, stake the nut with the nut stopper.








42. INSTALL MANUAL SHIFT LEVER
43. INSTALL FILLER TUBE AND TRANSAXLE DIPSTICK
44. INSTALL 2 OIL COOLER PIPES
45. INSTALL BREATHER HOSE