Part 2

REASSEMBLY

NOTICE:
- The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
- Recommended ATF: TYPE T-IV or equivalent
- All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
- Dry all parts with compressed air-never use shop rags.
- When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.
- The recommended automatic transaxle fluid or kerosene should be used for cleaning.
- After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly.
- When disassembling a valve body, be sure to match each valve together with the corresponding spring.
- New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.
- All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
- All gaskets and rubber O-rings should be replaced.
- Do not apply adhesive cements to gaskets and similar parts.
- Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
- If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.
- Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts in place.
- When working with FIPG material, you must observe the following.
Using a razor blade and a gasket scraper, remove all the old packing Formed In Place Gasket (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing Formed In Place Gasket (FIPG) material must be removed and reapplied.

18. INSTALL 2ND BRAKE
a. Install the 2nd brake piston sleeve.
b. U340E:
Install the 4 flanges and 3 discs.





c. U341E:
Install the 2 flanges, 4 discs and 3 plates.
Install in order: P = Plate, D = Disc, F = Flange
U340E: F - D - F - D - F - D - F
U341E: F - D - P - D - P - D - P - D - F





d. Using a vernier calipers, measure the dimension "A" in the illustration while pressing the disc and plate from the rear side.
Pack clearance: 0.847 - 1.247 mm (0.0333 - 0.0491 inch)

HINT: Pack clearance = Dimension A - Selected flange thickness - Snap ring thickness





Selected flange thickness: mm (inch)

19. INSTALL REAR PLANETARY SUN GEAR AND ONEWAY CLUTCH ASSEMBLY





a. Install the planetary carrier thrust washer No. 2 to the rear planetary sun gear.
b. Assemble the rear planetary sun gear and one-way clutch.





c. Install the planetary carrier thrust washer No. 1 and thrust needle roller bearing to the one-way clutch.





Bearing diameter: mm (inch)





d. Install the them to the transaxle case.





20. INSTALL DIRECT CLUTCH HUB
Install the thrust needle roller bearing, direct clutch hub, bearing, race and thrust needle roller bearing.





Bearing and race diameter: mm (inch)





21. INSTALL DIRECT & REVERSE CLUTCH ASSEMBLY
a. Install the bearing race to the 1st & reverse clutch.





Race diameter: mm (inch)

b. Install the 1st & reverse clutch assembly and thrust needle roller bearing to the transaxle case.





Bearing diameter: mm (inch)

22. INSTALL 2ND COAST & O/D BRAKE FLANGE, DISC AND PLATE
a. Using a screwdriver, install the snap ring.





b. Install the plates, discs and flange.
Install in order: D = Disc, F = Flange
F - D - F - D - F





c. Using a vernier calipers, measure the dimension "A" and "B" in the illustration while pressing the disc and plate from the rear side.
Pack clearance: 2.091 - 2.491 mm (0.0823 - 0.0981 inch)

HINT: Pack clearance = Dimension "A" - Dimension "B" - Selected flange thickness





Selected flange thickness: mm (inch)

d. Install the thrust needle roller bearing to the direct & reverse clutch assembly.





Bearing diameter: mm (inch)





23. INSTALL 4 NEW APPLY GASKETS
24. INSTALL TRANSAXLE REAR COVER





a. Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent





b. Install the transaxle rear cover and 11 bolts.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)





25. INSTALL COUNTER DRIVEN GEAR AND DRIVE PINION
Install the thrust needle roller bearing, counter driven gear and drive pinion to the transaxle case.





Bearing diameter: mm (inch)





26. INSTALL PARKING LOCK PAWL
Install the parking lock pawl, torsion spring and shaft to the transaxle case.





27. INSTALL FORWARD CLUTCH HUB
Install the forward clutch hub and thrust needle roller bearing.





Bearing diameter: mm (inch)

28. INSTALL FORWARD MULTIPLE DISC CLUTCH ASSEMBLY





a. Install the thrust needle roller bearing to the forward multiple disc clutch assembly.





Bearing diameter: mm (inch)





b. Install the forward multiple disc clutch assembly to the transaxle case.





29. INSTALL OIL PUMP
Install the 7 bolts and oil pump.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)





30. MEASURE INPUT SHAFT END PLAY
Measure the end play in axial direction.
End play: 0.37 - 1.29 mm (0.0146 - 0.0508 inch)
If the end play is not as specified, select and replace the thrust needle roller bearing.





31. INSTALL DIFFERENTIAL GEAR ASSEMBLY





32. INSTALL BRAKE DRUM GASKET





33. INSTALL 2 NEW APPLY GASKET
34. INSTALL TRANSAXLE HOUSING





a. Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent





b. Install the 14 bolts and transaxle housing.
Torque:
Bolt A: 29 Nm (300 kgf-cm, 21 ft. lbs.)
Bolt B: 22 Nm (220 kgf-cm, 16 ft. lbs.)
35. INSTALL MANUAL VALVE LEVER SHAFT
a. Coat a new oil seal lip with MP grease.
b. Install the oil seal to the transaxle case.
Oil seal in depth: 0 ± 0.5 mm (0 ± 0.0197 inch)
c. Install a new spacer to the manual valve lever.
d. Install the manual valve lever shaft and manual valve lever.





e. Using a pin punch and hammer, drive in the pin.





f. Turn the spacer and lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
g. Using a pin punch, stake the spacer through the small hole.
h. Check that the spacer does not turn.





i. Install the retainer spring.





j. Install the cam guide, bracket and 3 bolts.
Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.)
36. INSTALL ACCUMULATOR PISTON AND SPRING





a. Coat new 2 O-rings with ATF and install them to the B2 accumulator piston.
b. Install the spring and B2 accumulator piston.





Accumulator spring:





c. Coat new 2 O-rings with ATF and install them to the C3 accumulator piston.
d. Install the spring and C3 accumulator piston.





Accumulator spring:





e. Coat new 2 O-rings with ATF and install them to the C2 accumulator piston.
f. Install the spring and C2 accumulator piston.





Accumulator spring:





37. INSTALL CHECK VALVE
Install the spring and check valve.





38. INSTALL TRANSAXLE WIRE
a. Coat a new O-ring with ATF, install it to the transaxle wire.
b. Install the bolt and transaxle wire.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
39. INSTALL VALVE BODY ASSEMBLY





a. Install the valve body assembly and 13 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
b. Install the detent spring, detent spring cover and 2 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
Bolt length:
Bolt A: 22 mm (0.87 inch)
Bolt B: 32 mm (1.26 inch)
Bolt C: 45 mm (1.77 inch)
Bolt D: 55 mm (2.17 inch)
Bolt E: 14 mm (0.55 inch)





c. Connect the 5 solenoid connectors.
d. Coat a new O-ring with ATF, install it to the ATF temperature sensor.
e. Install the ATF temperature sensor, lock plate and bolt.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
Bolt length: 55 mm (2.17 inch)
40. INSTALL OIL STRAINER





a. Coat a new O-ring with ATF, install it to the oil strainer.





b. Install the oil strainer and 3 bolts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)





41. INSTALL OIL PAN AND GASKET
a. Install the 2 magnets in the oil pan.
b. Install a new gasket, oil pan and 19 bolts.
Torque: 7.8 Nm (80 kgf-cm, 71 inch lbs.)
42. INSTALL SCREW PLUG





a. Coat 4 new O-rings with ATF, install them to the screw plugs.
b. Install the 4 screw plugs.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





c. Coat a new O-rings with ATF, install it to the screw plug.
d. Install the screw plug.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)





43. INSTALL ELBOW AND UNION
a. Coat 2 new O-rings with ATF, install them to the elbow and union.
b. Install.the elbow and union.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
44. INSTALL PARK/NEUTRAL POSITION SWITCH





a. Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
b. Install a new lock washer and nuts.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)





c. Temporarily install the control lever.





d. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
e. Remove the control lever.





f. Align the groove with neutral basic line.
g. Tighten the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 11 inch lbs.)





h. Using a screwdriver, stake the nut with the lock washer.





i. Install the control lever, washer and nut.
Torque: 13 Nm (130 kgf-cm, 10 ft. lbs.)





45. INSTALL TRANSAXLE REVOLUTION SENSOR AND BREATHER PLUG
a. Coat a new O-ring with ATF, install it to the breather plug.
b. Install the breather plug, clip and breather hose.
c. Coat a new O-ring with ATF, install it to the transaxle revolution sensor.
d. Install the transaxle revolution sensor and bolt.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)