Part 1 of 2
REASSEMBLYNOTICE:
^ The automatic transaxle is composed of highly precision-finished parts, which necessitates a 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 can work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies are 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
^ 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 but never use shop rags.
^ When using compressed air, always aim at a place 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 of the oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces should be coated with ATF before reassembly.
^ All of the gaskets and rubber O-rings should be replaced.
^ Do not apply adhesive cements to the gaskets and similar parts.
^ Make sure that the ends of the 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 when necessary. Use petroleum jelly to keep parts in place.
^ When working with FIPG material, the following must be observed.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
Thoroughly clean all the components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 15 minutes after the application. Otherwise, the packing (FIPG) material must be removed and reapplied.
BEARING AND RACES INSTALLATION POSITION AND DIRECTION
1. INSTALL DIFFERENTIAL GEAR LUBE APPLY PIPE
Install the apply pipe, and clamp it to the transaxle case with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
NOTICE: Make sure to insert the pipe into the stopper.
2. INSTALL U/D CYLINDRICAL ROLLER BEARING
a. Install the oil seal ring to the transaxle housing.
b. Using SST and a press, install the U/D cylindrical roller bearing.
SST 09950-60020 (09951-00770), 09950-70010 (09951-07100)
NOTICE: Do not apply excessive pressure to it.
3. INSTALL U/D BRAKE
a. Install the 2 oil seal rings to the transaxle case.
b. Wind a vinyl tape around SST at the place of 4.0 mm (0.157 inch) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).
SST 09950-60010 (09951-00320)
NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.
c. Using SST and a press, install the needle roller bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
NOTICE:
^ When the wound vinyl tape contacts the transaxle case, stop press-fitting.
^ Face up the inscribed mark side of the bearing race.
d. Coat 2 new O-rings with ATF and install them to the U/D brake piston.
e. Install the U/D brake piston to the transaxle case.
f. Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 14.04 mm (0.5528 inch)
g. Install the return spring.
h. Using SST, a snap ring expander and a press, install the piston return spring and snap ring to the transaxle case.
SST 09387-00020
NOTICE:
^ Press-fit the bearing race RH until it contacts the snap ring.
^ Do not apply excessive pressure to it.
^ Do not expand the snap ring excessively.
4. INSTALL COUNTER DRIVE GEAR
a. Using a screwdriver, install the snap ring to the transaxle case.
b. Using SST and a press, install the 2 bearing outer races to the transaxle case.
SST 09950-60020 (09951-00890), 09950-70010 (09951-07150)
NOTICE:
^ Press-fit the bearing race until it contacts the snap ring.
^ Do not apply excessive pressure to it.
c. Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09649-17010
NOTICE:
^ Press-fit the bearing inner race until it contacts the counter drive gear.
^ Do not apply excessive pressure to it.
d. Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09950-60010 (09951-00890), 09950-70010 (09951-07150)
NOTICE: Do not apply excessive pressure to it.
5. CHECK 1ST AND REVERSE BRAKE PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 17.61 mm (0.6933 inch)
6. INSTALL 1ST AND REVERSE BRAKE PISTON
a. Coat 2 new O-rings with ATF.
b. Install the 2 O-rings to the 1st and reverse brake piston.
c. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case.
d. Install the return spring.
e. Using SST a press, and snap ring pliers, install the piston return spring and snap ring to the transaxle case.
SST 09387-00070
NOTICE:
^ Stop the press when the spring sheet is lowered to the place of 1 - 2 mm (0.039 - 0.078 inch) away from the snap ring groove.
^ This prevents the spring sheet from being deformed.
^ Do not expand the snap ring excessively.
7. INSTALL FRONT PLANETARY GEAR ASSEMBLY
Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
8. INSTALL FRONT PLANETARY GEAR
a. Install the front planetary gear to the brake hub.
b. Using SST and a press, press-fit the front planetary gear.
SST 09950-60010 (09951-00400)
NOTICE: Do not apply excessive pressure to it.
c. Install the lock washer, as shown in the illustration.
d. Using SST, install the lock nut.
SST 09387-00030, 09387-00080
Torque: 21 Nm (2,141 kgf-cm, 155 ft. lbs.)
e. Using SST and a torque wrench, measure the turning torque at 60 rpmtorque of the bearing. When the measured value is not within the specified value, gradually tighten the lock nut until it reaches the specified value.
SST 09387-00080
Turning torque at 60 rpm: 0.51 - 1.02 Nm (5.0 - 10.0 kgf-cm, 4.3 - 8.7 inch lbs.)
f. Using a chisel and hammer, stake the lock washer.
g. Install the 2 bearings, race and front planetary sun gear to the front planetary gear.
Bearing and race diameter: mm (in.)
9. INSTALL REAR PLANETARY GEAR
a. Coat the bearing race with ATF, and install it to the rear planetary gear assembly.
Bearing race diameter:
b. Install the thrust washer No.2.
c. Install the rear planetary gear to the rear planetary ring gear.
d. Using a screwdriver, install the snap ring.
10. INSPECT DISC AND FLANGE OF 1ST AND REVERSE BRAKE
Check if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.
HINT:
^ If the lining of the disc is peeled off or discolored, replace all the discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
11. INSTALL 1ST AND REVERSE BRAKE
a. Install the 5 plates and 5 discs.
b. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
c. Select the appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 1.02 - 1.21 mm (0.0401 - 0.0476 inch)
HINT: Pack clearance= Dimension A - Flange thickness
Flange thickness = mm (in.)
d. Install the selected flange.
12. CHECK 2ND BRAKE PISTON RETURN SPRING
Using vernier calipers, measure the free length of the spring with spring seat.
Standard free length: 16.61 mm (0.6539 inch)
13. INSTALL 2ND BRAKE PISTON
a. Coat 2 new O-rings with ATF, and install them to the 2nd brake piston.
b. Install the 2nd brake piston to the 2nd brake cylinder.
c. Install the return spring to the 2nd brake piston.
d. Using SST, a press and a screwdriver, install the snap ring.
SST 09387-00060
14. INSTALL 2ND BRAKE CYLINDER ASSEMBLY, ONEWAY CLUTCH NO.1 AND REAR PLANETARY SUN GEAR ASSEMBLY
a. Install the 2nd brake cylinder assembly to the transaxle case.
b. Using a screwdriver, install the snap ring.
NOTICE: Because the tapered snap ring has its own positioning direction, check It when Installing.
c. Using vernier calipers, measure the inside diameter.
Inside diameter: More than 167 mm (6.57 inch)
NOTICE: When the diameter does not satisfy the specified value, replace the snap ring with new one.
d. Install the one-way clutch outer race sleeve to the 2nd brake cylinder assembly.
NOTICE: Check the positioning direction of the outer sleeve.
e. Install the inner race to the one-way clutch.
NOTICE: Check the direction of the inner race.
f. Check the rotating direction of the one-way clutch for the lock or free operation, as shown in the illustration.
HINT: The rotating direction of the inner race is only counterclockwise.
g. Install the one-way clutch No. 1 and bearing to the one way clutch outer race sleeve.
Bearing diameter: mm (in.)
NOTICE: Install the thrust bearing properly so that no color race will be visible.
h. Coat the thrust washer No. 1 with petroleum jelly and install it onto the rear planetary sun gear.
(1) Coat the bearing with petroleum jelly and install it onto the rear planetary sun gear.
Bearing diameter: mm (in.)
i. Install the rear planetary sun gear assembly to the rear planetary gear.