Part 3

Transmission Assemble

Tools Required

* DT 46451 (DW240-020) Brake Clutch Spring Compressor

* DT 46453 (DW240-170) Adapter Handle

* DT 46454 (DW240-050) Overdrive Brake Adapter

* DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut

* DT 46456 (DW240-060-02) Brake Spring Compressor Plate

* DT 46457 DW240-070) 1st/Reverse Brake Adapter

* DT 46460 (DW240-100) Counter Drive Gear Installation Adapter

* DT 46461 (DW240-130) Differential Preload Adapter

* DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter

* DT 46463 (DW 260-031-02) Transaxle Case Side Bearing Outer Race Adapter

* DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter

* DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer

* DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket

* DT 47521 (DW 260-031-02) Transaxle Case Oil Seal Installer

Assembly Procedure





99. Install the differential gear assembly to the transaxle case.





100. Install the direct clutch hub to the transaxle case.





101. Install the thrust bearing race and thrust needle roller bearing to the transaxle case.

* The race inner diameter is 20.5 mm (0.807 in).

* The race outer diameter is 32.6 mm (1.283 in).

* The bearing inner diameter is 17.8 mm (0.701 in)

* The bearing outer diameter is 30.2 mm (1.189 in).





102. Install the clutch assembly to the transaxle case.





103. Install the new apply gasket.





Important:
Check the direction of the bearing.


104. Install the thrust needle roller bearing to the transaxle case.

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





Notice:
Refer to Fastener Notice Fastener Notice in Cautions and Notices.

106. Install the 6 oil pump bolts.

Tighten the bolts to 25 Nm (18 lb ft).





Important:
If the end play is not as specified, select and replace the thrust needle roller bearing.


107. Measure the end play in axial direction.

* The end play is 0.3-0.9 mm (0.012-0.035 in).

* The bearing inner diameter is 32.5 mm (1.280 in).

* The bearing outer diameter is 48.5 mm (1.909 in).

* The bearing thickness is 4.21 mm (0.1657 in).

* The bearing inner diameter is 32.9 mm (1.295 in).

* The bearing outer diameter is 48.5 mm (1.909 in).

* The bearing thickness is 3.62 mm 0.1425 in).





108. Make sure that the input shaft rotates smoothly.





109. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or transaxle case.

110. Apply formed in place gasket (FIPG) to the transaxle housing.

FIPG: Three bond 1281 or equivalent, seal bend width is 1.2 mm (0.047 in).





111. Install the transaxle housing to the transaxle case with the 16 bolts.

Tighten the bolts to 29 Nm (22 lb ft).

112. Apply seal packing or equivalent to the 3 bolts indicated by arrows.





113. Coat a new O-ring (1) with ATF, install it to the transaxle wire.





114. Install the transaxle wire to the transaxle case with the bolt.

Tighten the bolts to 5.4 Nm (48 lb in).





115. Coat new 6 O-rings with ATF and install them to the pistons (1,2,3).

116. Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes.





117. Coat a new apply gasket with ATF, install it to the transaxle case.





118. Coat a new brake drum gasket with ATF, install it to the transaxle case.





119. Install the spring and check valve.





120. Connect the manual valve control rod to the manual valve lever as shown in the illustration.





Important:
When installing the valve body to the transaxle case, do not let each of the accumulator pistons incline. When installing the valve body to the transaxle case, do not hold the solenoids.


121. Install the valve body assembly to the transaxle case.

Tighten the bolts to 11 Nm (97 lb in).





122. Connect the transaxle wire connector and harness to the valve body assembly.

123. Connect the 5 connectors.

1. Lock-up control solenoid (5)

2. Pressure control solenoid (1)

3. No. 2 shift solenoid (2)

4. No. 1 shift solenoid (3)

5. Timing solenoid (4)

Important:
Make sure that the transaxle wire does not come out from the oil pan installations surface.


124. Install the TFT sensor with clamp.





125. Install a new gasket to the oil strainer.





126. Install the oil strainer to the valve body with the 3 bolts.

Tighten the bolts to 9.8 Nm (87 lb in).





127. Install the 2 magnets in the oil pan.





128. Install a new gasket to the oil pan and install them to the transaxle case with the 18 bolts.

Tighten the bolts to 7 Nm (62 lb in).





129. Install the output shaft speed (OSS) sensor.

Tighten the bolt to 7.4 Nm (65 lb in).





130. Install the No. 1 breather plug.

131. Install the input shaft speed (ISS) sensor with the bolt.

Tighten the bolts to the 5.4 Nm (48 lb in).





132. Coat the new O-ring the ATF, install it to the screw plug.

133. Install the screw plug to the transaxle case.

Tighten the bolts to 7.4 Nm (65 lb in).





134. Coat the 2 new O-rings with ATF, install them to the unions.

135. Install the 2 unions to the transaxle case.

Tighten the unions to 25 Nm (18 lb ft).





136. Install the PNP switch to the manual valve lever shaft and temporarily install the 2 adjusting bolts.

137. Install a new lock washer and nuts.

Tighten the nuts to 12 Nm (106 lb in).





138. Temporarily install the control lever.





139. Turn the lever counterclockwise until it stops, turn it clockwise 2 notches.

140. Remove the control lever.





141. Align the groove with the neutral basic line.

142. Tighten the 2 bolts.

Tighten the bolts to 5.4 Nm (48 lb in).





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





144. Install the control lever, washer and nut.

Tighten the nut to 12 Nm (106 lb in).





145. Install the torque converter (2) to the transaxle.

146. Measure the installation depth of the torque converter.

The standard value is 11.1 mm (0.44 in).

147. If the measured value is beyond the standard value, readjust the torque converter within the specified value.