Part 2

Transmission Assemble




45. Using a pin punch and hammer, drive in a new pin.




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




49. Install the manual detent spring with the bolt.

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




50. Install the parking lock shaft, torsion spring and parking lock pawl.




51. Check that the edge of the torsion spring fits into the groove securely.




52. Install the parking lock pawl bracket with the 2 bolts.

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




53. Using the DT 46460 (2) and the DT 46455 (1), install the planetary ring gear.
54. Before installing the planetary ring gear, be sure to replace the planetary ring flange of the planetary ring gear with a new one.




55. Fix the counter drive gear with the parking lock pawl.




56. Using the DT 46472 (1), install a new nut.

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




57. Using a small torque wrench, while turning to counter drive gear 100 turn per minute and measure the preload.

Tighten the nut to 29 Nm (22 lb ft) or less.

When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 Nm (0.43-3.12 lb in).

58. Stake the nut.




59. Install the planetary gear to the transaxle case.




60. Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear.




61. Install the No. 2 one-way clutch to the transaxle case.




62. Check that the planetary gear turns freely counterclockwise and locks clockwise.




63. Install the anti-rattle clip in the place shown in the illustration (the space between the No. 2 one-way clutch outer race and transaxle case), push the anti-rattle clip in until you hear the click.




64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

The standard free length is 15.85 mm (0.6240 in).





Important: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.


Important: Before assembling the new discs, soak them in ATF for at least 15 minutes.


65. Check to see if the sliding surface of the disc, plate and flange of 2nd brake are worn or burnt. Replace them, if necessary.





Important: Make sure the snap ring is installed in the groove of the transaxle case correctly.


66. Install the flange, 2 discs and 2 plates.
67. Install in this order 2-1-3-1-3, 1=Disc, 3=Plate, 2=Flange.
68. Install the 2nd brake return spring.




69. Coat 2 new O-rings (1) with ATF, install them to the 2nd brake piston.





Important: Be careful not to damage the O-rings.


70. Install the 2nd brake piston into the 2nd brake clutch cylinder.




71. Install the 2nd brake clutch cylinder to the transaxle case.




72. Using the DT 46455 (1) and DT 46458 (2), compress the 2nd brake piston return spring.

Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.


73. Using the screwdriver, install the snap ring.




74. Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear.

* The race inner diameter is 19.3 mm (0.760 in).
* The race outer diameter is 29.0 mm (1.142 in).




75. Install the front planetary sun gear to the transaxle case.




76. Install the thrust washer and one-way clutch assembly to the rear planetary sun gear.





Important: Check the direction of the bearing.


77. Coat the thrust bearing race with petroleum jelly and install it onto the rear planetary sun gear and one-way clutch assembly.

* The bearing inner diameter 42.5 mm (1.673 in).
* The bearing outer diameter 57.5 mm (2.264 in).




78. Install the rear planetary sun gear and one-way clutch assembly to the transaxle case.





Important: Check the direction of the race.


79. Coat the thrust bearing race with petroleum jelly and install it onto the transaxle case.

* The race inner diameter is 34.95 mm (1.3760 in).
* The race outer diameter is 45.50 mm (1.7913 in).





Important: Check the direction of the bearing.


80. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch hub.

* The bearing inner diameter is 33.3 mm (1.311 in).
* The bearing outer diameter is 46.5 mm (1.831 in).




81. Install the forward clutch hub to the transaxle case.




82. Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.

* The race inner diameter is 19.3 mm (1.760 in).
* The race outer diameter is 30.6 mm (1.205 in).




83. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.

* The race inner diameter is 18.1 mm (0.713 in).
* The race outer diameter is 28.2 mm (1.110 in).
* The bearing inner diameter is 18.1 mm (0.713 in).
* The bearing outer diameter is 29.6 mm (1.165 in).




84. Install the forward and reverse clutch assembly to the transaxle case.





Important: If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.


Important: Before assembling new discs, soak them in ATF for at least 15 minutes.


85. Check to see if the sliding surface of the disc, plate and flange of 2nd coast and O/D brake are worn or burnt. Replace them, if necessary.





Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.


86. Using a screwdriver, install the snap ring to the transaxle case.




87. Install the flange, 2 discs and 2 plates to the transaxle case.
88. Install in the following order: 3-2-3-2-1, 3=Plate, 2=-Disc, 1=Flange.
89. Clean the connected part the transaxle case and transaxle rear cover.




90. As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers (a).




91. As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
92. Calculate the piston stroke value using the following formula. Select a flange which satisfies the piston stroke value and install it.




93. Install 4 new apply gaskets to the transaxle rear cover.