Assembly

Part 2 Of 4:

1. Align the bearing cover with guide bolts as shown, and press it in.

Tightening torque: 96-120 inch lbs. (10.8-13.7 Nm)

2. Install the idler gear and output gear as an assembly by tapping it with a plastic hammer.
3. Install the bearing housing.
A. Install the bearing housing on the converter housing.

B. Align the groove on the idler shaft with the mark on the bearing housing.
C. Tap a new roll pin in with a pin punch and hammer.
D. Install mounting bolts.

Tightening torque: 14-18 ft. lbs. (19-25 Nm)

4. Install the parking pawl.
A. Install the parking pawl and shaft.
B. Install the spring and snap ring.
C. Move the manual shaft and verify that the parking pawl operates.

5. Install solenoid harness.
A. Install new O-ring onto harness connector.
B. Insert solenoid harness connector into transaxle case.

6. Install the actuator support with new bolts.

Tightening torque: 11-13 ft. lbs. (15-17 Nm)

7. Install the detent lever and return spring.

8. Install the parking assist lever.

9. Install the lever holder and bolt.

Tightening torque: 69.6-94.8 inch lbs. (7.9-10.7 Nm)

10. Install the manual shaft and manual plate.
A. Install the manual plate, washer, and nut.
B. Tighten the nut to the specified torque.

Tightening torque: 31-40 ft. lbs. (42-54 Nm)

11. Install the differential assembly into the converter housing. Install SST (side gear holder).
12. Install a new oil control ring onto the output gear assembly.
13. Install the output shell to the output gear and install the bearing race onto the output shell.

Thrust bearing outer diameter: 2.84 inch (72.1 mm)

14. Apply a thin coat of silicone sealant to the contact surfaces of the converter housing and transaxle case.
15. Install the new O-rings onto the converter housing.

NOTICE: Insure that sealer will not be forced into the oil passages when the transaxle case is installed.

16. Mount the transaxle case to the converter housing.

Tightening torque: 28-38 ft. lbs. (38-51 Nm)

17. Install engine mount No. 1.

Tightening torque: 43-49 ft. lbs. (58-66 Nm)

18. Install the SST (or equivalent) to hold the turbine shaft.

19. Install the turbine shaft and 3-4 clutch assembly.
A. Assemble the turbine shaft and 3-4 clutch assembly.

B. Verify that the thrust bearing is properly installed.
C. Install the turbine shaft and 3-4 clutch assembly into the transaxle case as an assembly.

20. Install the internal gear.
A. Install the internal gear to the output shell.
B. Install the snap ring.

21. Install the planetary carrier assembly.
A. Verify that the thrust bearing and bearing race are properly installed.

B. Hold the turbine shaft with one hand to prevent if from rotating.
C. Install the planetary carrier assembly into the 3-4 clutch drum by rotating it.

22. Install the low and reverse brake drive and driven plates.

NOTICE: Installation order - Driven-Drive-Driven-Drive-Driven-Drive-Driven-Drive

23. Install the retaining plate.
24. Install the snap ring.

25. Install the one-way clutch No. 2.
A. Hold the one-way clutch No. 2 horizontally.
B. Install it by turning the planetary carrier counterclockwise.
C. Install the snap ring.

26. Install the anchor strut and shaft.

NOTICE: Interlock the 2-4 brake band and anchor strut as shown.

27. Install the 2-4 brake band in the transaxle case so that it is fully expanded.

28. Install the small sun gear and one-way clutch No. 1.
A. Verify that the thrust bearing and bearing race are installed in the correct position.

B. Install the small sun gear and one-way clutch No. 1 while rotating it.

29. Install the reverse/forward clutch assembly.
A. Verify that the thrust bearing is installed in the correct position.

B. Install the reverse/forward clutch assembly while rotating it.

NOTICE: Measure the height difference between the reverse/forward drum and the transaxle case.

Maximum: 0.035 inch (0.9 mm)

30. Install the snap ring into the bottom ring groove of the turbine shaft.

31. Measure the total end play and select a suitable bearing race as follows:
A. Set the thrust bearing onto the reverse/forward clutch assembly.

B. Remove the previously used race and gasket.
C. Set the thickest bearing race 0.087 inch (2.2 mm) onto the oil pump.
D. Set the oil pump onto the clutch assembly.

NOTICE: Do not install the oil pump gasket at this time.

E. Measure clearance (A) between the transaxle case and the oil pump.

F. Select a suitable bearing race from the chart.

G. Remove the oil pump.
H. Place the selected bearing race and a new gasket onto the oil pump.
I. Install the oil pump onto the transaxle assembly.

Tightening torque: 14-18 ft. lbs. (19-25 Nm)

32. Verify 2-4 brake band adjustment as follows:
A. Install the servo piston to the SST.
B. Install the servo retainer O-ring onto the SST.
C. Coat the O-ring with ATF, install the band servo assembly and SST into the transaxle case and secure it with the snap ring.

NOTICE: Insure that the 2-4 brake band is correctly positioned against the band servo piston stem.

D. Set a dial indicator against the piston stem.

E. Apply compressed air through the fluid passage with a rubber-tipped air nozzle as shown and measure the piston stem stroke.

Air pressure: 57 psi (392 kPa) maximum
Stroke: 0.039-0.067 inch (1.0-1.7 mm)

F. If not within specification, select the proper piston stem from the chart.

G. Remove the band servo assembly and remove the SST.

NOTICE: Do not deform the snap ring when removing it.

33. Install the servo into the transaxle case.
A. Install the servo spring and servo assembly.
B. Install the snap ring.
C. Position the 2~ brake band onto the band servo piston stem.

34. Install the A/T control cable as follows:
A. Install a new O-ring on the bracket, then feed the A/T control cable through the transaxle case and connect it to the throttle cam.
B. Install the A/T control cable bracket and attaching bolts.

Tightening torque: 69.6-94.8 inch lbs. (7.9-0.7 Nm)

35. Align the manual valve with the pin on the manual plate and install the control valve body.

Tightening torque: 69.6-94.8inch lbs. (7.9-0.7 Nm)

Bolt length (measured from below the head):
(A): 1.181 inch (30 mm)
(C): 1.969 inch (50 mm)

36. Connect solenoid valve and ATF temperature sensor connectors.

NOTICE: Attach the magnets inside the oil pan in the positions shown (in the oil pan).

37. Install a new gasket and the oil pan.

Tightening torque: 74.4-94.8 inch lbs. (8.4-10.7 Nm)

38. Install the input/turbine speed sensor.

Tightening torque:
Input turbine speed sensor - 74.4-94.8 inch lbs. (8.4-10.7 Nm)

39. Install the transaxle range switch.
A. Turn the manual shaft to the N position.
B. Install the transaxle range switch and loosely tighten the bolts.
C. Connect an ohmmeter between terminals 5 and 7.
D. Adjust the switch to the point where there is continuity between the terminals.
E. Tighten the transaxle range switch mounting bolts.

Tightening torque: 70-95 inch lbs. (7.9-10.7 Nm)

F. Verify that the selector lever range position and transaxle range switch correspond.

40. Install the harness with the remaining clip.

Tightening torque: 69.6-94.8 inch lbs. (7.9-10.7 Nm)

41. Remove the transaxle from the SST (or equivalent).
42. Install a new O-ring and install the oil level gauge and oil filler tube to the transaxle case.

Tightening torque: 69.6-94.8 inch lbs. (7.9-10.7 Nm)

43. Install the oil pump shaft.
44. Install a new O-ring onto the turbine shaft.
45. Fill the torque converter with ATF.

ATF type: M-III or Dexron III.

NOTICE:
- Hold the torque converter in an upright position when filling it with ATF. Do not allow the fluid to overflow.
- If the converter does not fit in easily, do not try to force it; install carefully.

46. Install the torque converter in the converter housing while rotating it to align the splines.

47. To ensure that the torque converter is installed accurately, measure distance A between the face of the torque converter and the mounting surface of the converter housing.

Distance (A): 0.535 inch (13.6 mm)