Reassembly
REASSEMBLYCAUTION:
- Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
- Never use grease other than blue petrolatum jelly and white Vaseline.
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- Never apply sealant or adhesive to gaskets.
O When replacing a bushing, replace the assembly which it belongs to.
- Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something. Change the oil in the cooler system.
1. Tap the differential bearing outer race into the transaxle case using special tools (09500-11000 and 09532-11500).
2. Tap the output shaft bearing outer race into the transaxle case using special tool (09500- 11000).
3. Install the spacer and the snap ring.
4. Install the low-reverse brake piston, return spring, and spring retainer.
5. Install the snap ring using special tools (09453-21000). To be sure that you have the correct snap ring, measure the thickness and compare it to the chart.
6. Install the wave spring.
NOTE: In steps 7 through 9, you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.
7. Replace the pressure plate of the low-reverse brake, then install the brake discs, 5 brake plates and the snap ring.
8. Install the low and reverse reaction plate and the old snap ring.
9. With a dial indicator installed, move the special tool up and down to measure the end play.
Standard Value: 0 - 0.16 mm (0 - 0.0063 inch)
If the end play is incorrect, measure the old snap ring, then select the proper snap ring and recheck the clearance.
10. Remove the special tool.
NOTE: In steps 11 through 16, you will determine the actual clearance between the second brake discs and plates when the clutch is released.
11. Install the 3 second brake discs and 2 plates.
12. Install the second brake return spring, second brake piston, and snap ring.
13. Install a dial indicator as shown in the illustration.
14. Move up and down, while observing the end play.
15. To determine the proper thickness of the second brake pressure plate.
Standard value 0.79 - 1.25 mm (0.0311 - 0.0492 inch)
16. If the standard value is incorrect, select a pressure plate of the proper thickness and recheck the clearance.
NOTE: In steps 18 through 21, you will determine the actual clearance between the low-reverse brake discs and plates when the clutch is released.
17. Install the special tool in place of the low/reverse brake pressure plate.
18. Install the 6 brake discs, 5 brake plates and snap ring.
19. Turn the transaxle upside down, install a dial indicator, as shown in the illustration.
20. Move the special tool up and down while observing the end play.
21. To determine the proper thickness of the low/reverse brake pressure plate.
Standard Value 1.65 - 2.11 mm (0.0650 - 0.0830 inch)
22. If the standard value is incorrect, select a pressure plate of the proper thickness and recheck the clearance.
23. Remove the special tool.
24. Install the output shaft.
25. Install the output bearing retainer mounting bolts. Tighten the bolts to 23 Nm (17 ft. lbs.) of torque.
26. Install the output shaft collar and tapered roller bearing using special tool (09455-33200).
NOTE: The output shaft lock nut is left-hand thread.
27. Apply ATF and install the old locknut and tighten to 167 Nm (123 ft. lbs.). Loosen the nut 1 full turn, then re-tighten to specifications. Do not stake the lock nut unless instructed to do so by the instructor.
28. Install a dial indicator as shown in the illustration.
29. Move the output shaft in and out to measure the end lay.
Standard value 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
30. If the standard value is incorrect, use this formula to select the correct spacer.
31. Install the output shaft protective cap.
32. Install the transfer drive gear using special tool (09500-11000).
33. Install the 7 transfer gear mounting bolts. Tighten the bolts to 19 Nm(14 ft. lbs.).
34. Install the parking pawl, spacer and spring, then install the parking pawl shaft.
35. Install the parking roller support, then the two parking roller support shafts.
CAUTION: Be sure to install the thrust bearing in the proper direction.
36. Install the underdrive sun gear and thrust bearing #3 to the output planetary carrier.
CAUTION: Be sure to install the thrust bearing in the proper direction.
37. Install the output planetary carrier and thrust bearing #4.
38. Install the overdrive planetary carrier.
NOTE: Rotating the output shaft will help align the clutch teeth and help the carrier seat.
39. Install the reverse planetary sun gear.
40. Install the wave spring.
41. Install the pressure plate, 6 brake discs, and 5 brake plates.
42. Install the snap ring.
43. Install the reaction plate.
44. Install the snap ring.
45. Install the pressure plate, 3 brake discs, and 2 brake plates.
46. Install the return spring and second brake piston.
47. Install the snap ring.
CAUTION: Be sure to install the thrust bearing in the proper direction.
48. Install thrust bearing #5.
CAUTION: Be sure to install the thrust bearing in the proper direction.
49. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.
CAUTION: Be sure to install the thrust bearing in the proper direction.
50. Install the reverse and overdrive clutch and thrust bearing #7.
51. Install the three O-rings.
52. Install the 3 seal rings into the rear cover.
NOTE: The cover should be clean and dry for step 56. It is only being installed to measure the underdrive sun gear end play.
53. Install the used thrust race #8 and the rear cover.
54. Using a dial indicator, measure the end play of the underdrive sun gear.
Standard Value: 0.25 - 0.45 mm (0.0098 - 0.0177 inch)
55. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size.
56. Reinstall the rear cover and mounting bolts. Tighten the mounting bolts to 23 Nm (17 ft. lbs.).
57. Install the underdrive clutch hub.
CAUTION: Be sure to install the thrust bearing in the proper direction.
58. Install thrust bearing #2.
59. Grasp the input shaft and lower the underdrive clutch into position.
NOTE: Looking into the hole where the in put speed sensor mounts to the case will help you ensure that the underdrive clutch is fully seated.
60. Install the used thrust bearing #1.
CAUTION: Be sure to use a new oil pump gasket.
61. Install the oil pump, a new gasket, and the oil pump mounting bolts.
62. Using a dial indicator, measure the end play of the input shaft.
Standard Value: 0.70 - 1.45 mm (0.0276 - 0.0371 inch)
63. If the end play exceeds the standard value, measure the used race with a micrometer and select the proper size.
64. Reinstall the oil pump and mounting bolts. Tighten the mounting bolts to 23 Nm (17 ft. lbs.).
65. Install the oil internal filter.
66. Install the differential.
67. Place two strips of solder, approximately 10 mm (0.39 inch) long and 3 mm (0.12 inch) thick, on the torque converter housing.
68. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 ft. lbs.) of torque.
69. Remove the torque converter housing, the bolts and the solder.
70. Using a micrometer, measure the thickness of the pressed solder.
71. Select a spacer that will give the following clearance.
Standard Value: 0.045 mm (0.0018 inch) - 0.105 mm (0.0041 inch)
72. Install the differential spacer selected in the previous step in the torque converter housing.
73. Use special tools 09532-11500 and 09500-11000 to press in the differential bearing outer race.
74. Install the two O-rings.
75. Install the torque converter housing and mounting bolts. Tighten the bolts to 47 Nm (35 ft. lbs.) of torque.
76. Install the manual control lever shaft and parking pawl.
77. Install the manual control shaft roller.
78. Install the three small springs and three larger springs into the accumulator pistons. The accumulator springs are identified in the illustration and in the chart below.
79. Install the accumulators with the springs according to the illustration and the chart below. The accumulators should be flush with the transaxle case.
80. Install the strainer and the second brake retainer oil seal.
NOTE: Note the oil seal orientation in the illustration.
81. Install the solenoid wiring harness, then install the snap ring in its groove.
82. Install the valve body, gasket, and two steel balls.
83. Install the oil temperature sensor. Tighten the mounting bolt to 11 Nm.
84. Install 28 valve body mounting bolts. Tighten all valve body mounting bolts to 11 Nm.
85. Connect the solenoid wiring and temperature sensor connectors according to the illustration and the chart below.
86. Install the manual control shaft detent. Tighten the nut to 6 Nm (4.4 ft. lbs.) of torque.
87. Install the valve body cover and mounting bolts. Tighten the mounting bolts to 9 Nm of torque.
88. Install the vehicle speed sensor and mounting bolt. Tighten the mounting bolt to 5 Nm of torque.
89. Install the park/neutral position switch. Tighten the mounting bolt to 11 Nm (8 ft. lbs.) of torque.
90. Install the manual control lever. Tighten the mounting nut to 22 Nm (26 ft. lbs.) of torque.
91. Install the input and output shaft speed sensors. Tighten the mounting bolts to 11 Nm of torque.
CAUTION: Make sure that you are installing the correct oil filter. While the engine oil filter and the transaxle oil filter lock similar, their filtering action is different. Installing the wrong oil filter could cause damage to the transaxle. Transaxle oil filters are identified as A/T ONLY.
92. Install the cooler feed tube with a new gasket and the eye bolt. Tighten the eye bolt to 30 Nm (22 ft. lbs.) of torque.
93. Install the dipstick.
94. Install the control cable bracket. Tighten the mounting bolt to 23 Nm (17 ft. lbs.).
95. Install the wiring harness bracket. Tighten the mounting bolt to 23 Nm (17 ft. lbs.).
96. Install the two roll stopper brackets. Tighten the mounting bolts to 69 Nm (51 ft. lbs.).
97. Install the torque converter and secure it so that dimension A. Meets the reference value.
Reference value: approx. 12.2 mm (0.480 inch)
CAUTION: Apply ATF to the oil pump drive hub before installing the torque converter. Be careful not to damage the oil pump seal.