Reassembly

REASSEMBLY





1. Align bush cover with guide bolts as shown and press it in.
Tightening torque: 96 - 120 inch lbs. (10.8 - 13.7 Nm, 110 - 140 kg-cm)
2. Install idler gear and output gear as an assembly by tapping it with a plastic hammer.
3. Install bearing housing.





a. Install bearing housing on converter housing.
b. Align groove on idler shaft with mark on bearing housing.
c. Tap a new roll pin in with a pin punch and hammer.





d. Install 11 mounting bolts.
Tightening torque: 14 - 18 ft. lbs. (19 - 25 Nm, 1.9 - 2.6 kg-m)





4. Install parking pawl.
a. Install parking pawl and shaft.
b. Install spring and snap ring.
c. Move manual shaft and verify that parking pawl operates.





5. Install actuator support with new bolts.
Tightening torque: 11 - 13 ft. lbs. (15 - 17 Nm, 1.5 - 1.8 kg-m)





6. Install detent lever and return spring.





7. Install parking assist lever.





8. Install lever holder and bolt.
Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg-cm)





9. Install manual shaft and manual plate.
a. Install manual plate, washer and nut.
b. Tighten nut to specified torque.
Tightening torque: 31 - 40 ft. lbs. (42 - 54 Nm, 4.2 - 5.6 kg-m)
10. Install differential assembly into converter housing. Install SST (OK201 270 014) or equivalent.
11. Install a new oil control ring onto output gear assembly.





12. Install output shell to output gear and install bearing race onto output shell.
Thrust bearing outer diameter: 2.84 inch (72.1 mm)
13. Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.
14. Install new O-rings onto converter housing.

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





15. Mount transaxle case to converter housing.
Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg-m)





16. Install SST (OK201 190 019) to hold turbine shaft.
17. Install turbine shaft and 3-4 clutch assembly.





a. Assemble turbine shaft and 3-4 clutch assembly.
b. Verify that thrust bearing is properly installed.





c. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly.
18. Install internal gear.
a. Install internal gear to output shell.





b. Install snap ring.
19. Install planetary carrier assembly.





a. Verify that thrust bearing and bearing race are properly installed.
b. Hold turbine shaft with one hand to prevent it from rotating.





c. Install planetary carrier assembly into 3-4 clutch drum by rotating it.





20. Install low and reverse brake drive and driven plates (four each).

NOTE:
Installation order: Driven - Drive - Driven - Drive - Driven - Drive - Driven - Drive





21. Install retaining plate.
22. Install snap ring.
23. Install friction plate.
24. Install one-way clutch No. 2.
a. Hold one-way clutch No. 2 horizontally.
b. Install it by turning planetary carrier counterclockwise.





c. Install snap ring.
25. Install anchor strut and shaft.





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





26. Install 2-4 brake band in transaxle case so that it is fully expanded.
27. Install small sun gear and one-way clutch No. 1.





a. Verify that thrust bearing and bearing race are installed in correct position.





b. Install small sun gear and one-way clutch No. 1 while rotating it.
28. Install reverse/forward clutch assembly.





a. Verify that thrust bearing is installed in correct position.
b. Install reverse/forward clutch assembly while rotating it.





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

Maximum: 0.035 inch (0.9 mm)





29. Install snap ring into bottom ring groove of turbine shaft.
30. Measure total end play select a suitable bearing race as follows:





a. Set thrust bearing onto reverse/forward clutch assembly
b. Remove previously used race and gasket.
c. Set thickest bearing race 0.087 inch (2.2 mm) onto oil pump.





d. Set oil pump onto clutch assembly.

NOTE: Do not install oil pump gasket at this time.





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





f. Select a suitable bearing race from chart shown.
g. Remove oil pump.
h. Place selected bearing race and a new gasket onto oil pump.





i. Install oil pump onto transaxle assembly.
Tightening torque: 14 - 18 ft. lbs. (19 - 25 Nm, 190 - 260 kg-cm)
31. Verify 2-4 brake band adjustment as follows:
a. Install servo piston to SST (OK201 190 021).
b. Install servo retainer O-ring onto SST (OK201 190 021).





c. Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.

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





d. Set a dial indicator against piston stem.





e. Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure piston stem stroke.
Air pressure: 57 psi (392 kPa, 4.0 kg/cm2) maximum
Stroke: 0.039 - 0.067 inch (1.0 - 1.7 mm)





f. If not within specification, select proper piston stem from below.
g. Remove band servo assembly and remove SST.

NOTE: Do not deform snap ring when removing it.

32. Install servo into transaxle case
a. Install servo spring and servo assembly.
b. Install snap ring.





c. Position 2-4 brake band onto band servo piston stem.





33. Align manual valve with pin on manual plate and install control valve body.
Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg-cm)
Bolt length: (measured from below the head)
A: 1.18 inch (30 mm)
B: 1.97 inch (50 mm)
C: 0.55 inch (14 mm)
34. Connect solenoid valve and ATF temperature sensor connectors.





35. Connect solenoid connector.





NOTE: Attach magnets inside oil pan in positions shown on illustration (in oil pan).





36. Install a new gasket and oil pan tighten 19 bolts.
Tightening torque: 74.4 - 94.8 inch lbs. (8.4 - 10.7 Nm, 80 - 110 kg-cm)
37. Install inlet pipe and outlet pipe.
38. Install driven gear and vehicle speed sensor.
39. Install crankshaft position sensor.
40. Install bracket and select bracket.
41. Install transaxle range switch.
a. Turn manual shaft to N position.
b. Install transaxle range switch.
c. Tighten transaxle range switch mounting bolts.
Tightening torque: 70 - 95 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg-cm)
d. Verify that the selector lever range position and transaxle range switch correspond.
42. Remove transaxle from SST (OK 130 990 007/OK130 175 011A).
43. Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.
Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg-cm)
44. Install input/turbine speed sensor.
Tightening torque: 69.6 - 94.8 inch lbs. (7.9 - 10.7 Nm, 80 - 110 kg-cm)
45. Install oil pump shaft.





46. Install a new O-ring onto turbine shaft.
47. Fill torque converter with ATF.
ATF type: SK ATF SP-III or DIAMOND ATF SP-III





NOTE:
^ Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to overflow.
^ If converter does not fit in easily, do not try to force it: install carefully.
^ Do not damage O-ring onto turbine shaft.

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





49. To ensure that the torque converter is installed accurately, measure distance "A" between face of torque converter and mounting surface of converter housing.
Distance (A): 0.535 inch (13.6 mm)

BEARING PRELOAD
1. Remove bearing outer race from bearing cover.





2. Install bearing cover with SST (OK201 190 017).
3. Align bearing cover with guide bolts as shown, and press it in. Torque bearing cover bolts.
Tightening torque: 96 - 120 inch lbs. (10.8 - 13.7 Nm, 110 - 140 kg-cm)





4. Remove bearing outer race and adjustment shims from bearing housing using a pin punch and hammer.





5. Install bearing outer race to bearing housing.

NOTE: Do not install adjustment shims. Eliminate gap (arrow) by turning A or B of selector.

6. Set SST (OK201 175 A01) onto converter housing.





7. Install outer race removed in step 1 to SST (OK201 175 A01).
8. Set output gear assembly onto SST (OK130 191 A03).





9. Set four SST (OK130 191 A03) on converter housing in positions shown.





10. Set bearing housing on output gear assembly and install four SST (OK130 175 A04); then tighten them to specified torque.
Tightening torque: 14 - 18 ft. lbs. (19 - 25 Nm, 1.9 - 2.6 kg-m)
11. To seat bearing, turn SST (OK201 175 A01) to increase clearance indicated by arrow with SST (OK130 175 A03) until SST (OK130 175 A03) no longer turns.





12. Turn selector in opposite direction until gap is reduced.
13. Mount SST (OK130 322 020) and torque meter on output gear.





14. Adjust clearance of SST (OK130 175 A03) to obtain specified preload.
Preload: 0.27 - 7.8 inch lbs. (0.03 - 0.8 Nm, 0.3 - 9.0 kg-cm)





NOTE: Read preload when output gear is rotating.

NOTE:
^ Measure clearance around entire circumference and select shims equivalent to maximum clearance.
^ The maximum allowable number of shims is 7.








15. Measure clearance. Select adjustment shim(s) equivalent to measured clearance.
16. Remove bearing housing and SST (OK201 175 AAO).





17. Remove bearing outer race from bearing housing, refer to Bearing and Race Locations.
18. Install required shim(s).
19. Press bearing race into bearing housing with SST (or equivalent).





20. Press bearing outer race into bearing cover.





21. Install output gear assembly and bearing housing.
Tightening torque: 14 - 18 ft. lbs. (19 - 25 Nm, 1.9 - 2.6 kg-m)

NOTE: Do not install idler gear at this time.





22. Using SST (OK130 191 A04) and a torque meter, verify that preload reading is within specification.
Preload: 0.27 - 7.8 inch lbs. (0.03 - 0.8 Nm, 0.3 - 9.0 kg-cm)
23. Remove bearing housing and output gear assembly.

INSPECTION
The torque converter is welded together and cannot be disassembled.
1. Check outer surface of converter for damage or cracks and replace it if necessary.
2. Check whether there is any rust on pilot hub of converter or on boss. If there is any, remove it completely.





3. Measure bushing of converter boss. Replace converter assembly if bushing is worn.
Bushing inner diameter
Standard: 2.088 inch (53.030 mm)
Maximum: 2.090 inch (53.075 mm)

WASHING INSIDE CONVERTER
1. Drain any ATF remaining in converter.
2. Pour in ATF 0.5 US qt (0.5 liter, 0.44 Imp qt).





3. Shake converter to clean inside. Pour out ATF.
4. Pour in ATF.
5. Shake converter to clean inside. Pour out ATF.

NOTE: Replace torque converter if it contains any metallic particles.