Part 1
REASSEMBLYCAUTION:
^ Keep the workbench and parts always clean and dirt free.
^ Do not use cotton gloves.
Use paper towel and nylon rag. Do not use nappy fabric.
Kimberly's Kimtowel J130, Kim WIPE L-100 or equivalent.
^ Do not use grease at any place otherwise specified.
Use white Vaseline or blue mineral oil if necessary.
^ Insert each snap ring firmly into the seat. Do not use deformed rings.
^ Do not allow dirt remain on the surface to apply liquid gasket during reassembly.
^ Gasket, O-ring, and oil shall not be used again, and use new ones in assembly.
^ A new clutch disc and a new brake disc shall be dipped in ATF for 2 hours or more before use.
^ Replace the ATF and clean the filter thoroughly in reassembly. Replace the damaged filter element with a new one.
^ Apply required minimum quantity of white Vaseline, blue mineral oil, or ATF on each of the bearing part, the thrust face moving part, the fluid pump moving part, the seal ring, and the O-ring.
^ Do not replace the ATF in the fluid cooler.
^ Be careful not to allow dirt come through the transaxle openings before mounting onto the vehicle. (including electronic part connector)
1. Install the differential bearing output race on the transaxle case using the special tool.
2. Apply ATF on the transaxle case and install 2 guide pins.
3. Install the transfer drive gear.
4. Connect the transfer drive gear mounting bolts (eight) using tightening torque.
Tightening torque
F5A51-2 : 31 - 36 Nm (320 - 370 kgf-cm, 23 - 27 ft. lbs.)
NOTE: Turn the transfer drive gear one revolution and ensure no interference with bolts.
5. Install the output shaft rear bearing.
6. Install the 4 seal rings.
7. Install the one way clutch.
NOTE: Be cautious to the direction of the one way clutch. Line marked side shall be located forward. (see figure).
8. Install the one way clutch holding snap ring.
9. Install the driveshaft oil seal on the transaxle case.
10. Install the LR brake piston and the return spring.
11. Install the spring retainer.
12. Install the one way clutch inner race.
13. Install the snap ring using the special tool.
14. Install the wave spring.
15. Install the LR brake pressure plate on the special tool, and install the brake disc, the brake plate and the snap ring as illustrated on the figure.
16. Install the reaction plate and the used snap ring.
17. Move special tool and check the end play, and install appropriate snap rings (8 sizes).
NOTE: Upon releasing the clutch, determine the actual gap between the LR brake disc and the plate.
18. Install the brake disc, the brake plate, and second brake pressure plate using special tool as illustrated on figure.
19. Install the return spring, the second brake piston and the snap ring.
20. Move the special tool and check the end play.
NOTE:
Using the below formula and the special tool installed at procedure 10, choose a pressure plate:
F5A51-2
[A (travel) + special tool thickness 0.079 inch (2.0 mm) 0.061 inch (1.55 mm)]
- [A (travel) + special tool thickness 0.079 inch (2.0 mm) 0.043 inch (1.09 mm)]
21. Turn the transaxle upside down.
22. Connect the special tool (09453-33100) with dial gauge, and move the special tool to check the end play.
NOTE:
Using the below formula and the special tool installed at procedure 7, choose a pressure plate:
F5A51-2
[A (travel) + special tool thickness 0.079 inch (2.0 mm) 0.083 inch (2.11 mm)]
- [A (travel) + special tool thickness 0.079 inch (2.0 mm) 0.065 inch (1.65 mm)]
23. Remove parts installed in procedures 14-22.
24. Install the overdrive planetary carrier and output planetary carrier.
25. Install the planetary gear reverse sun gear.
26. Install the wave spring.
27. Install the pressure plate, the brake disc, and the brake plate.
28. Install the snap ring.
29. Install the reaction plate.
30. Install the snap ring.
31. Install the brake disc, the brake plate, and the pressure plate.
32. Install the return spring and the second brake piston.
33. Install the snap ring.
34. Install the thrust bearing #5.
CAUTION: Be careful not to reverse the direction of the thrust bearing.
35. Assemble the overdrive clutch hub and the thrust bearing #6 into the reverse & overdrive clutch.
36. Install the reverse and overdrive clutch and the thrust bearing 47.
CAUTION: Be careful not to reverse the direction of the thrust bearing.
37. Install the overdrive clutch assembly
NOTE: Upon correct assembly the clutch retainer hole will match with the case surface.
38. Install O-rings (six).
39. Install the input shaft bearing.
40. Install the seal rings (four).
41. Insert the used thrust bearing #8 and install the rear cover.
NOTE: Rear cover will be installed in order to check the underdrive sun gear gap.