Part 5

OVERHAUL





101. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
a. Coat the 6 discs with ATF
b. Install the 6 plates and 6 discs.
102. INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE





a. Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
b. Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 inch)

HINT: Piston stroke = Dimension A - Flange thickness





Flange thickness: mm (in.)





c. Install the flange.
103. INSTALL SECOND BRAKE PISTON ASSY





a. Install the 2nd brake piston assy to the transaxle case.





b. Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 inch)

NOTICE:
^ Because the taper snap ring has the positioning direction, check it when installing.
^ When the diameter does not meet the specified value, replace the snap ring with new one.





104. INSTALL 1 WAY CLUTCH SLEEVE OUTER
a. Install the sleeve outer to the 2nd brake cylinder assy.

NOTICE: Check the positioning direction of the outer sleeve.

105. INSTALL 1 WAY CLUTCH ASSY





a. Install the inner race to the 1-way clutch.

NOTICE: Check the direction of the inner race.





b. Check the rotating direction of 1-way clutch for the lock, or free operation, as shown in the illustration.





c. Install the 1-way clutch and bearing to the 1-way clutch sleeve outer.





Bearing diameter: mm (in.)

NOTICE: Install the thrust bearing properly so that no-colored race will be visible.





106. INSTALL PLANETARY CARRIER THRUST WASHER NO.1
a. Coat the thrust washer No. 1 with petroleum jelly, install it onto the planetary gear assy.
107. INSTALL REAR PLANETARY SUN GEAR ASSY





a. Coat the thrust washer No. 2 with petroleum jelly, install it onto the rear planetary sun gear.





b. Coat the bearing with petroleum jelly, install it onto the rear planetary sun gear.





Bearing diameter: mm (in.)





c. Install the rear planetary sun gear assy to the rear planetary gear.





108. INSTALL 2ND BRAKE CLUTCH DISC
a. Coat the 4 discs with ATF.
b. Install the 4 discs and 4 plates to the transaxle case.
c. Temporarily install the snap ring.
109. INSPECT PACK CLEARANCE OF SECOND BRAKE





a. Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).
b. Select an appropriate flange so that the pack clearance will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 inch)

HINT: Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 inch).





Flange thickness: mm (in.)





c. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.

NOTICE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.





110. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY
a. Install the direct clutch hub to the planetary gear assy.
b. Install the bearing race and the thrust bearing to the direct clutch hub.





Bearing and race diameter: mm (in.)

111. INSTALL DIRECT CLUTCH ASSY





a. Install the direct clutch assy and thrust bearing to the rear planetary sun gear assy.

NOTICE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed.





b. Clean the connector part of the transaxle case and the rear cover.
c. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between transaxle case and the straight edge using vernier calipers (Dimension C).





d. Using vernier calipers and a simple straightedge, measure the position shown in the illustration.
e. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it.
End play: 0.260 - 0.917 mm (0.01024 - 0.03610 inch)

NOTICE: Make sure that the no colored race side is facing the direct clutch assy.

HINT: End play = Dimension D - Dimension C





Bearing thickness and diameter: mm (in.)

112. INSTALL BRAKE APPLY TUBE





a. Install the clamp to the brake apply tube.

NOTICE: Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

b. Install the clutch apply tube.





c. Install the brake apply tube and a bolt to the transaxle case.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Each pipe should be securely inserted until it reaches the stopper.





113. INSTALL GOVERNOR APPLY GASKET NO.1
a. Install the 3 new governor apply gaskets No. 1 to the transaxle case.





114. INSTALL NEEDLE ROLLER BEARING
a. Using SST and a press, install the bearing to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 inch)

NOTICE: Face the inscribed mark side of the bearing race up. Repeat the press fit until the specified value is obtained.

b. Coat a needle roller bearing with ATF.





115. INSTALL REAR CLUTCH OIL SEAL RING OUTER
a. Coat the 3 new oil seal rings with ATF, install them to the transaxle rear cover.





116. INSTALL TRANSAXLE CASE NO.1 PLUG
a. Install the 4 new O-ring to the 4 transaxle case No. 1 plugs.
b. Install the 4 transaxle case No. 1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
117. INSTALL TRANSAXLE REAR COVER SUB-ASSY





a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case.
b. Apply FIPG to the cover.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent.





c. Apply liquid sealer to the "A" bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
d. Install the 11 bolts.
Torque:
Bolt A: 18.6 Nm (190 kgf-cm, 14 ft. lbs.)
Other bolt: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
118. INSTALL UNDERDRIVE CLUTCH DISC NO.2





a. Coat the 4 discs with ATF
b. Install the 4 discs, 4 plates and flange to the transaxle case.





c. Using a screwdriver, install the snap ring.





119. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
a. Using a dial indicator, measure the U/D brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 inch)

HINT: Select an appropriate flange from the table so that it will meet the specified value.





Flange thickness: mm (in.)

b. Temporally remove the snap ring and attach to the flange.
c. Restore the snap ring.
120. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY





a. Install the U/D clutch assy to the 1-way clutch.





b. Rotate the U/D clutch assy to check the rotating direction for the lock or free operation.
121. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY





a. Install the outer race retainer to the 1-way clutch.





b. Install the 1-way clutch to the transaxle case.

NOTICE: Make sure that the mark on the 1-way clutch outer race is visible.





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





122. INSTALL UNDERDRIVE CLUTCH ASSY
a. Coat the bearing and bearing race with petroleum jelly, install them onto the U/D clutch.





Bearing and bearing race diameter: mm (in.)

b. Install the U/D clutch assy to the transaxle case.
123. INSTALL PARKING LOCK PAWL





a. Install the pawl pin and spring to the parking lock pawl.





b. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
124. INSTALL UNDERDRIVE PLANETARY GEAR ASSY





a. Install the U/D planetary gear assy to the transaxle case.

NOTICE: Engage all the discs of U/D clutch and hub splines of the U/D planetary gear assy firmly and assemble them securely.





b. Install the parking lock pawl shaft.





c. Install the pawl shaft clamp with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)





d. Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the U/D planetary gear and contact surface of the transaxle case and housing (Dimension E).

NOTICE: Note down the dimension E as it is necessary for the following process.





e. As shown in the illustration, measure the 2 places of the transaxle housing, calculate the dimension F using the formula.

NOTICE: Note down the dimension IF as it is necessary for the following process.

HINT: Dimension F = Dimension (1) - Dimension (2)

125. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB





a. Install the bearing race to the transaxle case while checking its direction.





Bearing race diameter: mm (in.)





b. Coat the thrust bearing and race with petroleum jelly, install them onto the multiple disc clutch hub.





Thrust bearing and race diameter: mm (in.)





c. Install the bearing to the multiple clutch hub.





Bearing diameter: mm (in.)

d. Install the multiple clutch hub to the transaxle case.