Part 6
OVERHAUL126. INSTALL FORWARD CLUTCH ASSY
a. Install the thrust bearing to the forward clutch.
Thrust bearing diameter: mm (in.)
NOTICE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible.
b. Install the forward clutch to the multiple clutch hub.
NOTICE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.
127. INSTALL OVERDRIVE BRAKE GASKET
a. Install the 2 new O/D brake gaskets.
128. INSTALL DIFFERENTIAL GEAR ASSEMBLY
a. Install the differential gear assy to the transaxle case.
129. INSTALL THRUST BEARING UNDERDRIVE RACE NO.2
a. Install the thrust bearing race to the U/D planetary gear assy.
130. INSTALL THRUST NEEDLE ROLLER BEARING
a. Calculate the end play value using the following formula and values of Dimension E and F that ware measured when installing cylindrical roller bearing and U/D planetary gear. Select an appropriate U/D planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 inch)
HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 inch) - U/D thrust bearing race No. 2 thickness.
Race thickness: mm (in.)
Bearing and bearing race diameter: mm (in.)
131. INSTALL OIL PUMP ASSY
a. Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.1 Nm (226 kgf-cm, 16 ft. lbs.)
b. Coat the O-ring of oil pump with ATF.
132. INSTALL TRANSAXLE HOUSING
a. Remove any parking material and be careful not to get oil on the contacting surface of the transaxle case or transaxle housing.
b. Apply FIPG to the transaxle case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
c. Install the transaxle housing with the 16 bolts to the transaxle case.
Torque:
Bolt A and D: 22.1 Nm (225 kgf-cm, 16.3 ft. lbs.)
Bolt B and C: 29.4 Nm (300 kgf-cm, 21.7 ft. lbs.)
HINT: Apply seal packing or equivalent to the bolt A and D.
Seal packing: THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 inch)
Bolt B: 50 mm (1.969 inch)
Bolt C: 42 mm (1.654 inch)
Bolt D: 72 mm (2.835 inch)
NOTICE: Because the bolt A and D are a seal bolts, apply the seal packing to new bolts and tighten them within 10 minutes after application.
133. INSPECT INPUT SHAFT ENDPLAY
a. Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0103 - 0.0492 inch)
134. FIX AUTOMATIC TRANSAXLE ASSY
a. Fix the transaxle assy.
135. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
a. Coat a new oil seal with ATF.
b. Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010 (09951-07100)
Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.0197 inch)
136. INSTALL PARKING LOCK ROD SUB-ASSY
a. Install the parking lock rod to the manual valve lever.
137. INSTALL MANUAL VALVE LEVER SUB-ASSY
a. Install a new spacer and manual valve lever shaft to the transaxle case.
b. Using a pin punch and hammer, drive in a new pin.
c. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
d. Using a pin punch, stake the spacer through the small hole.
e. Check that the spacer does not turn.
138. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING
a. Using needle-nose pliers, install the retainer spring.
139. INSTALL PARKING LOCK PAWL BRACKET
a. Install the parking lock pawl bracket with the 2 bolts.
Torque: 20.1 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt length: 25 mm (0.984 inch)
140. INSTALL MANUAL DETENT SPRING SUB-ASSY
a. Install the manual detent spring with the 2 bolts.
NOTICE: Make sure to install the manual detent spring and cover in this order.
HINT: Tighten them in the order, A and B.
Torque:
Bolt A: 20.1 Nm (205 kgf-cm, 15 ft. lbs.)
Bolt B: 11.8 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt length:
Bolt A: 27 mm (1.063 inch)
Bolt B: 16 mm (0.630 inch)
141. INSTALL B-3 ACCUMULATOR PISTON
a. Coat a new O-ring with ATF, install it to the B-3 accumulator piston.
b. Coat the piston with ATF, install it to the transaxle case,
Accumulator spring
142. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON
a. Coat the 2 new O-rings with ATF, install them to the reverse accumulator piston.
b. Coat the piston with ATF, install it to the transaxle case.
Accumulator spring
143. INSTALL C-3 ACCUMULATOR PISTON
a. Coat a new O-ring with ATF, install it to the C-3 accumulator piston.
b. Coat the piston with ATF, install it to the transaxle case.
Accumulator spring
c. Install the spring from the C-3 accumulator piston.
144. INSTALL CHECK BALL BODY
a. Install the check ball body and spring.
145. INSTALL BRAKE DRUM GASKET
a. Coat a new brake drum gasket with ATF, install it to the transaxle case.
146. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
a. Coat a new transaxle case 2nd brake gasket with ATF, install it to the transaxle case.
147. INSTALL GOVERNOR APPLY GASKET NO.1
a. Coat a new governor apply gasket No. 1 with ATF, install it to the transaxle case.
148. INSTALL TRANSMISSION WIRE
a. Coat a new O-ring with ATF, install it to the transmission wire.
b. Install the transmission wire retaining bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
149. CONNECT TRANSMISSION WIRE
a. Coat a O-ring of the ATF temperature sensor with ATF
b. Install the ATF temperature sensor, with the lock plate and bolt.
Torque: 6.6 Nm (67 kgf-cm, 58 inch lbs.)
c. Connect the 7 solenoid connectors.
150. INSTALL TRANSMISSION VALVE BODY ASSY
a. Make sure that the manual valve lever position, install the valve body with 17 bolts to the transaxle case.
Torque: 10.8 Nm (110 kgf-cm, 8 ft. lbs.)
Bolt length:
Bolt A: 25 mm (0.984 inch)
Bolt B: 57 mm (2.244 inch)
Bolt C: 41 mm (1.614 inch)
NOTICE:
^ Push the valve body against the accumulator piston spring and the check ball body to install it.
^ When installing the valve body to the transaxle case, do not hold the solenoids.
^ Tighten temporarily those bolts marked by * in the illustration first because they are positioning bolts.