Part 2

41. Install the kickdown band; attach the ends of the band to the ends of the anchor rod and servo piston rod.

NOTE: Install the band with the arrow mark facing toward oil pump.





42. When putting the kickdown drum in the kickdown band, engage the splines of the kickdown drum with those of the reverse sun gear. Place the kickdown band on the kickdown drum and tighten the kickdown servo adjusting screw to keep the band in position.





43. Apply petrolatum jelly to thrust bearing #8 and attach the thrust bearing to the kickdown drum.





44. Apply petrolatum jelly to thrust race #7 and attach the thrust race to the rear clutch hub.





45. Install clutch hub, engaging it with the forward sun gear splines.





46. Apply petrolatum jelly to thrust bearing #6 and attach it to the clutch hub.





47. Apply petrolatum jelly to thrust washer #2 and thrust bearing #4 and attach the washer and bearing to the rear clutch assembly.





48. Mate the rear clutch assembly with the front clutch assembly.





49. Install the clutch assembly.





50. Install the differential.





51. Attach thrust race #3 and thrust washer #1 on the rear end face of the oil pump with petrolatum jelly.





52. Install the special tool on the transaxle case. Using the special tool as a guide, install a new oil pump gasket and the oil pump in the case.
53. Remove the special tool.
54. Tighten the oil pump bolts to the specified torque.





55. Measure the end play of the input shaft. If the measurement is out of the standard value, replace thrust race #3 and thrust washer #1 to meet the standard value.
Standard value: 0.3-1.0 mm (.012-.039 inch)





56. Place two pieces of approximately 10 mm (.39 inch) long and 2.5 mm (.063 inch) diameter solder at the locations shown on the converter housing and assemble the outer race.
57. Install the converter housing directly to the transaxle case without installing the rubber coated metal gasket.





58. Tighten the bolts to the specification.
59. Loosen the bolts and remove the converter housing and remove the pieces of flattened solder.





60. Measure the thickness of the flattened solder using a micrometer. Add the measured solder thickness (T) to the value 0.38 mm (.0150 inch), which corresponds to the gasket thickness.
Then subtract from that sum a value corresponding to the specified end play.
The result obtained is the thickness of the spacer to be selected.
Select a spacer whose thickness falls within the range determined by the formulas below:
[T + 0.38 mm (.0150 inch) - 0.13 mm (.0051 inch)] to [T + 0.38 mm (.0150 inch) - 0.08 mm (.0031 inch)]
61. Place the spacer which was selected in Step 60 and the outer race on the converter housing.





62. Apply silicone grease to all gasket surfaces of the transaxle case.
63. Install a new gasket on the transaxle case.

CAUTION: Do not reuse the gasket which was previously removed.





64. Install converter housing and tighten the 14 bolts indicated by arrows to the specified torque.
Tightening torque: 21 Nm (16 ft. lbs.)





65. Install the end clutch shaft, inserting the end that has the longer splines first.





66. Install the thrust washer on the return spring at the end clutch side.





67. Install the end clutch hub on the end clutch assembly.





68. Attach thrust bearing #13 to the end clutch hub with petrolatum jelly.





69. Install the end clutch assembly.





70. Install a new O-ring in the groove of the end clutch cover. Check the bearing for smooth rotation and replace it if defects are evident.
Apply an ample amount of automatic transmission fluid to the bearing.





71. Secure the end clutch cover by tightening its mounting bolts to the specified torque.
Tightening torque: 7 Nm (5 ft. lbs.)





72. Install the parking sprag rod to the manual control shaft. Then, insert the shaft in the transaxle as shown in the illustration. In doing this work, do not install O-ring in the O-ring groove.





73. After installing a new O-ring on the manual control shaft assembly; draw the shaft back into the case, then install the set screw and gasket.
Tighten the detent plate mounting bolt to the specified torque.
Tightening torque: 11 Nm (8 ft. lbs.)
74. Place the case with the oil pan mounting surface up.





75. Install the sprag rod support and tighten the two bolts to the specified torque.
Tightening torque: 24 Nm (18 ft. lbs.)





76. Install the O-ring at the top of the valve body.
77. Replace the O-ring of the solenoid valve connector with a new one.





78. Install the valve body in the transaxle case while fitting the detent plate pin in the gap between the lands of the manual valve.





79. Tighten the valve body mounting bolts (10 pieces) to the specified torque.
A bolt 18 mm (.71 inch) long
B bolt 25 mm (.98 inch) long
C bolt 40 mm (1.57 inch) long





80. Install the oil filter and tighten the four oil filter mounting bolts to the specified torque.





81. Install five magnets in the five depressions provided inside the oil pan. Be sure to remove metal particles from the magnets and clean the inside of the oil pan beforehand.





82. Clean the gasket surfaces of the transaxle case and oil pan. Install a new oil pan gasket and then the oil pan by tightening the 12 bolts to the specified torque.
Tightening torque: 11 Nm (8 ft. lbs.)
83. Adjust the kickdown servo by the following procedure:





a. Fit the claw of the special tool in the notch of the piston to prevent the piston from turning, and use adapter to secure it as illustrated at left.

CAUTION:
- Do not push in the piston with the special tool.
- When the adapter is installed to the transaxle case, do not apply excessive torque but tighten by hand.





b. Loosen the lock nut until it is about to reach the V-groove in the adjusting rod. Tighten the special tool (inner) until it touches the lock nut.





c. Fit the special tool (outer) to the lock nut. Turn the outer cylinder counterclockwise and the inner cylinder clockwise to lock the lock nut and the special tool (inner).





d. Fit torque wrench to the special tool (inner) to tighten it to a torque of 10 Nm (7.2 ft. lbs.) and loosen. Repeat this sequence two times before tightening the special tool (inner) to 5 Nm (3.6 ft. lbs.) torque. Then back off the special tool (inner) 2 1/2 to 2 3/4 turns.





e. Fit the special tool (outer) to the lock nut.
Turn the outer cylinder clockwise and the inner cylinder counterclockwise to unlock the lock nut and the special tool (inner).

CAUTION: When unlocking is carried out, apply equal force to both special tools to loosen.





f. Tighten the lock nut by hand until it touches the piston. Then, use torque wrench to tighten the lock nut to the specified torque.
Tightening torque: 29 Nm (21 ft. lbs.)

CAUTION: The lock nut may turn with the adjusting rod if tightened quickly with socket wrench or torque wrench.

g. Remove the special tool for securing the piston. Install the plug to the Low/Reverse pressure outlet and tighten to the specified torque.





84. Set a new D-ring in the kickdown servo switch, push the switch into the case and secure it with the snap ring.





85. Install the park/neutral position switch and manual control lever, and tighten the manual control lever nut to the specified torque.





86. Adjust the park/neutral position switch as follows:
a. Place the manual control lever in the "N" (neutral) position.
b. Turn the park/neutral position switch body until the 12 mm (.47 inch) wide end of the manual control lever aligns with the switch body flange [12 mm (.47 inch) wide portion]. Alternatively, turn the switch body until the 5 mm (.20 inch) hole in the manual control lever aligns with the 5 mm (.20 inch) hole in the switch body.
c. Tighten the attaching bolts to the specified torque taking care that switch body is not displaced.
Tightening torque: 11 Nm (8 ft. lbs.)

Internal Connection In The Park/Neutral Switch.:

87. Check the continuity between terminals with the manual control lever at each position.
The continuity between terminals should be as shown in the table below.
Lack of continuity indicates a poorly adjusted switch or faulty switch. Readjust the switch. If still without continuity, replace the switch.





88. Install pulse generators "A" and "B" and tighten the bolt to the specified torque.
Tightening torque: 11 Nm (8 ft. lbs.)
89. After applying automatic transmission fluid to the outside surface of the oil pump-side cylindrical portion of the torque converter, install the torque converter carefully so as not to give damage to the oil seal lip. Make certain that the torque converter is in mesh with the oil pump drive gear.





90. Measure the distance between the ring gear end and the converter housing end.
The torque converter has been properly installed when the measurement is about 12 mm (.47 inch)