Steps 1-30

1. Using the special tool, install the oil seals to the differential bearing retainer and transaxle case.





2. Using the special tool, install the rear output shaft oil seal.





3. Using the Special tool, press-fit the outer race in the transaxle case.





4. Install the front output shaft assembly.





5. Place solder with a length of Approximately 10 mm (0.039 inch) and a diameter of 1.6 mm (0.063 inch) on the front bearing retainer in the shown positions and then install the outer race.





6. Install the front bearing retainer and tighten the bolt to the specified torque.

Front bearing retainer mounting bolts: 49 Nm (35 ft. lbs.)

7. Loosen the bolts and remove the front bearing retainer.
8. Remove the outer race from the front bearing retainer and remove the solder. If the solder does not break, perform the work in steps 5-8 with large diameter solder. Measure the thickness of the crushed solder with a micrometer and select a spacer with the correct thickness so the preload reaches the standard value.

Standard value: 0.055 - 0.115 mm (0.00217 - 0.00453 inch)





9. Install the spacer selected in the previous step and the outer race in the, front bearing retainer.
10. First install the front bearing retainer and apply sealant to the bolts and then tighten to the specified torque.

Specified sealant: 3M Stud Locking Part No. 4170 or equivalent
Front bearing retainer mounting bolts: 49 Nm (35 ft. lbs.)





11. Using a bearing puller, support the viscous coupling and insert in the case. Then, install the stopper ring.





12. Using the special tool, install the outer race in the center bearing retainer.





13. Install the center bearing retainer stopper bolt.

Center bearing retainer stopper bolt: 5 Nm (4 ft. lbs.)





14. Install the center bearing retainer so the projection of the stopper bolt fits in the groove of the center bearing retainer.





15. Install the special tool in the center differential and install the center differential in the transaxle case.





16. Place solder with a length of approximately 10 mm (0.39 inch) and diameter of 1.6 mm (0.06 inch) on the output bearing retainer at the shown positions and install the outer race.





17. Install the output bearing retainer and tighten the bolts to the specified torque.

Output bearing retainer mounting bolts: 24 Nm (18 ft. lbs.)

18. Loosen the bolts and remove the output bearing retainer.





19. Remove the outer race from the output bearing retainer and remove the solder. If the solder is not crushed, repeat steps (16)-(18), using the solder with diameter of 3 mm (0.12 inch). Measure the thickness of the crushed solder with a micrometer and select a spacer with a thickness that will provide the standard value for the preload.

Standard value: 0.075 - 0.1315 mm (0.00295 - 0.00531 inch)

20. Install the spacer selected in the previous item and the outer race on tile output bearing retainer.





21. Install a new O-ring around the outer inside diameter of the outer bearing retainer.
22. Coat the O-ring with automatic transmission fluid and tighten the output bearing retainer mounting bolts to the specified torque.

Output bearing retainer mounting bolts: 24 Nm (18 ft. lbs.)





23. Insert the output flange into the case and install a snap ring around the bearing.





24. Install the beating retainer using new bolts.

Bearing retainer mounting bolts: 20 Nm (15 ft. lbs.)





25. Caulk the heads of the bolts.





26. Apply a coating of petrolatum to thrust bearing #10 and attach to the planetary carrier.





27. Assemble the planetary carrier.





28. Assemble the forward sun gear, thrust race #9, thrust bearing #8 and reverse sun gear





29. Install both sun gears assembled in the previous item into the planetary carrier.





30. Assemble the reaction plate, brake disc and brake plate.