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Part 3 Of 3:

REASSEMBLY








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 of 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 (0.0399 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 - 0.135 mm (0.00295 - 0.00531 inch)
20. Install the spacer selected in the previous item and the outer race on the 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 bearing 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.








Identification of thrust bearings, thrust races and thrust washers





31. Assemble the pressure plate used in disassembly and install the return spring.

CAUTION: Position the return spring correctly when installing.





32. Apply a coating of petrolatum jelly to the wave spring and attach it to the center support.





33. Mount the special tool on the center support, install 2 new O-rings and push into the transaxle case.

CAUTION:
1. Coat the O-rings with automatic transmission fluid and align the oil holes.
2. Do not move the wave spring out of position when installing.





34. Install the snap ring.





35. Use a feeler gauge and measure the end play of the low-reverse brake. Adjust to the standard value by selecting the proper pressure plate.
Standard value: 1.0 - 1.2 mm (0.039 - 0.047 inch)





36. Install the air exhaust plug, and then install the plug.
Air exhaust plug: 33 Nm (24 ft. lbs.)





37. Install the anchor rod.





38. Install the kickdown servo spring, piston and sleeve.

CAUTION: The seal ring alignment hole of the kickdown servo piston must not overlap the oil filler port (indicated by the arrow in the diagram).





39. Use the special tool to push in the kickdown servo piston and sleeve, and then install a snap ring.





40. Install the kickdown band.

CAUTION: Install so the arrow mark is facing forward.





41. Install thrust bearing #4 and thrust washer #2 on the rear clutch.





42. Combine the rear clutch assembly and the front clutch assembly.





43. Install thrust bearing #5 on the rear clutch hub.





44. Install the rear clutch hub on the rear clutch.





45. Install thrust race #6 on the end of the rear clutch hub.





46. Install thrust bearing #7 in the kickdown drum.





47. Install the clutch assembly in the kickdown drum.





48. Install the clutch assembly and kickdown drum into the transaxle case at the same time.





49. Adhere thrust race #3 and thrust washer #1 to the back of the oil pump with petrolatum.





50. Use the special tool to install a new oil pump gasket and oil pump assembly.
Oil pump assembly mounting bolts: 21 Nm (16 ft. lbs.)