Part 2 of 2

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REASSEMBLY





51. Measure the end play of the input shaft. If not the standard value, replace thrust race #3 and thrust washer #1 and adjust to the standard value.
Standard value: 0.3 - 1.0 mm (0.012 - 0.039 inch)





52. Install the spacer, idler gear and bearing and then insert the idler shaft.

CAUTION: Assemble so that the identification groove on the idler gear faces backward.





53. Tighten the idler shaft lock bolt together with the new lock plat to the specified torque. Bend the three fingers of the lock plate to prevent turning.
Idler shaft lock bolt: 38 Nm (28 ft. lbs.)





54. Install the idler gear cover and a new gasket.
Idler gear cover mounting bolt: 11 Nm (8 ft. lbs.)





55. Insert the end clutch shaft from the end with the long spline.





56. Fit the thrust washer on the return spring of the end clutch.





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





58. Adhere thrust bearing #1 to the end of the clutch hub with petrolatum.





59. Install the end clutch assembly.





60. Attach a new O-ring to the end clutch cover.





61. Install the end clutch cover and tighten the bolts to the specified torque.
End clutch cover mounting bolts: 11 Nm (8 ft. lbs.)





62. Install the differential assembly.





63. Place solder with a length of approximately 10 mm (0.39 inch) and diameter of 1.6 mm (0.063 inch) on the differential rear bearing retainer at the shown positions and install the outer race.





64. Install the differential rear bearing retainer and tighten the bolts to the specified torque.
65. Loosen the bolts, remove the differential rear bearing retainer and remove the solder. If the solder is not crushed, repeat steps 63 - 65, using the solder with the diameter of 3 mm.
Differential rear bearing retainer mounting bolts: 35 Nm (26 ft. lbs.)





66. Measure the thickness of the crushed solder with a micrometer and adjust by selecting a spacer with a thickness that will provide the standard value for the end play and preload.
Standard value: 0.075 - 0.135 mm (0.00295 - 0.00531 inch)





67. Install a new O-ring on the differential rear bearing retainer, coat the O-ring with automatic transmission fluid; then install in the transaxle case and tighten the mounting bolts to the specified torque.
Differential rear bearing retainer mounting bolts: 35 Nm (26 ft. lbs.)





68. Install the front bearing cap and tighten the bolts to the specified torque.
Differential front bearing cap mounting bolts: 70 Nm (51 ft. lbs.)
69. Install the differential cover and a new gasket.
Differential cover mounting bolts: 11 Nm (8 ft. lbs.)





70. Install the detent plate.
Detent plate mounting bolt: 11 Nm (8 ft. lbs.)





71. Install a new O-ring on the manual control shaft assembly, coat the O-ring with automatic transmission fluid and then insert into the transaxle case.
72. Align the groove in the manual control shaft and the set screw hole; then install the set screw.
Manual control shaft set screw: 9 Nm (7 ft. lbs.)





73. Install the parking roller support.
Parking roller support mounting bolts: 24 Nm (18 ft. lbs.)





74. Insert the oil temperature sensor into the case.





75. Install an O-ring in the O-ring groove at the top of the valve body assembly.





76. Replace the solenoid valve harness grommet O-ring with a new one.
77. Pass the solenoid valve connector through the transaxle case hole from the inside.
78. Push the solenoid valve harness grommet into the case hole.





79. Insert the knock pin of the valve body into the case, keeping the detent plate pin in the manual valve groove. Temporarily install the valve body, install the oil temperature sensor and holder; then tighten the mounting bolts to the specified torque.
A bolt: 18 mm (0.71 inch)
B bolt: 25 mm (0.98 inch)
C bolt: 40 mm (1.57 inch)
Valve body assembly mounting bolts: 11 Nm (8 ft. lbs.)

CAUTION: Firmly fasten the solenoid valve and oil temperature sensor harness at the shown positions. Especially, be sure to route the Pressure Control Solenoid Valve (PCSV) harness, which is separated from other harness, as shown in the diagram and clamp the harness. Failure to fasten it may result in contact with the detent plate or parking rod.





80. Install the oil screen.
Oil filter mounting bolts: 6 Nm (5 ft. lbs.)





81. Install the magnets in the oil pan and install the oil pan.
Oil pan mounting bolts: 11 Nm (8 ft. lbs.)





82. Install the Park/Neutral Position (PNP) switch and manual control lever.
Park/neutral position switch mounting bolts: 11 Nm (8 ft. lbs.)
Manual control lever mounting bolt: 19 Nm (14 ft. lbs.)
83. Install the speedometer gear assembly.
Speedometer gear locking plate mounting bolt: 5 Nm (4 ft. lbs.)





84. Install the pulse generator A and B.
Pulse generator mounting bolts: 11 Nm (8 ft. lbs.)

CAUTION: Install the black tube on the output gear side and the transparent tube on the end clutch side.

85. Install the oil filler tube and insert the dipstick.
Oil filler tube mounting bolt: 24 Nm (18 ft. lbs.)
86. Install the brackets.
Transaxle mounting bracket bolts: 70 Nm (51 ft. lbs.)
87. Adjust the kickdown servo.
88. 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.

CAUTION:
1. Do not push in the piston with the special tool.
2. 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 a 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 twice before tightening the special tool (inner) to 5 Nm (3.6 ft. lbs.) torque. Then back off the special tool (outer) 2 to 2 1/4 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 a torque wrench to tighten the lock nut to the specified torque.
Lock nut: 29 Nm (21 ft. lbs.)

CAUTION: The lock nut may turn with the adjusting rod if tightened quickly with a 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.





89. Install the kickdown servo switch and fasten with a snap ring.





90. Insert the center shaft and hit it with a plastic hammer or similar instrument to install it securely.

NOTE: Apply Automatic Transmission Fluid (ATF) to the oil seal lip and do not scratch it.





91. Coat the oil pump drive hub with automatic transmission fluid and install the torque converter. Push in firmly so that dimension A in the diagram is at the standard value.
Standard value: approximately 16.3 mm (0.642 inch)