Part 1

ASSEMBLY

CAUTION:
^ Do not reuse the gasket, O-ring, oil seal. Always replace with a new one when assembling.
^ Do not use grease. Use petroleum jelly (i.e. Vaseline).
^ Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse new clutch discs or brake discs in ATF for at least two hours before assembling them.
^ When replacing a bushing, replace the assembly which it belongs to.
^ Do not use cloth gloves or shop towels during assembly. Use nylon cloth or other lint-free material.





1. Install special tool MD998412 in the installation screw hole of the transfer drive gear bearing located in the transaxle case. Using this as a guide, install the transfer drive gear bearing and gear in the transaxle case.





2. Tighten the mounting bolts (eight pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34 ± 2 Nm (25 ± 1 ft-lb)





3. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.





4. Fit a new O-ring into the groove of one-way clutch inner race.





5. Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.





6. Put the snap ring on the inner race.
7. Set special tools MD999577 and MD998924 as shown, and then compress the one-way clutch inner race and install the snap ring.





8. Install the wave spring onto the low-reverse brake piston.





9. Install the brake discs (six pieces), brake plates (five pieces) and snap ring as shown in the figure.

NOTE: Do not install the pressure plate at this time.

10. Install special tool MB991632 on the brake disc.
11. Install the reaction plate and the used snap ring.
12. Move special tool MB991632 to measure the end play of reaction plate. Then replace the snap ring installed in step 11 to adjust the end play to standard value.
Standard value of end play:
0 - 0.16 mm (0 - 0.006 inch)





13. Install the brake discs (four pieces) and brake plates (three pieces) as shown in the figure.

NOTE: Do not install the pressure plate at this time.

14. Place special tool MB991632 on top of the brake disc in place of the pressure plate.
15. Install the return spring, second brake piston and snap ring.





16. Move special tool MB991632 and measure its movement.
Standard value of end play (Reference):
1.09 - 1.55 mm (0.043 - 0.061 inch)
17. Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.





PRESSURE PLATE FOR SECOND BRAKE





18. Turn the transaxle over so that the installation surface of the torque converter housing is facing up.





19. Install special tool MD998913 in a dial gauge, and then move special tool MB991632 and measure its movement.
Standard value of end play (Reference):
1.65 - 2.11 mm (0.065 - 0.083 inch)
20. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.





PRESSURE PLATE FOR LOW-REVERSE BRAKE





CAUTION: If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.

21. Remove all parts and special tools that were installed to take the measurements in steps 9 to 18. Remove and separate the pressure plate and snap ring chosen in steps 12, 16 and 18.





22. Install the needle bearing as shown in the illustration.
23. Install the two seal rings.





24. Install the snap ring into the groove of transaxle case output shaft bore.





25. Install the snap ring.





26. Install the planetary carrier assembly.





27. Install the planetary reverse sun gear.





28. Install the wave spring on the low-reverse brake piston.





29. Install the pressure plate that was selected in step 19. Next, install brake discs (six pieces) and brake plates (five pieces), one on top of the other.





30. Install the snap ring.





31. Install the reaction plate.





32. Install the snap ring that was selected in step 12.





33. Install second brake discs (four pieces) and second brake plates (three pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.





34. Install the return spring and second brake piston.





35. Install the snap ring.