Part 1
TRANSAXLEDISASSEMBLY AND ASSEMBLY Continued
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 transmission fluid to friction components, rotating parts, and sliding parts before installation. Immerse new clutch discs or brake discs in transmission fluid 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 (seven 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. Install a new O-ring into the groove of one-way clutch inner race.
5. Check where the identification notches of the one-way clutch inner race are. Install the one-way clutch inner race to the transfer drive gear bearing so that either of the identification notches can be located on the line A - A.
6. Put the snap ring on the inner race.
7. Set special tools MD998903 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 illustration.
NOTE: Do not install the pressure plate at this time.
10. Install special tool MB991631 on the brake disc.
11. Install the reaction plate and the used snap ring.
12. Move special tool MB991631 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: 0 - 0.16 mm (0 - 0.0063 inch) (For brake reaction plate end play)
13. Install the brake discs (three pieces) and brake plates (two pieces) as shown in the illustration.
NOTE: Do not install the pressure plate at this time.
14. Place special tool MB991631 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 MB991631 and measure its movement.
Standard value (Reference): 0.79 - 1.25 mm (0.0311 - 0.0492 inch) (For second brake end play)
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. Install special tool MD998913 in a dial gauge, and then move special tool MB991631 and measure its movement.
Standard value (Reference): 1.65 - 2.11 mm (0.0649 - 0.0831 inch) (For low-reverse brake end play)
19. 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.
20. 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.
21. Install the snap ring into the groove of transaxle case output shaft bore.
22. Use special tools MB990930 and MB990938 to tap the output shaft bearing outer race in the transaxle case.
CAUTION:
Do not reuse the bolt, as it has had sealant applied.
23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Tightening torque: 29 ± 2 Nm (21 ± 1 ft-lb)
24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.
25. Apply transmission fluid to a new lock nut, and use special tools MB990607 and MB991625 to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Tightening torque: 170 ± 10 Nm (125 ± 7 ft-lb)
NOTE: The lock nut is reverse threaded.
26. Move the output shaft to measure the end play and record the measurement value.
Standard value (reference): 0.01 - 0.09 mm (0.0004 - 0.0035 inch) (For output shaft preload)
27. Remove the parts that were installed in steps 22 to 25.
28. Select a spacer whose thickness corresponds to the measured amount of movement from the following table.
SPACER FOR OUTPUT SHAFT
29. Repeat steps 22 to 25 again, installing each part and using the appropriate adjustment spacer determined in step 28.
30. Stake the lock nut with a punch (two places).
31. Use special tools MB990931 and MB990938 to install the cap as shown in the illustration.
32. Install the planetary carrier assembly.
33. Install the planetary reverse sun gear.
34. Install the wave spring on the low-reverse brake piston.
35. 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.
36. Install the snap ring.
37. Install the reaction plate.
38. Install the snap ring that was selected in step 12.
39. Install second brake discs (three pieces) and second brake plates (two pieces), one on top of the other. Next, install the pressure plate that was selected in step 17.