Transaxle
TRANSAXLEDISASSEMBLY AND ASSEMBLY
Removal Steps 1-22:
Required Special Tools:
^ MB992332: Clutch remover & installer
^ MB992324: Seal cover guide A
^ MB992325: Seal cover guide B
^ MB992323: Seal cover installer
^ MB992311: Oil seal guide
^ MB992310: Oil seal installer
^ MB992313: Oil seal guide
^ MB992312: Oil seal installer
^ MB992314: V ring guide
CAUTION
^ When installing or removing screws, use magnetic tools to prevent them from failing out.
^ If debris or parts enter into the transaxle case, pay attention to the following to replace the transaxle assembly:
^ When the mechatronic assembly is replaced, reprogram the ECU and carry out the following Teach-in (TC-SST Teach-In).
^ When the clutch assembly is replaced, the following Teach-in must be carried out (TC-SST Teach-In).
DISASSEMBLY SERVICE POINTS
[A] TRANSAXLE CASE OIL SEAL (RH) / TRANSAXLE CASE OIL SEAL (LH) REMOVAL
1. Insert the tapping screw ([diameter] 3 mm [0.1 inch]) to one of four hollows (round shape) on the oil seal by turning it 2 or 3 times.
2. Tap the opposite side of the inserted tapping screw using a knock pin punch to press in the oil seal approximately 1 mm (0.04 inch).
3. Hold the inserted tapping screw with pliers or similar tools, and remove the oil seal.
NOTE: If the transaxle case oil seal (RH) is replaced, the V-ring must also be replaced.
[B] SEAL COVER BRACKET AND SEAL COVER REMOVAL
1. Remove the seal cover bracket.
CAUTION
^ Before removing the seal cover, securely remove iron powders including dusts by air spray.
^ Before removing the seal cover, use the ladder sheet and so forth for the supporting point not to damage the clutching housing.
2. Remove the seal cover from the transaxle, using the tool such as crowbar.
[C] CLUTCH ASSEMBLY REMOVAL
1. Align the four pins of the special tool, clutch remover & installer (MB992332), with the four holes of the clutch assembly to set the special tool, clutch remover & installer (MB992332), to the clutch assembly.
2. Rotate the clutch assembly in the axial direction to insert the pins into all four clutch disks in the clutch assembly.
NOTE: When the pins are inserted into all four clutch disks, the clutch assembly cannot easily be rotated in the axial direction.
3. Rotate the clutch assembly counterclockwise six to seven times to loosen the clutch assembly.
CAUTION
^ When lifting the clutch assembly, the tool must not hook the clutch disk.
^ The clutch assembly might possibly have the needle bearing. Pay attention to it.
^ Carefully handle the clutch assembly to place it on the clean place.
4. Lift the clutch assembly in the vertical direction to remove the clutch assembly from the transaxle assembly.
[D] OIL PAN ASSEMBLY REMOVAL
CAUTION
When removing the oil pan assembly, pay attention to avoid damage to the connector and the O-ring between the oil pan assembly and the connector.
[E] MECHATRONIC ASSEMBLY REMOVAL
1. Remove the connector carefully.
2. Remove the three bolts.
3. Pull carefully at the connector to loose by approx. 2 - 3 mm (0.08 - 0.12 inch).
4. Remove the eleven bolts as shown and remove the mechatronic assembly carefully.
[F] MANUAL CONTROL SHAFT REMOVAL
1. Move the park manual outer lever from D in clock direction to the service position as shown.
2. Remove the plug.
3. When removing the screw located behind the plug, pay attention to the screw not to fall in the transaxle case.
4. Remove the manual control shaft carefully.
ASSEMBLY SERVICE POINTS
[A] MANUAL CONTROL SHAFT INSTALLATION
1. Install the manual control shaft carefully and tighten the screw to the specified torque.
Tightening torque: 10 ± 1.5 Nm (89 ± 8 in-lb)
2. Tighten the plug to the specified torque.
Tightening torque: 32 ± 2 Nm (24 ± 1 ft-lb)
[B] GASKET A / GASKET C / MECHATRONIC ASSEMBLY INSTALLATION
1. As shown in the illustration, fix the gasket to the transaxle case by pushing the gasket at the area to which the gasket dowel pin is inserted.
2. Install the mechatronic assembly carefully and tighten the mechatronic assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 5.0 ± 1.0 Nm (44 ± 8 in-lb)
3. Tighten again the mechatronic assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 10 ± 1.5 Nm (89 ± 8 in-lb)
4. Tighten the bolts to the specified torque.
Tightening torque: 6.0 ± 1.0 Nm (53 ± 8 in-lb)
[C] OIL PAN ASSEMBLY INSTALLATION
1. Completely degrease the oil pan assembly installation surface on the transaxle side.
2. Remove the gasket from the oil pan assembly, and completely degrease the groove of the oil pan assembly (gasket installation area) and the gasket. Then, install the gasket to the groove of the oil pan assembly.
CAUTION
When installing the oil pan assembly, pay attention to avoid damage to the connector and the O-ring installed to the connector.
3. Tighten the screws to the specified torque in the order shown in the figure.
Tightening torque: 10 ± 1 Nm (89 ± 8 in-lb)
[D] NEEDLE ROLLER BEARING INSTALLATION
1. Insert the needle roller bearing and ensure that the lock is closed completely.
[E] SEAL RING INSTALLATION
CAUTION
Do not expand the seal ring more than necessary.
1. Insert the seal ring.
2. Ensure that the lock is closed completely and it is seated flat into its position.
[F] CLUTCH ASSEMBLY INSTALLATION
CAUTION
Pay attention to the clutch assembly not to touch the seal ring and needle bearing.
1. Put down the clutch assembly in the vertical direction to carefully install it.
2. Align the four pins of the special tool, clutch remover & installer (MB992332), with the four holes of the clutch assembly to set the special tool, clutch remover & installer (MB992332), to the clutch assembly.
3. Rotate the clutch assembly in the axial direction to insert the pins into all four clutch disks in the clutch assembly.
4. Rotate the clutch assembly clockwise to install it.
Tighten it to the specified torque.
Tightening torque: 7.5 ± 1.0 Nm (66 ± 8 in-lb)
[G] SEAL COVER BRACKET AND SEAL COVER INSTALLATION
1. Install the seal cover to the special tool MB992324 and MB992325.
2. Remove the special tool MB992324 from MB992325.
3. Install the seal cover to the transaxle case. Remove the special tool MB992325.
4. Use special tool MB992323 to install the seal cover to the transaxle.
5. Install the seal cover bracket.
Confirm that it is not shaky.
6. Tighten the seal cover bracket mounting bolt to the specified torque.
Tightening torque: 10 ± 1 Nm (89 ± 8 in-lb)
[H] TRANSAXLE CASE OIL SEAL (LH) INSTALLATION
1. Apply the transaxle oil to the special tool MB992311. Insert the oil seal to the special tool MB992311.
2. Use special tool MB992310 to install the oil seal to the transaxle.
[I] TRANSAXLE CASE OIL SEAL (RH) ASSEMBLY INSTALLATION
1. Apply the transaxle oil to the special tool MB992313. Insert the oil seal to special tool MB992313.
2. Use special tool MB992312 to install the oil seal to the transaxle.
[J] V RING INSTALLATION
1. Clean the spline with a brush or the like.
2. Apply the transaxle oil to the special tool MB992314. Insert the V ring to the special tool MB992314. and install the V ring.
3. Check that the V ring is installed securely.