Part 2

DISASSEMBLY 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 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 (seven pieces) of the transfer drive gear bearing to the specified torque.
Tightening torque: 34± 2Nm (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 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 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 of end play: 0 - 0.16 mm (0 - 0.006 inch)






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 of end play (Reference): 0.79 - 1.25 mm (0.031 - 0.049 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.
Install special tool MD998913 in a dial gauge, and then move special tool MB991631 and measure its movement.
Standard value of end play (Reference): 1.65 - 2.11 mm (0.065 - 0.083 inch)
19. Select a pressure plate whose thickness corresponds to the measured amount of movement from the table below.
PRESSURE PLATE FOR LOW-REVERSE BRAKE





20.
CAUTION:
If necessary, take the measurements in steps 9 to 18 after replacing the pressure plate, brake plate and brake disc.

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.





23.
CAUTION:
Do not reuse the bolt, as it has had sealant applied.

Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Tightening torque: 29± 2Nm (21± 1 ft-lb)






24. Use special tool MD998350 to install the collar and taper roller bearing on the output shaft.





25. Apply ATF 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± 10Nm (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 of end play (reference): 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
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 brake discs (three pieces) and brake plates (two pieces), one on top of the other.
Next, install the pressure plate that was selected in step 17.





40. Install the return spring and second brake piston.





41. Install the snap ring.





IDENTIFICATION OF THRUST BEARING, THRUST RACES, AND THRUST WASHERS










42.
CAUTION:
Be sure to install the thrust bearing in the correct direction as shown.

Check the installation direction of the thrust bearing number 5, and install it on the hub of the planetary reverse sun gear.





43.
CAUTION:
Use care to install the thrust bearing in the proper direction.

Attach thrust bearing number 6 to the inside of the overdrive clutch hub using petroleum jelly (Vaseline). Then install the assembly in the reverse and overdrive clutch.





44.
CAUTION:
Be sure to install the thrust bearing in the correct direction as shown.

Check the installation direction of thrust bearing number 7, and install it on the reverse clutch retainer.





45. Use special tool MB990938 to tap the input shaft rear bearing in the rear cover.
46. Install the seal rings (four pieces) in the grooves of the rear cover.





47. Measure the end play of the under drive sun gear by the following procedures:
(1) Install the thinnest thrust race number 8 [thickness 1.6 mm (0.063 inch);
part number MD707267] on thrust bearing number 7.
(2) Install the rear cover on the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 23± 3Nm (17± 2 ft-lb)
(3) Turn over the transaxle case so that the installation surface of the torque converter housing is facing up.
(4) Install the underdrive clutch hub on the underdrive sun gear.
(5) Measure end play of the underdrive sun gear and record the measurement value.
Standard value of end play (Reference):
0.25 - 0.45 mm (0.010 - 0.017 inch)
(6) After taking the measurement in steps (5), take out the installed parts in steps (1) through (4).





48. Install the O-rings (three pieces).