Part 4
DISASSEMBLY AND ASSEMBLY (Continued)
35. Install the control valve assembly on the transaxle case as follows:
(1) Insert pins etc. (dia.3 mm) into linkage stopper holes of the control valve assembly to fix the pulley ratio linkage.
(2) Install the terminal body on the transaxle case, while aligning the detent of terminal body with the transaxle case as shown in the diagram.
(3)
CAUTION:
Align the notch of pulley ratio linkage with the prong of pulley sensor.
Slide the control valve assembly from the bottom, and install it on the transaxle case.
(4)
CAUTION:
Apply transmission fluid when attaching the bush.
Install the bush on the control valve assembly.
(5) Install the fastening bolts of control valve assembly and tighten the bolt to the specified torque.
Tightening torque: 7.9 Nm (70 in-lb)
36. Install the manual lever and tighten the bolt to the specified torque.
Tightening torque: 22.1 Nm (16 ft-lb)
37. Install the bracket on the control valve assembly and tighten the bolt to the specified torque.
Tightening torque: 7.9 Nm (70 in-lb)
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
38. Install the O-ring on the oil strainer.
39. Install the oil strainer and tighten the bolt to the specified torque.
Tightening torque: 7.9 Nm (70 in-lb)
CAUTION:
- Do not re-use the oil pan gasket.
- Remove any moisture, oil, and used gasket from the mounting surface of oil pan gasket.
- When installing the oil pan gasket, align the dowel pins of transaxle case with dowel pin holes A of the oil pan gasket.
40. Install the oil pan gasket on the transaxle case.
41. Install the magnet on the oil pan.
CAUTION:
When installing the oil pan, align the dowel pins of transaxle case with dowel pin holes A of the oil pan.
42. Install the oil pan on the transaxle case and tighten the bolts to the specified torque.
Tightening torque: 7.9 Nm (70 in-lb)
CAUTION:
Do not re-use the drain plug gasket.
43. Install the drain plug and drain plug gasket on the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 34.3 Nm (25 ft-lb)
44. Install the oil pump cover on the transaxle case, and fix the fastening bolts temporarily.
45. Install the baffle plate, and fix the fastening bolts temporarily.
46. Install the oil guide and tighten the bolt to the specified torque.
Tightening torque: 5.9 Nm (52 in-lb)
47. Install the bracket, and tighten the fastening bolts of the bracket to the bolts to the specified torque.
Tightening torque: 26 Nm (19 ft-lb)
48. Tighten the fastening bolts of the oil pump cover and baffle plate to the bolts to the specified torque.
Tightening torque: 19 Nm (14 ft-lb)
CAUTION:
- Make sure the tang of thrust washer is aligned with the mounting hole of oil pump cover.
- Apply Vaseline when installing the thrust washer.
49. Install the thrust washer on the oil pump cover.
CAUTION:
Pull the driven sprocket up softly to make sure it is securely attached.
50. Expand the snap ring, and install the driven sprocket, oil pump chain, and drive sprocket.
51. Install the chain cover, and tighten the fastening nuts to the specified torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
52. Install the O-ring on the input shaft.
53. Install the differential assembly on the transaxle case.
54. Install the reduction gear assembly on the transaxle case.
CAUTION:
- Do not re-use the converter housing oil seal.
- Apply transmission fluid when installing the converter housing oil seal.
55. Using the special tools MB992141 and MB992075, install the converter housing oil seal on the converter housing.
Depth from the case edge: within - 1.0 ± 0.5 mm (recessed)
CAUTION:
- Do not re-use the converter housing side oil seal.
- Apply transmission fluid when installing the converter housing side oil seal.
56. Using the special tools MB992206 and MB992075, install the converter housing side oil seal on the converter housing.
CAUTION:
- Remove any moisture, oil and oil sealant from the application surface.
- Make sure the starting point and the ending point are about the middle between the bolts.
57. Apply the sealant on the converter housing mounting surface of the transaxle case in the following way.
Specified sealant: Loctite 509
58. Install the converter housing on the transaxle case, and tighten the fastening bolts to the specified torque.
Tightening torque: 45 Nm (33 ft-lb)
CAUTION:
Do not re-use the snap ring.
59. Install the snap ring on the terminal body.
CAUTION:
- Do not re-use the side oil seal.
- Apply transmission fluid when installing the side oil seal.
60. Using the special tool MB992140 and MB992075, install the side oil seal on the transaxle case.
Depth from the case edge: within - 1.8 ± 0.5 mm (recessed)
CAUTION:
Do not re-use the inhibitor switch.
61. Install the inhibitor switch on the transaxle case as follows:
(1) Install the inhibitor switch on the transaxle case.
(2) Install the shift lever on the manual shaft, and tighten the fastening nuts to the specified torque.
Tightening torque: 17.2 Nm (13 ft-lb)
(3) Set the manual shaft at N position.
(4) Insert pins etc. (dia.5 mm) in adjusting holes in both inhibitor switch and shift lever, and after alignment, tighten the fastening bolts to the specified torque.
Tightening torque: 5.5 Nm (49 in-lb)
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
62. Install the oil ring on the primary pulley speed sensor.
63. Install the primary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
64. Install the O-ring on the secondary pulley speed sensor.
65. Install the secondary pulley speed sensor on the transaxle case, and tighten the fastening bolts to the specified torque.
Tightening torque: 5.9 Nm (52 in-lb)
CAUTION:
- Apply transmission fluid or Vaseline when installing the transmission fluid cooler filter.
- Do-not re-use the transmission fluid cooler filter.
66. Install the transmission fluid filter on the transaxle case.
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
- When installing O-ring, make sure that projection of the O-ring is put into the groove on the filter.
67. Install the O-ring on the transmission fluid filter.
68. Install the transmission fluid cooler on the transaxle case, and tighten the fastening bolts to the specified torque.
Tightening torque: 4.2 Nm (37 in-lb)
CAUTION:
- Do not re-use the O-ring.
- Apply transmission fluid when installing the O-ring.
69. Install the O-ring on the plug.
70. Fasten the plug on the transaxle case and tighten the bolt to the specified torque.
Tightening torque: 7.5 Nm (66 in-lb)
CAUTION:
When conducting measurements, measure two or more places, and find the average value.
71. Install the converter on the transaxle, and measure the size A to check if it meets the standard value.
Standard value: 15.9 mm (0.63 in)
72. Install the oil filler tube and oil level gage on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 8.5 ± 3.5 Nm (75 ± 31 in-lb)
73. Install the control cable bracket and breather hose on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 25 ± 4 Nm (18 ± 2 ft-lb)
74. Install the harness bracket on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 25 ± 4 Nm (18 ± 2 ft-lb)
75. Install the RR roll stopper bracket and FR roll stopper bracket on the transaxle.
Refer to the following or the exploded view for the tightening torque.
Tightening torque: 90 ± 10 Nm (66 ± 7 ft-lb)
76. Install the transfer on the transaxle. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 68 ± 9 Nm (50 ± 7 ft-lb)