Part 1

Transmission Assemble

Special Tools

J-35405 - Differential Preload Wrench




1. Coat the front differential side gears, side gear thrust washers, font differential pinions and pinion thrust washers with ATF WS and install them to the differential case.




2. Coat the No. 1 front differential pinion shaft with ATF WS, and install it to the differential case.




3. Using a pin punch and a hammer, tap in the pinion shaft straight pin.




4. Using a chisel and a hammer, stake the differential case.




5. Using a press (1), press in the front differential case rear tapered roller bearing to the differential case.




6. Using a suitable driver (1) and a hammer, tap in the front differential case tapered roller bearing front outer race to the transaxle housing.




7. Using a press, press in the front differential case rear tapered roller bearing to the differential case.




8. Using a brass bar (1) and a hammer, tap in the front differential case tapered roller bearing front outer race to the transaxle housing.




9. Install the differential assembly to the transaxle case.




10. Clean the matching surfaces of the transaxle case and transaxle housing.

Caution: Refer to Fastener Caution (Fastener Caution).

11. Install the transaxle housing to the transaxle case with the bolts. Refer to Transmission General Specifications (Transmission General Specifications) for bolt length.

* Bolts 1 and 2 to 29 Nm (22 lb ft)
* Bolts 3 and 4 to 22 Nm (16 lb ft)
* Bolt 5 to 10 Nm (89 lb in)




12. Using J-35405 - wrench (1), turn the differential assembly right and left 2 or 3 times to allow the bearing to settle.
13. Using J-35405 - wrench and a torque wrench, measure the turning torque of the differential.

Standard turning torque at 60 rpm - 0.20-0.69 Nm (1.8-6.1 lb in)
If the turning torque is not within the specified value, refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness A.




14. Remove the bolts (1-18) and the transaxle housing.




15. Remove the differential assembly.





Note: Do not overheat the ring gear to 110°C (230°F) or more.

16. Using ATF WS and a heater, heat the front differential ring gear to 90-110°C (194-230°F)
17. Clean the contact surface of the front differential case.





Note: Do not install the bolts while the ring gear is hot.

18. Align the matchmarks (1), and install the front differential ring gear case quickly.





Note: Tighten the bolts a little at a time in diagonal order.

19. Install the bolts and tighten to 95 Nm (70 lb ft).




20. Coat the lip of a new oil seal with MP grease.
21. Using a suitable driver (1) and a hammer, tap in the differential side bearing retainer oil seal.




22. Coat the lip of a new oil seal with MP grease.
23. Using a suitable driver (1) and a hammer, tap in the transaxle housing oil seal.





Note: The seal end should be flat with the outer edge of the oil pump.

24. Using a suitable tool (1), install a new oil seal to the pump.
25. Coat the lip of the oil seal with grease.




26. Coat the new O-ring with ATF WS, and install it to the oil pump body.




27. Coat the front oil pump driven gear (1) with ATF WS, and install it to the oil pump body with the marked side facing up.




28. Coat the front oil pump drive gear with ATF WS, and install it to the oil pump body with the marked side facing up (1, 2).




29. Set the stator shaft by aligning each bolt hole.
30. Install the bolts and tighten to 10 Nm (89 lb in).




31. Install the clutch drum oil seal rings.




32. Install the apply tube and clamp to the transaxle housing with the bolt and tighten to 10 Nm (89 lb in).




33. Install a new oil seal ring to the transaxle housing.




34. Using a press (1), press in the underdrive cylindrical roller bearing.




35. Install new oil seal rings to the transaxle.




36. Using a press (1), press in the needle-roller bearing to the transaxle until a depth of 4.0 mm (0.157 in) is reached.




37. Coat the new O-rings (1, 2) with ATF WS, and install them to the underdrive brake piston.




38. Install the underdrive brake piston to the transaxle.




39. Using a press (1), press in the piston return spring and snap ring to the transaxle.
40. Install the No. 2 breather plug.




41. Using a screwdriver, press in the snap ring to the transaxle.




42. Using a press (2), press in the bearings outer races to the transaxle.




43. Using a press (1), press in the tapered roller bearing to the counter drive gear until the bearing race contacts with the snap ring.




44. Using a press (1), install the counter drive gear and bearing to the transaxle.




45. Coat the new O-rings (1, 2) with ATF WS.
46. Install the O-ring to the 1st and reverse brake piston.




47. Coat the 1st and reverse brake piston with ATF WS, and install it to the transaxle.





Note: Stop pressing when the spring sheet is lowered to 1 to 2 mm (0.039 to 0.078 in) from the snap ring groove, preventing the spring sheet from being deform.

48. Using a press (1) and snap ring expander, press the piston return spring and snap ring into the transaxle.




49. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.




50. Install the front planetary gear assembly to the brake hub.