Part 2

51. Using a press (1), press-fit the front planetary gear.




52. Install the washer, as shown.




53. Using DT-49189 - counter gear nut wrench (2) install the nut and tighten to 280 Nm (206 lb ft).




54. Measure the turning torque of the bearing while rotating DT-49189 - counter gear nut wrench (1) at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.

* New nut to 0.51-1.02 Nm (4.4-8.7 lb ft)
* Used nut to 0.3-0.5 Nm (2.7-4.4 lb ft)




55. Using a chisel and hammer, stake the front planetary gear washer.




56. Install the thrust bearings, bearing race and front planetary sun gear to the front planetary gear.




57. Coat the bearing race with ATF WS, and install it to the rear planetary gear assembly.

* Standard inside bearing race diameter - 38.6 mm (1.52 in)
* Standard outside bearing race diameter - 58 mm (2.83 in)




58. Install the No. 2 thrust washer.




59. Install the rear planetary gear to the rear planetary ring gear.




60. Using a screwdriver, install the snap ring.





Note:
* P = Plate (2)
* D = Disc (1)

61. Install the 5 plates and 5 discs.
Make sure you install in order - P-D-P-D-P-D-P-D-P-D




62. Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle (Dimension A).
63. Select an appropriate flange so that the pack clearance will meet the specified value. 0.745 to 1.21 mm (0.0293 to 0.0476 in.) Refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness B.




64. Install the flange.




65. Coat the new O-rings with ATF WS, and install them into the 2nd brake piston.




66. Press in the 2nd brake piston into the 2nd brake cylinder with your hands.




67. Install the piston return spring.




68. Compress the piston return spring with a press (1).

Note: Be sure the end gap of the snap ring is not aligned with the piston return spring claw.

69. Using a screwdriver, install the snap ring.




70. Install the 2nd brake piston to the transaxle.

Note:
* Because the taper snap ring has the positioning direction, check it when installing.
* When the diameter does not satisfy the specified value, replace the snap ring with a new one.

71. Install the snap ring and measure the inside diameter.

Standard inside diameter is more than 167 mm (6.57 in).





Note: Check the positioning direction of the outer sleeve.

72. Install the 1-way clutch outer sleeve to the 2nd brake cylinder.





Note: Check the direction of the inner race.

73. Install the inner race to the 1-way clutch.




74. Check the rotating direction of the 1-way clutch (1) for the lock or free operation.





Note: Install the thrust bearing properly so that no colored race will be visible.

75. Install the 1-way clutch and bearing to the 1-way clutch sleeve outer.

* Standard inside bearing race diameter - 53.6 mm (2.11 in)
* Standard outside bearing race diameter - 69.6 mm (2.74 in)




76. Coat the No. 1 thrust washer with petroleum jelly, and install it onto the rear planetary sun gear.




77. Coat the bearing with petroleum jelly, and install it onto the rear planetary sun gear.

* Standard inside bearing race diameter - 33.8 mm (1.331 in)
* Standard outside bearing race diameter - 48.2 mm (1.898 in)




78. Install the rear planetary sun gear to the rear planetary gear.





Note:
* P = Plate (2)
* D = Disc (1)

79. Install the discs and plates to the transaxle.
Make sure you install in order - P-D-P-D-P-D
80. Temporarily install the snap ring.




81. Using a vernier caliper, measure the distance between the disc surface and snap ring surface.
82. Select an appropriate flange so that the pack clearance will meet the specified value. Refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness (a).

Standard pack clearance - 0.50- 0.91 mm (0.0197-0.0358 in)
Piston stroke = Clearance - Flange thickness - Snap ring thickness 1.6 mm (0.063 in)





Note: Secure the snap ring so that its gap is visible through the groove of the transaxle case.

83. Temporarily remove the snap ring, attach the selected flange and restore the snap ring.




84. Coat the direct clutch piston with ATF WS, and install it to the direct clutch drum.




85. Install the piston return spring to the direct clutch drum.




86. Install the clutch balancer to the direct clutch drum.




87. Compress the piston return spring with a press (1).

Note: Be sure the end gap of the snap ring is not aligned with the clutch balancer claw.

88. Using a snap ring expander, install the snap ring to the direct clutch drum.





Note:
* P = Plate (3)
* D = Disc (2)
* F = Flange (1)

89. Install the plates, discs and flange to the direct clutch drum.
Make sure you install in order - P-D-P-D-P-D-F




90. Using a screwdriver, install the snap ring.
91. Check that the end gap of the snap ring is not aligned with one of the cutouts.




92. Install the direct clutch on the transaxle rear cover.
93. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air.

Standard pack clearance - 0.515- 0.825 mm (0.0203-0.0324 in)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the stroke is not as specified, select another flange.
There are six flanges in different thickness. Refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness C.





Note: Do not place the rear planetary sun gear in a vise.

94. Check that the disc rotates after inserting the rear planetary sun gear.




95. Install the bearing race to the direct clutch.

* Standard inside bearing race diameter - 30.3 mm (1.193 in)
* Standard outside bearing race diameter - 46.0 mm (1.811 in)





Note: The disc in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

96. Install the direct clutch and thrust bearing to the rear planetary sun gear.




97. Clean the contact area of the transaxle case and rear cover.
98. Place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using a vernier caliper (Dimension B).




99. Measure two places on the rear cover. Calculate dimension C using the following formula.
Dimension C = Dimension A - Dimension B

Note: Make sure that the colored race side is facing the direct clutch assembly.

100. Calculate the end play value using the following formula.
End play = Dimension C - Dimension B

End play - 0.198- 0.936 mm (0.0078-0.0368 in)