Part 4

151. Using a pin punch and a hammer, stake the lock nut.




152. Install the pawl pin and spring to the parking lock pawl.




153. Hand tighten the parking lock pawl (1), shaft and spring to the transaxle case.





Note: Engage all the discs of underdrive clutch and the hub splines of the underdrive planetary gear firmly and assemble them securely.

154. Install the underdrive planetary gear to the transaxle.




155. Install the parking lock pawl shaft (1).




156. Install the pawl shaft clamp with the bolt and tighten to 10 Nm (89 lb in).





Note: Make a note of dimension E as it is necessary for the following process.

157. Using a straightedge and vernier calipers, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and contact surface of the transaxle and housing (Dimension E).





Note: Make a note of dimension E as it is necessary for the following process.

158. Measure two places on the transaxle housing. Calculate the dimension E using the formula.
Dimension E = Dimension A - Dimension B




159. Install the bearing race to the transaxle while checking its direction.

* Standard inside bearing race diameter - 34.5 mm (1.358 in)
* Standard outside bearing race diameter - 48.5 mm (1.909 in)




160. Coat the thrust bearing and race with petroleum jelly, and install them onto the multiple disc clutch hub.

* Standard inside thrust bearing diameter - 36.3 mm (1.429 in)
* Standard outside thrust bearing diameter - 52.2 mm (2.055 in)




161. Install the bearing to the multiple clutch hub.

* Standard inside bearing diameter - 23.5 mm (0.925 in)
* Standard outside bearing diameter - 44.0 mm (1.732 in)

162. Install the forward clutch hub to the transaxle.




163. Compress the oil seal ring from both sides to reduce dimension A.

Standard A dimension - 5 mm (0.197 in)

164. Coat the oil seal ring with ATF WS and install it to the input shaft.




165. Coat the new O-rings (1) with ATF WS, and install them on the forward clutch piston.




166. Install the forward clutch piston on the forward clutch drum.




167. Place the return spring onto the piston.




168. Compress the return spring with a press (1).
169. Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.





Note: The end gap of the snap ring should not coincide with any of the stoppers (1).

170. Set the end gap of the snap ring in the piston.





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

171. Install the plates, discs and flange.
Make sure you install in order - P-D-P-D-P-D-P-D-P-D-F




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




174. Install the forward clutch on the oil pump.
175. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (1).

Standard piston stroke - 1.74-2.08 mm (0.0685-0.0819 in)
If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble again. If the clearance is not as specified, select another flange. Refer to Transmission General Specifications (Transmission General Specifications) for standard flange thickness E.





Note: Do not place the forward clutch in a vise.

176. Inspect the clutch disc rotation.
After inserting the multiple disc clutch into the multiple disc clutch hub, rotate the forward clutch and check that the disc lightly rotates.





Note: Install the thrust bearing properly so that the race (1) will be visible.

177. Install the thrust bearing to the forward clutch.

* Standard inside bearing diameter - 33.85 mm (1.3327 in)
* Standard outside bearing diameter - 52.2 mm (2.055 in)





Note: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely.

178. Install the forward clutch to the multiple clutch hub.




179. Install new overdrive brake gaskets.




180. Install the differential gear to the transaxle.




181. Install the thrust bearing race to the underdrive planetary gear.




182. Calculate the end play value using the following formula and values of Dimensions D and E that were measured when installing cylindrical roller bearing and underdrive planetary gear.

End Play - 0.498-0.993 mm (0.0196-0.039 in)
End play = Dimension E - Dimension D - thrust bearing thickness 3.28 mm (0.1291 in) - underdrive thrust bearing race thickness.

* End play formula value less than 7.64 mm (0.3008 in)-3.5 mm (0.138 in)
* End play formula value 7.64 mm (0.3008 in)-3.8 mm (0.150 in)

183. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, then install it.

* Standard inside bearing diameter - 57.2 mm (2.252 in)
* Standard outside bearing diameter - 84.96 mm (3.3449 in)
* Standard inside bearing race diameter - 56.4 mm (2.22 in)
* Standard outside bearing race diameter - 83.0 mm (3.268 in)




184. Install the oil pump to the transaxle with the bolts and tighten to 22 Nm (16 lb ft).




185. Coat the O-ring of the oil pump with ATF WS.




186. Remove any sealant and be careful not to get oil on the contacting surface of the transaxle housing.
187. Apply Three Bond 1281 sealant (1), or equivalent, to the transaxle.





Note: Because the bolt labeled four are seal bolts, Apply Three Bond 1281 sealant (1), or equivalent, to new bolts and tighten them within 10 minutes after application.

188. Install the transaxle housing to the transaxle with the bolts and tighten. Refer to Transmission General Specifications (Transmission General Specifications) for bolt length B.

* 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)




189. Install new O-rings to the plugs.
190. Install the plugs to the transaxle housing and tighten to 7 Nm (62 lb in).




191. Support the automatic transaxle assembly.




192. Coat a new oil seal with ATF WS.
193. Install the oil seal to the transaxle.




194. Install the parking lock rod to the manual valve lever.




195. Install a new spacer and manual valve lever shaft to the transaxle.




196. Using a pin punch and hammer, tap in a new pin.




197. Turn the spacer and lever shaft to align the small hole for locating the staking position mark on the lever shaft.
198. Using a pin punch, stake the spacer through the small hole.
199. Check that the spacer does not turn.




200. Using needle-nose pliers, install the retainer spring.