Part 1

Transmission Assemble

Special Tools
* DT-49189 - Counter Gear Nut Wrench
* J-35405 - Differential Preload Wrench




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




2. Coat the front number 1 differential pinion shaft (2) with ATF WS, and install it to the differential case.




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





Note: Stake the differential case after adjusting the backlash.

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




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




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




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





Note: Make sure there is no clearance between the bearing and transaxle housing.

8. Using a suitable driver (1) and a hammer, install the front differential case rear tapered roller bearing outer race to the transaxle housing.




9. Install the differential assembly to the transaxle case.




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

Caution: Refer to Fastener Caution (Fastener Caution)

11. Install the transaxle housing to the transaxle case and tighten the bolts.

* Bolts 1 to 29 Nm (21 lb ft)
* Bolts 2 to 29 Nm (21 lb ft)
* Bolts 3 to 22 Nm (16 lb ft)
* Bolt 4 to 25 Nm (18 lb ft)
* Bolts 5 to 10 Nm (89 lb in)
* Bolts 6 to 33 Nm (24 lb ft)
Refer to Transmission General Specifications (Transmission General Specifications) for Bolt Length - C




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

* Turning torque at 60 RPM, new bearing - 0.20-0.69 Nm (1.8-6.1 lb in)
* Turning torque at 60 RPM, used bearing - 0.10-0.35 Nm (0.9-3.1 lb in)

If the rotating torque is not within the specified range, refer to the flange thickness table to select a thrust washer so that the rotating torque is within the specified range. Refer to Transmission General Specifications (Transmission General Specifications) for flange thickness.




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




15. Remove the differential assembly.





Note: Do not heat the ring gear (a) to over 110°C (230°F).

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 (2) quickly.




19. Tighten the bolts on the differential ring gear (1).

Tighten the bolts to 95 Nm (70 lb ft).




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

Seal depth: -0.5 to +0.5 mm (-0.0197 to +0.0197 in)




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

Seal depth: -0.5 to +0.5 mm (-0.0197 to +0.0197 in)




24. Using a suitable driver (1) and a hammer, install a new oil seal to the oil pump body.
The seal end should be flush with the outer edge of the oil pump.
25. Coat the lip of the oil seal with MP grease.




26. Coat a new O-ring (1) with ATF WS, and install it to the oil pump body.




27. Coat the front oil pump driven gear with ATF WS, and install it to the oil pump body with the marked side up (2).




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




29. Align the bolt holes in the stator shaft assembly with those in the front oil pump and gear body sub-assembly.
30. Install the bolts (1-11) and tighten to 10 Nm (89 lb in).




31. Coat the new clutch drum oil seal rings with ATF WS.
32. Install the clutch drum oil seal rings (1).




33. Install the differential gear lube apply tube and transaxle apply tube clamp (1) to the transaxle housing with the bolt (2) and tighten to 10 Nm (89 lb in).




34. Install the new O-rings to the number 1 transaxle case plugs.
35. Install the number 1 transaxle case plugs to the transaxle rear housing and tighten to 7 Nm (62 lb in).




36. Coat a new oil seal ring with ATF WS and install it to the transaxle housing.




37. Coat the underdrive cylindrical roller bearing with ATF WS.
38. Using a press (1), install the underdrive cylindrical roller bearing.




39. Coat the new oil seal rings (1) with ATF WS, and install them to the transaxle rear cover.
40. Coat a new needle roller bearing with ATF WS.




41. Using a press (1), install the needle roller bearing to the transaxle case.

Bearing installation depth - 4.0 mm (0.157 in)




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




44. Install the underdrive brake piston (1) to the transaxle case.




45. Compress the return spring with a press (2).

Note:
* Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove to prevent the spring seat from being deformed.
* Do not expand the snap ring excessively.
* After installing the spring sub-assembly, check that all of the springs are fitted in the piston correctly.
* The snap ring should be securely engaged in the groove of the transaxle case.

46. Using a snap ring expander, install the snap ring (1) to the transaxle case.




47. Install the snap ring to the transaxle case.




48. Using a press (1), install the bearing outer race (rear side) to the transaxle case.




49. Using a press (1), install the bearing outer race (front side) to the transaxle case.
50. Coat the counter drive gear with ATF WS.