Part 2

AUTOMATIC TRANSAXLE UNIT

REASSEMBLY (STEPS 27-52)





27. INSTALL FRONT PLANETARY SUN GEAR
a) Install the planetary sun gear and needle roller bearing to the planetary gear.





28. INSTALL OUTER RACE RETAINER
a) Install the retainer to the No. 2 1-way clutch.





29. INSTALL NO. 2 1-WAY CLUTCH
a) Install the 1-way clutch and 2nd brake piston assembly to the rear planetary gear.





30. INSTALL PLANETARY GEAR REAR THRUST NEEDLE ROLLER BEARING
a) Install the No. 2 thrust bearing race, planetary gear thrust needle roller bearing and No. 1 thrust bearing race to the rear planetary gear.





31. INSTALL REAR PLANETARY GEAR ASSEMBLY
a) Install the rear planetary gear to the transaxle case.
b) Using a screwdriver, install the snap ring.
32. INSPECT NO. 2 1-WAY CLUTCH





33. INSTALL 2ND BRAKE PISTON SLEEVE
a) Install the 2nd brake piston sleeve to the transaxle case.





34. INSTALL 2ND BRAKE DISC
a) Install the 3 discs, 3 plates and flange to the transaxle case.
b) Using a screwdriver, install the snap ring to the transaxle case.





35. INSPECT PACK CLEARANCE OF 2ND BRAKE
a) Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2, 57 to 114 psi).
Standard pack clearance: 0.847 to 1.247 mm (0.0333 to 0.0491 inch)

HINT: Pack clearance = Dimension A - Selected flange thickness - Snap ring thickness.

Standard selected flange thickness

Standard selected flange thickness:

36. INSTALL 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING
a) Using a screwdriver, install the snap ring to the transaxle case.





37. INSTALL 1-WAY CLUTCH ASSEMBLY
a) Install the No. 2 thrust washer to the rear planetary gear.
b) Install the 1-way clutch to the rear planetary sun gear.
38. INSPECT 1-WAY CLUTCH ASSEMBLY





39. INSTALL REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
a) Install the thrust bearing and washer to the rear planetary sun gear.





40. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
a) Install the rear planetary sun gear assembly.





41. INSTALL REAR PLANETARY SUN GEAR, NO. 2 THRUST NEEDLE BEARING
a) Install the thrust bearing to the rear planetary sun gear.





42. INSTALL DIRECT CLUTCH HUB
a) Install the direct clutch hub.





43. INSTALL THRUST NEEDLE ROLLER BEARING
a) Install the No. 3 thrust bearing race, thrust needle roller bearing and C-2 hub thrust bearing race to the direct clutch hub.





44. INSTALL 2ND COAST AND OVERDRIVE BRAKE DISC
a) Install the 2 discs, 2 plates and 2 flanges to the transaxle case.





45. INSTALL INTERMEDIATE SHAFT ASSEMBLY
a) Install the intermediate shaft to the transaxle case.





46. INSPECT PACK CLEARANCE OF 2ND COAST AND OVERDRIVE BRAKE
a) As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straightedge using a vernier caliper (Dimension A).





b) As shown in the illustration, place a straightedge on the O/D brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper (Dimension B).
Calculate the piston stroke valve using this formula. Select a flange which satisfies the piston stroke valve and install it.
Standard pack clearance: 2.091 to 2.491 mm (0.0823 to 0.0981 inch)

HINT: Pack clearance = Dimension "A" - Dimension "B" - Selected flange thickness.

Selected flange thickness

Selected flange thickness:

47. INSTALL REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
a) Install the bearing to the intermediate shaft.





48. INSPECT INTERMEDIATE SHAFT ASSEMBLY
a) Install the transaxle rear cover with the 11 bolts.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)





b) Using a dial indicator, measure the end play of intermediate shaft.
Standard end play: 0.204 to 0.966 mm (0.008 to 0.038 inch)
c) Remove 11 bolts and transaxle rear cover.





49. INSTALL TRANSAXLE CASE GASKET
a) Install 4 new gaskets to the transaxle case.





50. INSTALL TRANSAXLE REAR COVER ASSEMBLY
a) Apply FIPG to the transaxle case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





b) Install the transaxle rear cover with the 11 bolts.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)





51. INSTALL FORWARD CLUTCH HUB SUB-ASSEMBLY
a) Install the forward clutch hub to the transaxle case.





52. INSTALL FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
a) Install the bearing to the forward clutch hub.