Part 1

Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly.
If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.

Recommended ATF: DEXRON (R) II (A540E) Type T (A540H)

GENERAL INSTALLATION NOTES:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least two hours.
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air-never use shop rags.

8. Be sure to install the thrust bearings and races in the correct direction and position.

INSTALLATION OF DIFFERENTIAL AND DRIVE PINION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE

a. Place the bearing cage onto the drive pinion shaft.

CAUTION: (A540E) Be careful not to damage the oil seals with the pinion shaft.

b. (A540E) Install the two new O-rings to the bearing cage.
c. (A540E) Coat the O-rings with ATF.

d. Using a hammer and brass bar, slightly tap the bearing cage into the transaxle case until the snap ring groove in the bore can be seen

e. Using SST, install snap ring into the bore.
SST 09350-32014 (09351-32050)

2. (A540E) PLACE SENSOR ROTOR ONTO DRIVE PINION SHAFT

3. (A540H) INSTALL DRIVE PINION BEARING No.2 SPACER

4. PLACE OIL SLINGER AND NEW SPACER

NOTE: Install the spacer with the small end downward.

5. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)

6. INSTALL COUNTER DRIVEN GEAR
a. Place SST into the transaxle hole to hold the drive pinion shaft.
SST (a) 09350-32014 (09351-32130, 09351-32150)
b. Using SST, press in the counter driven gear until slightly thickness between the counter driven gear bearing and outer race.
SST (b) 09350-32014 (09351-32140)

7. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION PRELOAD

a. Install the new lock nut.
b. Using SST to hold the gear, tighten the nut.
SST 09330-00021, 09350-32014 (09351-32032)

Torque: 2,100 kg.cm. (152 ft.lb., 206 N.m)

c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the A drive pinion.

Drive pinion preload (at starting):
New bearing: 10 - 16 kg.cm. (8.7 - 13.9 in.lb., 1.0 - 1.6 N.m)
Reused bearing: 5 - 8 kg.cm. (4.3 - 6.9 in.lb., 0.5 - 0.8 N.m)

- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less than specified, retighten the nut 130 kg.cm. (9 ft.lb., 1 3 N.m) at a time until the specified preload is reached.

If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Do not back off the nut to reduce the preload.

Maximum torque: 3,600 kg.cm. (260 ft.lb., 353 N.m)

e. If the preload is adjusted within specification, make a note of it.
f. Stake the lock nut.

8. (A540E) PLACE OUTER RACE AND SHIM ONTO RH SIDE BEARING
9. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE

(A540E) Be sure to install the shim and outer race into place.

(A540H) Be sure to install the ring gear mount case sleeve and outer race into place.

10. INSTALL CARRIER COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case.

b. Apply seal packing to the carrier cover as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the carrier cover within ten minutes after applying seal packing.

c. Install the two apply gaskets.

d. Install and torque the eleven bolts.
NOTE: Each bolt length (mm (in.)) is indicated in the figure.

Torque: 400 kg.cm. (29 ft.lb., 39 N.m)

11. ADJUST SIDE BEARING PRELOAD

a. Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case.

NOTE: Do not apply seal packing yet.

b. Install the LH bearing retainer and torque the six bolts.

Torque: 195 kg.cm. (14 ft.lb., 19 N.m)

c. Snap down the bearings by turning the differential case several times.

d. Using a torque meter, measure the differential total preload.

Total preload (at starting): Add drive pinion preload

If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with another thickness one.

12. INSTALL LH BEARING RETAINER

a. Remove the six bolts and LH bearing retainer.

b. Remove any packing material on the contacting surfaces of LH bearing retainer, transaxle case and carrier cover.
c. Apply the seal packing to the transaxle case and carrier cover as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the LH bearing retainer with ten minutes after applying seal packing.

d. Install the LH bearing retainer.
e. Coat the threads of bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent

f. Tighten the bolts.

Torque: 195 kg.cm. (14 ft.lb., 19 N.m)

g. Snap down the bearings.
h. Recheck the differential total preload.

13. INSTALL NEW OIL SEAL

a. Place the oil baffle onto the LH bearing retainer.

b. Using SST, driven in a new oil seal until its end is flush with the surface of the LH bearing retainer.
SST 09223-15010

14. (A540E) INSTALL RH RETAINER

a. Remove any packing material on the contacting surfaces of RH retainer and transaxle case.
b. Apply the seal packing to the RH retainer as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the RH retainer within ten minutes after applying seal packing.

c. Coat the threads of bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent

d. Tighten the bolts.

Torque: 195 kg.cm. (14 ft.lb., 19 N.m)

15. INSTALL DRIVE PINION CAP
a. Install a new O-ring to the cap.
b. Install the drive pinion cap to the transaxle case.

14. (A540E) INSTALL RH RETAINER
a. Remove any packing material on the contacting surfaces of RH retainer and transaxle case.
b. Apply the seal packing to the RH retainer as shown.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

NOTE: Install the RH retainer within ten minutes after applying seal packing.

c. Coat the threads of bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent

d. Tighten the bolts.

Torque: 195 kg.cm. (14 ft.lb., 19 N.m)

15. INSTALL DRIVE PINION CAP
a. Install a new O-ring to the cap.
b. Install the drive pinion cap to the transaxle case.