Part 3

31. INSTALL SECOND COAST BRAKE BAND
a. Place the band into the case.
b. Install the pin through the oil pump mounting bolt hole.

32. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH













a. Coat the races and bearing with petroleum jelly, and install them onto both sides of the clutch drum.




b. Coat the clutch drum thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum.




c. Align the flukes of discs in the direct clutch.




d. Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch.
e. If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch.




f. Place the direct clutch and forward clutch into the case.
g. Rotate the forward clutch to mesh the front planetary ring gear and discs.




h. Check the distance between the A and B as shown in the illustration.

Distance: Approx. 3 mm (0.118 in.)

33. INSTALL OIL PUMP INTO CASE




a. Coat the race with petroleum jelly and install it onto stator shaft.

Race:
Outer diameter 43.0 mm (1.693 in.)
Inner diameter 30.5 mm (1.201 in.)

NOTE: After installing the oil pump, measure the input shaft thrust play.

If the thrust play is in excess of standard, select and insert one of the two different size races.




b. Coat a new O-ring with ATF and install it to oil pump.




c. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.
d. Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.

CAUTION: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.




e. Install and tighten the seven bolts.

Torque: 225 kg-cm (16 ft-lb, 22 N.m)




34. MEASURE THRUST PLAY OF INPUT SHAFT
Measure the thrust play with a dial gauge.

Thrust play: 0.3 - 0.9 mm (0.012 - 0.035 in.)

NOTE: There are two thickness of races for the end of stator shaft. If the thrust play is in excess of standard, select one of them.

Race thicknesses: 0.8 mm (0.031 in.) 1.4 mm (0.055 in.)




35. CHECK INPUT SHAFT ROTATION
Make sure that the input shaft rotates smoothly.




36. INSTALL SECOND COAST BRAKE PISTON
a. Coat the new O-rings with ATF and install them on the cover.
b. Install the outer spring with the piston.
c. Place the cover into the bore.




d. Using SST, install the snap ring while pressing the cover.
SST 09350-32014 (09351-32050)
e. Check that the front end of the piston rod contacts the center of the second brake band depression.

37. CHECK SECOND COAST BRAKE PISTON STROKE




a. Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.




b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240-0020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

If the stroke is more than specified, replace the piston rod with a longer one.

Piston rod length: 72.9 mm (2.870 in.) 71.4 mm (2.811 in.)

It is still more than standard value, replace the brake band with a new one.







38. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Install the new O-rings to the piston.




b. Install the springs and pistons into the bore.
c. Place the cover with a new gasket and gradually tighten the bolts a little a time in sequence.

NOTE: Each bolt length (mm (in.)) is indicated in the figure.




39. INSTALL SECOND BRAKE APPLY GASKET AND GOVERNOR OIL STRAINER




40. INSTALL THROTTLE CABLE IN CASE
Push the cable through the case, being careful not to damage the O-ring. Check for full seating.

CAUTION: In subsequent work, to avoid breaking the cable fitting do not roll the case over the cable.




41. PLACE VALVE BODY ON TRANSAXLE CASE
a. While holding the cam down with your hand, slip the cable end into the slot.
b. Lower the valve body into place.

CAUTION: Do not entangle the kick-down switch wire or solenoid wire.




42. INSTALL BOLTS IN VALVE BODY

NOTE: Each bolt length (mm (in.)) is indicated in the figure.

Hand tighten the fourteen bolts first, then torque with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




43. INSTALL MANUAL VALVE BODY AND DETENT SPRING

NOTE: Each bolt length (mm (in.)) is indicated in the figure.

a. Align the manual valve with the pin on the manual shaft lever.
b. Lower the manual valve body into place.
c. Hand tighten the four bolts first. Then, tighten them with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




d. Place the detent spring on the manual valve body and hand tighten the two bolts first.
Then, tighten them with a torque wrench.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)

e. Check that the manual valve lever is touching the center of the detent spring tip roller.




44. INSTALL OIL TUBES
Using a plastic hammer, install the tubes into the positions indicated in the figure.

CAUTION: Be careful not to bend or damage the tubes.




45. INSTALL TUBE BRACKET
Each bolt length (mm (in.)) is indicated in the figure.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




46. INSTALL OIL STRAINER
Each bolt length (mm (in.)) is indicated in the figure.

Torque: 100 kg-cm (7 ft-lb, 10 N.m)




47. INSTALL MAGNETS IN PLACE AS SHOWN

CAUTION: Make sure that the three magnets do not interfere with the oil tubes.




48. INSTALL OIL PAN WITH NEW GASKET

Torque: 50 kg-cm (43 in.-lb, 4.9 N.m)




49. INSTALL GOVERNOR BODY
a. Install the governor body adaptor.
b. Install the governor body with the plate washer.
c. Install the thrust washer onto the governor body.
d. Install the new O-ring to the cover.




e. Install the cover to the case.
f. Install the cover bracket with two bolts.

Torque: 130 kg-cm (9 ft-lb, 13 N.m)




50. INSTALL THROTTLE CABLE RETAINING PLATE
51. INSTALL FILLER TUBE AND DIPSTICK




52. INSTALL NEUTRAL START SWITCH
a. Install the neutral start switch to the manual valve shaft.
b. Install the seal gasket and locking plate.
c. Tighten the nut and stake it with the locking plate.

Torque: 70 kg-cm (61 in.-lb, 6.9 N.m)

53. ADJUST NEUTRAL START SWITCH




a. Align the groove and return neutral line.




b. Lock the switch with two bolts.
Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)




54. INSTALL MANUAL SHIFT LEVER

Torque: 130 kg-cm (9 ft-lb, 13 N.m)




55. INSTALL UNION AND ELBOW
a. Coat a new O-ring with ATF.
b. Install the O-ring to the union and elbow.
c. Install the union and elbow to the transaxle case.

Torque: 275 kg-cm (20 ft-lb, 27 N.m)