Part 1
GENERAL NOTESThe instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: ATF DEXRON II
1. General cleaning notes:
a. All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air.
b. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transaxle fluid or kerosene in your face.
c. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
2. Parts arrangement:
a. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly.
b. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
c. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least fifteen minutes before assembly.
3. General assembly:
a. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly.
b. All gaskets and rubber O-rings should be replaced.
c. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
d. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
e. Check thrust bearings and races for wear or damage. Replace if necessary.
f. Use petroleum jelly to keep parts in place.
COMPONENT PARTS INSTALLATION
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 II
General Installation Notes:
a. 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.
b. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
c. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
d. Use petroleum jelly to keep small parts in their places.
e. Do not use adhesive cements on gaskets and similar parts.
f. When assembling the transaxle, be sure to use new gaskets and O-rings.
g. Dry all parts with compressed air-never use shop rags.
h. Be sure to install the thrust bearings and races in the correct direction and position.
DIFFERENTIAL AND DRIVE PINION INSTALLATION
1. INSTALL DRIVE PINION INTO TRANSAXLE CASE
a. Using Special Service Tool (SST), install the bearing to the drive pinion shaft.
SST 09350-32014 (09351-32120)
b. Place the bearing cage onto the drive pinion shaft.
NOTICE: Be careful not to damage the oil seals with the pinion shaft.
c. 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.
d. Using SST, install snap ring into the bore.
SST 09350-32014 (09351-32050)
e. Using SST, install the snap ring.
SST 09350-32014 (09351-32050)
2. PLACE OIL SLINGER AND NEW SPACER
HINT: Install the spacer with the small end downward.
3. INSTALL OUTER RACE TO TRANSAXLE CASE
Using SST, press in the outer race.
SST 09350-32014 (09351-32100, 09351-32140)
4. INSTALL COUNTER DRIVE GEAR
a. Place a brass bar into the transaxle hole to hold the drive pinion shaft.
b. Using SST, press in the counter driven gear until the counter driven gear bearing almost touches the counter gear.
SST 09350-32014 (09351-32140)
5. 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.
Torque: 280 Nm (2,855 kgf-cm, 206 ft. lbs.)
SST 09330-00021, 09350-32014 (09351-32032)
c. Turn the gear counterclockwise and clockwise several times.
d. Using a torque meter, measure the preload of the drive pinion.
Drive pinion preload (at starting):
Now bearing: 1.0 - 1.6 Nm (10 - 16 kgf-cm, 8.7 - 13.9 inch lbs.)
Reused bearing: 0.5 - 0.8 Nm (5 - 8 kgf-cm, 4.3 - 6.9 inch lbs.)
- If the preload is greater than specified, replace the bearing spacer.
- If the preload is less then specified, retighten the nut 13 Nm (130 kgf-cm, 9 ft. lbs.) 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: 353 Nm (3,600 kgf-cm, 260 ft. lbs.)
e. If the preload is adjusted within specification, make a note of it.
f. Stroke the lock nut.
6. INSTALL APPLY GASKET
7. PLACE OUTER RACE AND SHIM ONTO RH SIDE BEARING
8. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE
Be sure to install the shim and outer race into place.
9. 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.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
HINT: Install the carrier cover within 10 minutes after applying seal packing.
c. Install and torque the 11 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 100 mm (3.937 inch)
Bolt B: 65 mm (2.559 inch)
Bolt C: 75 mm (2.953 inch)
10. ADJUST SIDE BEARING PRELOAD
a. Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case.
HINT: Do not apply seal packing yet.
b. Install the LH bearing retainer and torque the 6 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
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
New bearing: 0.2 - 0.4 Nm (2.5 - 5.1 kgf-cm, 2.2 - 3.6 inch lbs.)
Reused bearing: 0.1 - 0.2 Nm (1.3 - 2.0 kgf-cm, 1.1 - 1.7 inch lbs.)
If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with one of a different thickness.
Adjusting shim thickness
11. INSTALL LH BEARING RETAINER
a. Remove the 6 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.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
HINT: Install the LH bearing retainer within 10 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: 19 Nm (195 kgf-cm, 14 ft. lbs.)
g. Snap down the bearings.
h. Recheck the differential total preload.
12. INSTALL NEW OIL SEAL
a. Place the oil baffle onto the LH bearing retainer.
b. Using SST, drive in a new oil seal unit its end is flush with surface of the LH bearing retainer.
SST 09223-15010
13. 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.
Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent
HINT: Install the RH retainer within 10 minutes after applying seal packing.
c. Coat the bolts' threads with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent
d. Tighten the bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
e. Using SST, press in the oil seal.
SST 09226-10010
14. INSTALL DRIVE PINION CAP
a. Install a new O-ring to the cap.
b. Install the drive pinion cap to the transaxle case.
4-SPEED GEAR UNIT INSTALLATION
1. INSTALL PARKING LOCK PAWL
a. Place the parking lock pawl onto the case.
Hook the spring ends to the case and pawl.
b. Install the pin into the hole of the case through the spring and pawl.
2. INSTALL MANUAL VALVE SHAFT
a. Coat the oil seal lip with the Multipurpose (MP) grease.
b. Install the manual valve shaft oil seal to the case.
c. Assembly a new collar to the manual valve lever.
d. Install the manual valve shaft to the transmission case through the manual lever.
e. Install the parking lock rod.
f. Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface.
g. Match the collar hole to the lever caulking hollow and caulk the collar to the lever.
h. Install the retaining spring.
3. INSTALL PARKING LOCK PAWL BRACKET AND GUIDE
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
4. CHECK OPERATION OF PARKING LOCK PAWL
Make sure the counter driven gear is locked when the manual valve lever is in the P position.
5. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE
a. Coat the new O-rings with Automatic Transmission Fluid (ATF).
b. Install the 2 O-rings on the piston.
c. Push the piston into the bore of the case, facing the spring seat upward.
6. INSTALL PISTON RETURN SPRING
a. Place the return spring and snap ring on the piston.
b. Place SST, and compress the return spring evenly by tightening the bolt gradually.
SST 09350-32014 (09351-32040)
c. Install snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer.
Be sure the end gap of snap ring is not aligned with the spring retainer claw.
d. Remove the SST.
7. INSTALL SNAP RING TO TRANSAXLE CASE
8. INSTALL OVERDRIVE UNIT
a. Install the overdrive brake apply gasket and overdrive clutch apply gasket.
b. Install the overdrive brake drum to the case.
c. Install the new case gasket to the case.
d. Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 inch).
e. Place the new gasket onto the transaxle case.
f. Install the overdrive assembly with overdrive case to the transaxle case.
g. Coat the threads of 23 mm (0.91 inch) bolts with sealer.
Sealer: Part No.08833-00070, THREE BOND 1324 or equivalent
h. Install and tighten the 13 bolts.
HINT: Each bolt length is indicated below.
Bolt length:
Bolt A: 61 mm (2.402 inch)
Bolt B: 38 mm (1.496 inch)
Bolt C: 23 mm (0.906 inch)
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
9. CHECK INTERMEDIATE SHAFT END PLAY
a. Make sure that the intermediate shaft as end play in axial direction.
End play: 0.47 - 1.50 mm (0.0185 - 0.0591 inch)
If the end play is not within specification, check the installation of intermediate shaft.
b. Make sure that the intermediate shaft turns smoothly.
10. INSTALL REAR PLANETARY GEAR
a. Install the rear planetary ring gear.
b. Place the bearing onto the ring gear.
Bearing outer diameter: 38.7 mm (1.524 inch)
Bearing inner diameter: 22.6 mm (0.890 inch)
c. Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear.
d. Install the rear planetary gear.
11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE
a. Install the 6 plates and 6 discs.
Install in order: P=Plate D=Disc
P-D-P-D-P-D-P-D-P-D-P-D
b. Install the flange, facing the flat end downward.
c. Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not aligned with one of the cutouts.
12. CHECK FIRST AND REVERSE BRAKE
a. Check the operation of the first and reverse brake piston.
Apply compressed air into the case passage and con firm that the piston moves.
b. Using a filler gauge, check that pack clearance of the first and reverse brake.
Clearance: 1.92 - 2.68 mm (0.0756 - 0.1055 inch)
13. INSTALL NO.2 ONE-WAY CLUTCH INTO CASE
a. Place the No.2 one-way clutch with the shiny side of flange upward.
b. Install the one-way clutch while turning the planetary gear clockwise with SST.
SST 09350-32014 (09351-32050)
If the planetary gear cannot turn clockwise, check the installation of the one-way clutch.
c. Install the snap ring.
HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts.
d. Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear.