Part 2

14. INSTALL SECOND COAST BRAKE BAND GUIDE
15. PLACE NO.1 ONE-WAY CLUTCH





a. Coat the thrust washer with petroleum jelly and install it on the No.1 one-way clutch.





b. Place the No.1 one-way clutch onto the rear planetary gear.

16. INSTALL SECOND BRAKE





a. Install the flange, facing the flat end upward.
b. Install the 4 discs and plates.
Install in order:
P = Plate D = Disc
D-P-D-P-D-P-D-P





c. Place the piston return spring into the case.





d. Place the second brake drum into the case.

HINT: Align the groove of the drum with the bolt.





e. Place the snap ring into the case so that end gap is installed into the groove.
f. While compressing the piston return spring over the drum with screwdriver, install the snap ring into the groove.
g. Be sure that the end gap of the snap ring is not aligned with one of cutouts.





17. INSTALL NEW SECOND BRAKE GASKET
Install a new gasket until it makes contact with the second brake drum.





18. CHECK OPERATION OF SECOND BRAKE
Apply compressed air into the second brake gasket and confirm that the piston moves.

19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM





a. Coat the thrust washer with petroleum jelly and install it on the sun gear input drum.





b. While turning the sun gear clockwise, install it into the No.1 one-way clutch.





20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

HINT: After installing the oil seal ring, check that it moves smoothly.

21. INSTALL FRONT PLANETARY GEAR





a. Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear.

Bearing outer diameter: 45.5 mm (1.791 inch)
Bearing inner diameter: 30.1 mm (1.185 inch)





b. Install the planetary gear onto the sun gear.





22. INSTALL FRONT PLANETARY RING GEAR





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

24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH





a. Coat the bearing with petroleum jelly and install it onto rear side of the forward clutch.

Bearing outer diameter: 47.6 mm (1.874 inch)
Bearing inner diameter: 31.4 mm (1.236 inch)





b. Coat the bearing with petroleum jelly and install it onto the front side of the forward clutch.

HINT: There are 2 different thickness bearings for adjustment of the input shaft thrust play.

Bearing thickness








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




d. Mesh the hub of the forward clutch flukes with the direct clutch discs.

HINT: Be careful that the bearing and thrust washer do not get out of place.





e. Install the direct clutch and forward clutch into the case.

HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place.

25. INSTALL OIL PUMP INTO CASE





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





b. Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case.

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

Torque: 22 Nm (225 kgf-cm, 16 ft. lbs.)





26. MEASURE END PLAY OF INPUT SHAFT
Measure the end play with a dial gauge.

End play: 0.25 - 0.90 mm (0.0098 - 0.0354 inch)

HINT: There are 2 different thickness bearings for end of stator shaft. If the end play is in excess of standard, select one of them.

Bearing thickness:
3.60 mm (0.1417 inch)
4.19 mm (0.1650 inch)

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

28. INSTALL SECOND COAST BRAKE PISTON
a. Coat the new O-rings with ATF and install it to 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.

29. CHECK SECOND COAST BRAKE PISTON STROKE





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





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4-8 kgf/cm2, 57 - 114 psi).
SST 09240-00020

Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 inch)

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

Piston rod length:
- 9.52 mm (3.748 inch)
- 96.3 mm (3.791 inch)

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


HYDRAULIC CONTROL UNIT INSTALLATION
1. INSTALL ACCUMULATOR PISTONS AND SPRINGS
a. Install the new O-rings to the pistons.





b. Install the springs and pistons into the bores.

Spring dimensions









c. Place the cover with a new gasket and gradually tighten the bolts a little at a time in sequence.

Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





2. PLACE NEW SECOND BRAKE APPLY GASKET





3. INSTALL SOLENOID WIRE





4. INSTALL THROTTLE CABLE
5. INSTALL VALVE BODY TO 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.

NOTICE: Do not entangle the solenoid wire.





c. Install and tighten the 9 bolts.

HINT:
- Each bolt length is indicated below.
- Hand tighten the 9 bolts first, then torque with a torque wrench.

Bolt length:
Bolt A: 30 mm (1.181 inch)
Bolt B: 43 mm (1.693 inch)
Bolt C: 48 mm (1.890 inch)
Bolt D: 52 mm (2.047 inch)

Torque: 11 Nm (1110 kgf-cm, 8 ft. lbs.)





6. INSTALL B3 APPLY PIPE

NOTICE: Be careful not to bend or damage the pipe.





7. INSTALL CONNECTOR CLAMP AND PIPE RETAINER

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 48 mm (1.890 inch)
Bolt B: 39 mm (1.535 inch)

Torque: 11 Nm (1110 kgf-cm, 8 ft. lbs.)





8. CONNECT SOLENOID CONNECTORS





9. INSTALL OIL PIPES
Using a plastic hammer, install the pipes into the positions.

NOTICE: Be careful not to bond or damage the pipes.

10. INSTALL MANUAL VALVE BODY AND DETENT SPRING

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 37 mm (1.457 inch)

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 5 bolts first. Then, tighten them with a torque wrench.

Torque: 11 Nm (1110 kgf-cm, 8 ft. lbs.)





d. Place the detent springs on the manual valve body and hand tighten the 2 bolts first.
Then, tighten them with a torque wrench.

Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)

HINT: Each bolt length is indicated below.

Bolt length:
Bolt A: 14 mm (0.551 inch)
Bolt B: 37 mm (1.457 inch)

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





11. INSTALL PIPE BRACKET AND OIL STRAINER
Each bolt length is indicated below.

Bolt length:
Bolt A: 22 mm (0.866 inch)
Bolt B: 53 mm (2.087 inch)

Torque
Pipe bracket: 10 Nm (100 kgf-cm, 7 ft. lbs.)
Oil strainer: 11 Nm (110 kgf-cm, 8 ft. lbs.)





12. INSTALL MAGNETS IN PLACE

NOTICE: Make sure that the magnets do not interfere with the oil pipes.





13. INSTALL OIL PAN WITH NEW GASKET
a. Install a new gasket and oil pan.
b. Install and torque 17 new bolts.

Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)





14. INSTALL THROTTLE CABLE RETAINING PLATE





15. INSTALL TRANSAXLE UPPER COVER





16. INSTALL T/M REVOLUTION SENSOR
a. Install the new O-ring to the T/M revolution sensor.
b. Install the T/M revolution sensor with the bolt.

17. INSTALL PARK/NEUTRAL POSITION SWITCH
a. Install the park/neutral position switch to the manual valve shaft.
b. Place the new locking plate and tighten the nut.
c. Stake the nut with locking plate.





d. Install the 2 bolts.





e. Adjust the park/neutral position switch.

HINT: Align the groove and neutral basic line.

f. Tighten the 2 bolts.





18. INSTALL UNION AND ELBOW
a. Install the new O-rings to the union and elbow.
b. Install the union elbow to the transaxle case.

Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)





HINT: Install the elbow, as shown in the illustration.





19. INSTALL MANUAL SHAFT LEVER





20. INSTALL SHIFT CONTROL CABLE BRACKET