Transaxle Overhaul

CAUTION:
1. The gasket, O-ring, and oil seal should never be reused.
Whenever they have been removed, they must be replaced with new ones. (Note: The rubber used in the oil level gauge does not require replacement.)
2. Never use grease other than petrolatum.
3. Be sure to apply ATF to the friction elements and rotary and sliding surfaces before reassembly. A new clutch disc and brake disc should be dipped in ATF for more than 2 hours before installation.
4. Do not use sealant or adhesive for gaskets.
5. When replacing a bushing, replace the whole assembly containing that bushing.
6. Do not use cotton work gloves or waste cloth for the reassembly job. Use nylon cloth or paper towel if necessary.
7. Replace oil in the cooler.




1. Using the special tool, press-fit the drive shaft oil seal into position.




2. Using the special tool, press-fit the outer race into the
transaxle case.




3. Install the transfer shaft.




4. Place 10 mm-long (0.39 in.), 1.6 mm-dia. (0.063 in.) solders at the locations shown of the output bearing retainer and install the outer race.




5. Install the output bearing retainer and tighten bolts to specification.
6. Loosen the bolts and remove the output bearing retainer.




7. Remove the outer race from the output bearing retainer and remove the solders. If the solders are not crushed, use larger dia. (3 mm or 0.12 in.) solders to repeat steps 4 to 6.
Measure the thickness of the solders crushed with a micrometer and select a spacer to obtain the specified preload.

Standard value: 0.075-0.135 mm (0.00295-0.00531 in.)

8. Install the spacer selected in the preceding step as well as outer race into the output bearing retainer.




9. Fit a new O-ring over the periphery of the output bearing retainer.

10. Coat the O-ring with ATF and tighten the output bearing retainer mounting bolts to specification.




11. Insent the output flange into the case and fit the snap ring over the periphery of the bearing.




12. Install the bearing retainer with new bolts.




13. Stake the heads of the bolts.




14. Coat thrust bearing # 10 with petrolatum and affix the bearing to the planetary carrier.




15. Install the planetary carrier.







IDENTIFICATION OF THRUST BEARINGS, THRUST RACES AND THRUST WASHERS LOCATION




16. Assemble the forward sun gear, thrust race # 9, thrust bearing # 8, and reverse sun gear.




17. Install the two sun gears assembled in the preceding step into the planetary carrier.




18. lnstall the reaction plate, brake disc, and brake plate.

CAUTION: If a new brake disc is to be used, it should be dipped in ATF for more than two hours.




19. lnstall the pressure plate disassembled and return spring.

CAUTION: Make sure the return spring is installed in the correct direction.




20. Coat the wave spring with petrolatum and affix it to the center support.




21. Install the special tool to the center support, fit new O-rings (at two places), and press the center support into the transaxle case.

CAUTION:

1. Coat the O-rings with ATF and align oil holes.
2. Install with care not to allow the wave spring to shift its position.




22 Fit the snap ring.




23. Using a feeler gauge, measure the end play in low-reverse brake. Select a pressure plate to obtain the specified end play.

Standard value: 1.0-1.2 mm (0.039-0.047 in.)




24. Install the air exhaust plug and mount the plug.




25. Install the anchor rod.




26. lnstall the kickdown servo spring, piston, and sleeve.

CAUTION: Make sure that the ends of seal ring on the kickdown servo piston are not located at the oil supply port (indicated by arrows).




27. Using previously released drivers or deep well socket, press the kickdown servo piston and sleeve into position and fit the snap ring.




28. Fit the kickdown band.

CAUTION: Install so that the arrow points to the front.




29. Install thrust bearing # 4 and thrust washer # 2 to the rear clutch.




30. Mate the rear clutch with the front clutch.




31. Mount thrust bearing # 5 to the rear clutch hub.




32. Assemble the rear clutch hub to rear clutch.




33. Install thrust race # 6 to the rear clutch hub end face.




34. Install thrust bearing # 7 to the kickdown drum.




35. Assemble the clutch assembly to kickdown drum.




36. Install the clutch assembly and kickdown drum to the transaxle case at the same time.




37. Using petrolatum, affix thrust race # 3 and thrust washer # 1 to the rear end face of oil pump.




38. Using the special tool, install a new oil pump gasket and oil pump assembly.




39. Measure the end play in input shaft. If the measurement is out of specification, replace thrust race # 3 and thrust washer # 1 to obtain the specified end play.

Standard value: 0.3-1.0 mm (0.012-0.039 in.)




40. Install the spacer, idler gear, and bearing and insert the idler shaft.

CAUTION: Install so that the identification groove in the idler gear end face is on the rear face side.




41. Tighten the idler shaft lock bolt to specification and raise the new lock plate for locking.




42. Install the idler gear cover and new gasket.




43. Insert the end clutch shaft with its longer splines facing front.




44. Fit the thrust washer onto the end clutch return spring.




45. Install the end clutch hub to the end clutch assembly.




46. Using petrolatum, affix the thrust bearing to the end clutch hub.




47. Install the end clutch assembly.




48. Mount a new O-ring onto the end clutch cover.




49. Install the end clutch cover and tighten bolts to specification.




50. Install the differential assembly.




50. Place 10 mm-long (0.39 in), 1.6 mm-dia. (0.063 in.) solders at the locations shown of the differential rear bearing retainer and install the outer race.




51. Install the differential rear bearing retainer and tighten bolts to specification.
53. Loosen the bolts, remove the differential rear bearing retainer, and remove the solders. If the solders are not crushed, use larger dia. (3 mm or 0.12 in.) solders to repeat steps 51 to 53.




54. Measure the thickness of the solders crushed with a micrometer and select a spacer to obtain the specified and play and preload.

Standard value: Front differential case preload 0.075-0.135 mm (0.00295-0.00531 in.)




55. Fit a new O-ring to the differential rear bearing retainer, apply ATF, and mount the retainer to the transaxle case before torquing the bolts to specification.




56. Mount the front bearing cap and tighten bolts to specification. Be sure to install the short bolt to the side marked "S" of the bearing cap and the long bolt to the side marked "L".
57. Install the differential cover and new gasket.




58. Install the detent plate.




59. Fit new O-rings to the manual control shaft assembly, apply ATF, and insent it into the transaxle case.
60. Align the groove in manual control shaft with the set screw hole and install the set screw.




61. Mount the parking roller support.




62. Install the oil temperature sensor into the case.




63. Fit the O-ring into the O-ring groove in the top surface of valve body assembly.




64. Replace the solenoid valve harness grommet O-ring with a new one.
65. Pass the solenoid valve connector into the hole in transaxle case from the inside.
66. Press the solenoid valve harness grommet into the case hole.




67. Fitting the detent plate pin into the groove in manual valve, temporarily secure the valve body. Then, install the oil temperature sensor and holder and tighten bolts" to specification.

Bolt A = 18 mm (0.71 in.)
Bolt B = 25 mm (0.98 in.)
Bolt C = 40 mm (1.57 in.)

CAUTION:

Secure the solenoid valve and oil temperature sensor harnesses as shown. Especially the pressure control solenoid valve (PCSV) harness must be routed and clamped as shown in the illustration, since it is separated from other harnesses. Failure to secure the harness results in its contact with the detent plate or parking rod.

68. Install the oil screen.




69. Mount the magnet to oil pan and install the oil pan.




70. Install the park/neutral position switch and manual control lever.
71. Install the speedometer gear assembly.




72. Install pulse generator A and B.

CAUTION:

Install the black tube to the output gear side and transparent tube to end clutch side.

73. Mount the oil filler tube and insert the level gauge.
74. Install the brackets.
75. Adjust the kickdown servo.




76. Install the kickdown servo switch and secure it with the snap ring.




77. Apply ATF to the oil pump drive hub, install the torque converter, and push converter into position so that dimension A is up to specification.

Standard value: Approx. 16.3 mm (0.642 in.)