Part 2
36. After applying a coating of ATF to the O-rings, install the special tool (09453 - 21310) or equivalent, to the center support, and install within the case.
CAUTION: Be sure that the wave spring is not out of position.
37. Install the snap ring.
38. Install the anchor rod.
39. Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston. Install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.
40. Press the kickdown servo and sleeve in using special tools (09222 - 28000, 09222 - 28100, 09456 - 21100) or equivalents, then install the snap ring.
41. Install the kickdown band. Attach the band ends to the end of the anchor rod and servo piston rod.
42. Install kickdown drum with its splines in mesh with the sun gear. Place the kickdown band on the kickdown drum and tighten kickdown servo adjusting screw to keep the band in position.
43. Apply a coating of petroleum to thrust bearing #8, and attach to the kickdown drum.
44. Apply a coming of petroleum to thrust race #7, and attach to the rear clutch hub.
45. Install clutch hub to the sun gear splices.
46. Attach thrust bearing #6 onto the hub using petroleum.
47. Apply a coating of petroleum to thrust washer #2 and thrust bearing #4, and attach them to the rear clutch assembly.
48. Combine the rear clutch and front clutch assembly.
49. Install the clutch assembly.
50. Install the differential assembly.
51. If the end play measured and recorded at disassembly is not standard value, adjust end play to specification by selecting thrust washer #1.
Standard value:
End play: 3-1.0 mm (0.012-0.040 inch)
When the thrust race is replaced with one of a different thickness, also replace thrust race #3, located between oil pump and front clutch, with washer of proper thickness corresponding to thrust race.
Find correct pair of thrust races (metal) and thrust washers (fiber) from following table.
Example: When a different thickness thick thrust washer is selected, a corresponding thrust washer must be paired with it.
52. Attach the reused thrust washer #1, or the one selected in step 51 to the front clutch by using petroleum jelly.
53. Install the special tool (09452 - 21401) or equivalent, to the case.
54. Use a coating of petroleum jelly to attach the reused thrust race #3, or the one selected in step 51, to the oil pump.
55. Install a new oil pump gasket and the oil pump assembly.
56. Install a new O-ring in groove of oil pump housing and apply automatic transaxle fluid lightly to the outside surface of O-ring.
57. Install the oil pump assembly by evenly tightening six bolts. When installing the oil pump assembly, be careful not to drop the thrust washer.
58. Check input shaft end play. Readjust if necessary (see step 51).
Standard value:
Input shaft end play: 0.012-0.040 mm (0.3-1.0 inch).
59. Apply solder length approximately 10 mm (0.40 inch) in diameter 3 mm (0.118 inch) to the differential assembly at the locations shown in the illustration.
60. Install new case gasket to transaxle case.
61. Install converter housing and tighten 14 bolts to 19-23 Nm (14-16 ft. lbs.).
62. Remove the converter housing and gasket.
63. Remove the crushed solder from outer race of differential bearing.
64. Measure the thickness of the crushed solder with a micrometer and select and install a spacer with a thickness that gives standard preload.
Standard value:
Thickness of the crushed solder: 0-0.15 mm (0-0.006 inch).
65. Apply silicone to hatched area of transaxle case.
66. Install new case gasket on transaxle case.
67. Install converter housing and tighten 14 bolts to 19-23 Nm (14-16 ft. lbs.).
68. Install end clutch shaft. Be sure to install the longer splines toward the front as shown.
69. Fit the thrust washer to the return spring at the end clutch side.
70. Install the end clutch hub to end clutch.
71. Attach, by petrolatum to attach thrust bearing #13 to the end clutch hub.
72. Install end clutch assembly.
73. Attach a new O-ring and D-ring to the end clutch cover.
CAUTION:
a. Install so that the D-ring is not twisted.
b. Apply a sufficient amount of automatic transaxle fluid to the bearing.
74. Attach the end cover and fasten it with four bolts.
CAUTION: When installing the end cover, be sure the screw hole is correctly aligned. If the end cover is turned (after it is installed) in order to align with the screw hole, the O-ring and/or the D-ring may be twisted as a result.
75. Install O-ring at center of top of valve body assembly (low & reverse oil pressure passage).
76. Install valve body assembly to case, fitting detent plate (manual control shaft) pin in slot of manual valve.
77. Replace the solenoid valve connector O-ring with a new one.
78. Insert the solenoid valve connector into the case. Be sure that the notched part of the connector faces as shown in the figure.
79. Tighten valve body assembly mounting bolts (10 pieces) to 10-12 Nm (90-102 inch lbs.).
A: 18 mm (0.709 inch) long.
B: 25 mm (0.984 inch) long.
C: 40 mm (1.575 inch) long.
80. Install oil filter. Tighten four oil filter mounting bolts to 5-7 Nm (48-60 inch lbs.).
81. Install five magnets in the five depressions provided on the oil pan.
82. Install new oil pan gasket and oil pan by tightening 12 bolts to 10-12 Nm (90-102 inch lbs.).
83. Install a new D-ring to the kickdown servo switch; then press into the case and secure it with a snap ring.
84. Install transaxle range switch and manual control lever. Adjust transaxle range switch.
85. Install pulse generators A and B.
86. After applying automatic transaxle fluid to outside surface of oil pump-side cylindrical portion of torque converter. Install torque converter carefully so as not to damage oil seal lip. Ensure that torque converter is in mesh with oil pump drive gear. Measure distance between ring gear end and converter housing end. Torque converter has been properly installed when measurement is about 12 mm (0.47 inch).