Part 1 of 2

REASSEMBLY

CAUTION:
- Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
- Never use grease other than blue petrolatum jelly and white Vaseline.
- Apply ATF to friction components, rotating parts, and sliding parts before installation. Immerse a new clutch disc or brake disc in ATF for at least two hours before assembling them.
- Never apply sealant or adhesive to gaskets.
- When replacing a bushing, replace the assembly which it belongs to.
- Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.
- Change the oil in the cooler system.





1. Use the special tools to tap the differential bearing outer race in the transaxle case.





2. Use the special tools to tap the output shaft bearing outer race in the transaxle case.
3. Install the used spacer and snap ring.





4. Install the transfer gear, low-reverse brake piston, return spring, and spring retainer, one-way clutch and O-ring.
5. Use the special tools to install the snap ring.





6. Install the wave spring.





7. Replace the pressure plate of the low-reverse brake with the special tool, and then install the (6) brake discs, (5) brake plates and snap ring as shown in the figure.





8. Install the reaction plate and the used snap ring.
9. Move the special tool to measure the end play, and then replace the snap ring installed in step (8) to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)





10. Replace the pressure plate of the second brake with the special tool, and then install the brake disc and brake plate as shown in the figure.
11. Install the return spring, second brake piston and snap ring.





12. Move the special tool (MB991632) to measure the end play.
Standard value: 1.09 - 1.55 mm (0.042 - 0.06 inch)





Remove the special tool. Use the following formula to determine the proper thickness range for the pressure plate. Install the correct size pressure plate based on your calculations.
Reference: Pressure Plate Thickness
A=Special tool end play measurement determined earlier in this step.
Metric values: [(A + 2.0 mm) - 1.55 mm] to [(A + 2.0 mm) - 1.09 mm]
English values: [(A + 0.079 inch) - 0.061 inch] to [(A + 0.079 inch) - 0.042 inch]
13. Turn the transaxle over.





14. Install the special tool (MD9989113) in a dial gauge, and then move the special tool (MB991632) to measure the axial play.
Standard value: 1.65 - 2.11 mm (0.065 - 0.08 inch)





Reference: Pressure Plate Thickness
A=Special tool end play measurement determined earlier in this step.
Metric values: [(A + 2.0 mm) - 2.11 mm] to [(A + 2.0 mm) - 1.65 mm]
English values: [(A + 0.079 inch) - 0.08 inch] to [(A + 0.079 inch) - 0.065 inch]
15. Remove the parts installed from steps (6) to (14).





16. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
Standard value: 23 Nm (17 ft. lbs.)





17. Install the output shaft in the transaxle case, and then use the special tool to install the collar and taper roller bearing in the output shaft.





18. Apply ATF to a new lock nut, and use the special tool to tighten the lock nut to the specified torque. Then turn back one turn, and tighten to the specified torque again.
Standard value: 167 Nm (123 ft. lbs.)

CAUTION: The lock nut has left-handed threads.





19. Move the output shaft to measure operating amount (A), and then replace the spacer installed in step (3) with a new one which thickness is within the following value.
A=Operating amount
B=Thickness of the old spacer
Metric values: [A + B + 0.015 mm] to [A + B + 0.075 mm]
English values: [A + B + 0.0006 inch] to [A + B + 0.003 inch]





20. Prevent the lock nut from turning by staking it in two places.





21. Install the cap as shown in the figure.





22. Use the special tool to install the transfer drive gear.





23. Tighten the eight mounting bolts of the transfer drive gear to the specified torque.
Standard value: 34 Nm (25 ft. lbs.)





24. Install the parking pawl, spacer, and spring. Then install the parking pawl shaft.





25. Install the parking roller support, and then the two parking roller support shafts.





26. Install the overdrive planetary carrier.

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS





27. Install the planetary reverse sun gear.





28. Install the wave spring.





29. Install the pressure plate, brake disc, and brake plate.





30. Install the snap ring.





31. Install the reaction plate.





32. Install the snap ring.





33. Install the brake disc, brake plate, and pressure plate.





34. Install the return spring and second brake piston.





35. Install the snap ring.





36. Install thrust bearing #5.

CAUTION: Be sure to install the thrust bearing in the correct direction.





37. Install the overdrive clutch hub and thrust bearing #6 to the reverse and overdrive clutch.

CAUTION: Be careful about the installation direction of the thrust bearing.





38. Install the reverse and overdrive clutch, and thrust bearing V.

CAUTION: Be careful about the installation direction of the thrust bearing.





39. Install the three O-rings.