Part 1 of 2
REASSEMBLY
CAUTION:
1. Never reuse the gasket, O-ring, oil seal, etc. Always replace with a new one when reassembling.
2. Never use grease other than blue petrolatum jelly and white Vaseline.
3. 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.
4. Never apply sealant or adhesive to gaskets.
5. When replacing a bushing, replace the assembly which it belongs to.
6. Never use any cloth gloves or any rags during reassembly. Use nylon cloth or paper towels if you need to use something.
7. 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 tool to install the transfer drive gear.
3. Tighten the seven mounting bolts of the transfer drive gear to the specified torque.
4. Install the low-reverse brake piston, return spring, and spring retainer into the transaxle case.
5. Fit a new O-ring into the groove of one-way clutch inner race.
6. Check the placement of the identification notches in the one-way clutch inner race. Install the one-way clutch inner race to the transfer drive gear bearing so that the notches fall along the A - A line.
7. Put the snap ring on the inner race.
8. Set special tools as shown, and then compress the one-way clutch inner race and install the snap ring.
9. Install the wave spring.
10. Install the brake discs, brake plates and snap ring as shown in the figure.
NOTE: Do not install the pressure plate at this time.
Number of brake discs and plates
CAUTION: If necessary, take the measurements in steps 10 to 19 after replacing the pressure plate, brake plate and brake disc.
11. Install special tool as shown in the figure.
12. Install the reaction plate and the used snap ring.
13. Move the special tool to measure the end play, and then replace the snap ring installed in step (12) to adjust the end play to standard value.
Standard value: 0 - 0.16 mm (0 - 0.0063 inch)
14. Install the brake disc and brake plate as shown in the figure.
Number of brake discs and plates
15. Install special tool as shown in the figure.
NOTE: Do not install the pressure plate at this time.
16. Install the return spring, second brake piston and snap ring.
17. Move the special tool (MB991631) and measure its movement.
Standard value:
0.49 - 0.95 mm (0.0193 - 0.0374 inch)
0.79 - 1.25 mm (0.0311 - 0.0492 inch)
Select a pressure plate whose thickness corresponds to the measured amount of movement from the following table.
PRESSURE PLATE
PRESSURE PLATE
18. Turn the transaxle over.
19. Install the special tool (MD998913) in a dial gauge, and then move the special tool (MB991631) and measure its movement.
Standard value:
1.05 - 1.51 mm (0.0413 - 0.0594 inch)
1.35 - 1.81 mm (0.0531 - 0.0713 inch)
Select a pressure plate whose thickness corresponds to the measured amount of movement from the table.
PRESSURE PLATE
PRESSURE PLATE
20. Remove all parts and special tools that were installed to take the measurements in steps 9 to 19. Remove and separate the pressure plate and snap ring chosen in steps 13, 17 and 19.
21. Install the snap ring and the thinnest adjustment spacer [1.88 mm (0.0740 inch)].
NOTE: The spacer may have to be replaced with one having an adequate thickness after the end play of the output shaft is checked in step (26).
22. Use the special tools to tap the output shaft bearing outer race in the transaxle case.
23. Tighten the mounting bolts of the output shaft bearing retainer to the specified torque.
CAUTION: Do not reuse the bolt, as it is coated with sealant.
24. 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.
25. 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.
CAUTION: The lock nut has left-handed threads.
26. Move the output shaft to measure the shaft end play, and then replace the spacer installed in step (21) with a new one which thickness is within the following value.
A = Shaft end play mm (inch)
B = Thickness of spacer assembled in step (21) [1.88 mm (0.0740 inch)]
Metric values: [A + B + 0.01 mm] to [A + B + 0.09 mm]
American values: [A + B + 0.0004 inch] to [A + B + 0.0035 inch]
27. Prevent the lock nut from turning (two parts).