Part 1

REASSEMBLY

NOTICE:
The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
Recommended ATF: D-11 or DEXRON III (DEXRON II)
All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
Dry all parts with compressed air-never use shop rags.
When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face.
The recommended automatic transaxle fluid or kerosene should be used for cleaning.
After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly.
When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
New discs for the brakes and clutches that are to be used for replacement mist be soaked in ATF for at least 15 minutes before reassembly.
All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.
All gaskets and rubber O-rings should be replaced.
Do not use adhesive cements on gaskets and similar parts.
Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
If a worn bushing is to be replaced, the sub-assembly containing that bushing must also be replaced.
Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts inch place.
When working with FIPG material, you must observe the following.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surface.
Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.








Bearing And Races Installation Position And Direction





1. INSTALL BEARING TO TRANSAXLE HOUSING
a. Using SST and a press, install the bearing into the transaxle housing.
SST 09350 - 32014 (09351 - 32140)





b. Install the bearing stopper with the bolt.

Torque: 17 Nm (170 kgf-cm, 12 ft. lbs.)





2. INSTALL OIL PIPE
a. Using a plastic hammer, install the 2 oil pipes.

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





b. Install the 3 pipe clamps with the 3 bolts.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





3. INSTALL BEARING TO TRANSAXLE CASE
Using SST and a press, install the bearing into the transaxle case.
SST 09350 - 32014 (09351 - 32090)





4. INSTALL B4 ACCUMULATOR PISTON AND SPRING





5. INSTALL OIL GALLERY COVER AND GASKET
a. Clean the threads of the screws and case with white gasoline.
b. Install a new gasket and oil gallery cover inch place.
c. Install and tighten the 3 bolts.

Torque: 10 Nm (1102 kgf-cm, 7 ft. lbs.)





d. Apply seal packing or equivalent to the 6 screws.

Seal packing: Part No. 08833 - 00070, THREE BOND 1324 or equivalent

e. Using a torx wrench, install the 6 screws.

Torque: 7.0 Nm (75 kgf-cm, 65 inch lbs.)





6. INSTALL MANUAL VALVE SHAFT AND LEVER
a. Install the parking lock rod to the manual valve lever.
b. Slide in the shaft and install the washer, a new spacer and manual lever.





c. Install the retaining spring.

HINT: Make sure there is a washer between the retaining spring and case.





d. Using a punch and hammer, drive in the pin.
e. Position the spacer and stake it.





7. INSTALL PARKING LOCK PAWL
a. Install the cam guide bracket and then insert the parking lock rod into the guide bracket.





b. Install the parking lock sleeve protruding portion upward.





c. Place the stopper plate on the protruding portion of lock sleeve.





d. Install the guide sleeve and spring with the 2 bolts.

Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





e. Install the parking lock pawl.





f. Install the parking lock pawl shaft and install the shaft clamp with the 2 bolts.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)





8. INSTALL 1ST & REVERSE BRAKE
a. Install 2 new O-rings to the piston.
b. Coat the O-rings with ATF.





c. Place the piston into the bore of the case, facing the spring seats upward.

NOTICE: Be careful not to damage the O-rings.





d. Install the piston return spring assembly and snap ring in place.
e. Place SST on the return spring, and compress the return spring with a press.
SST 09350 - 32014 (09351 - 32040)
f. Using snap ring pliers, install the snap ring.

HINT: Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw.





9. INSTALL U/D BRAKE
a. Coat 2 new rings with ATF.
b. Install the 2 O-rings to the piston.





c. Place the piston into the case with the cup side up, being careful not to damage the O-rings.





d. Install the return spring.





e. Install the Plates, discs and flange in order.

Install in order: D = Disc P = Plate F = Flange P-D-P-D-P-D-F

HINT: Install the flange with the flat end facing downward.





f. Place SST on the flange, and compress the flange with a press.
SST 09350 - 32014 (09351 - 32070)
g. Using a screwdriver, install the snap ring.

HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.





10. CHECK PACK CLEARANCE OF U/D BRAKE
Using a dial indicator, measure the U/D brake pack clearance.

Pack clearance (reference): 1.15 - 1.97 mm (0.0453 - 0.0776 inch.)

If the pack clearance is non-standard, parts have been misassembled. Check them.





11. INSTALL OIL SEAL RING TO TRANSAXLE CASE
Install the 2 oil seal rings to the transaxle case.





12. INSTALL COUNTER DRIVE GEAR
a. Install the front bearing and spacer.





b. Using SST and a press, install the counter drive gear, front bearing, and a new spacer.
SST 0935G - 32014 (09351 - 32130, 09351 - 32150)





13. INSTALL INTERMEDIATE SHAFT
a. Install the intermediate shaft.





b. Using SST, install the lock nut.
SST 09960 - 10010(09962 - 01000,09963 - 01000)





14. CHECK DRIVE GEAR PRELOAD
Using a torque wrench, measure the starting torque of the counter drive gear.

Starting torque:
New bearing: 0.3 - 0.7 Nm (3.1 - 7.1 kgf-cm, 2.6 - 6.1 inch lbs.)
Reused bearing: 0.2 - 0.4 Nm (2.0 - 4.1 kgf-cm, 1.7 - 3.5 inch lbs.)

If the torque is exceeded, replace the spacer.





15. STAKE LOCK NUT
Using pin punch and hammer, stake the lock nut.





16. INSTALL U/D ONE-WAY CLUTCH





17. INSTALL ANTI-RATTLE CLIP
In the place shown in the illustration (the space between the one-way clutch outer race and case), push the anti-rattle clip in until you hear the "click".





18. INSTALL U/D CLUTCH ASSEMBLY
a. Align the flukes of discs in the U/D brake.
b. Install the clutch assembly.
c. Turn the clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.





19. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the inner race.

Height: 17.3 - 18.2 mm (0.681 - 0.717 inch.)





20. CHECK PISTON STROKE OF U/D CLUTCH
a. Set a dial indicator and measuring terminal (SST) together.
SST 09350 - 32014 (09351 - 32190)





b. While applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi), measure the U/D clutch piston stroke.

Piston stroke: 1.47 - 1.87 mm (0.0579 - 0.0736 inch.)

If the piston stroke is less than limit, parts may have been misassembled. Check them.
If the piston stroke is non-standard, select another flange.

HINT: There are 4 different thicknesses for the flange.

Flange thickness:
2.04 mm (0.0803 inch.)
2.20 mm (0.0866 inch.)
2.40 mm (0.0945 inch.)
2.50 mm (0.0984 inch.)





21. INSTALL THRUST BEARING WITH RACE
Install the thrust bearing with race, with the bearing facing upward.

Bearing:
Outer diameter: 43.9 mm (1.728 inch.)
Inner diameter: 31.0 mm (1.220 inch.)





22. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.





23. INSTALL COUNTER SHAFT ASSEMBLY
a. Align the flukes of the discs in the U/D clutch.
b. Install the thrust bearing with the race, with the bearing facing upward.

Bearing:
Outer diameter: 43.9 mm (1.728 inch.)
Inner diameter: 31.0 mm (1.220 inch.)

c. Install the counter shaft assembly.





24. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.

Height: 30.3 - 32.5 mm (1.193 - 1.280 inch.)





25. INSTALL THRUST NEEDLE BEARING

Bearing:
Outer diameter: 58.0 mm (2.283 inch.)
Inner diameter: 41.0 mm (1.614 inch.)