Install Underdrive Output Shaft Oil Seal Ring

(a) Coat a new oil seal ring with ATF and install it to the transaxle housing.

5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING

(a) Coat the underdrive cylindrical roller bearing with ATF.

(b) Using SST and a press, install the underdrive cylindrical roller bearing.

SST 09950-60020 (09951-00810), 09950-70010

(09951-07100) NOTICE:

Do not apply excessive pressure to the bearing.

6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING

(a) Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover. NOTICE:

• Do not expand the end gap of the oil seal ring too much.

• Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.

D003810E01

7. INSTALL NEEDLE ROLLER BEARING

(a) Wrap vinyl tape around the SST 4.0 mm (0.157 in.) from the bottom of the SST until the thickness of the tape is about 5.0 mm (0.197 in.).

SST 09950-60010 (09951-00320), 09950-70010

(09951-07100) NOTICE:

Clean SST to remove deposited oil, before wrapping vinyl tape.

(b) Coat the needle roller bearing with ATF.

(c) Using SST and a press, install the needle-roller bearing to the transaxle case.

SST 09950-60010 (09951-00320), 09950-70010

(09951-07100) NOTICE:

When the wrapped vinyl tape contacts the transaxle case, stop press-fitting.

D003810E01

8. INSTALL UNDERDRIVE BRAKE PISTON

(a) Coat 2 new O-rings with ATF, and install them to the underdrive brake piston.

NOTICE:

• Make sure that the O-rings are not twisted or pinched when they are installed.

• Apply sufficient ATF to the O-ring before installing.

(b) Coat the underdrive brake piston with ATF.

(c) Install the underdrive brake piston to the transaxle case. NOTICE:

Be careful not to damage the O-ring.

9. INSTALL UNDERDRIVE BRAKE RETURN SPRING

SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.

SST 09387-00020

(b) Using a snap ring expander, install the snap ring to the transaxle case.

NOTICE:

• Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.

• Do not expand the snap ring excessively.

• Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.

• The snap ring should be fully engaged in the groove of the transaxle case.

10. INSTALL BREATHER PLUG NO.2 (ATM)

11. INSTALL COUNTER DRIVE GEAR BEARING

(a) Coat the counterdrive gear bearing with ATF.

(b) Using SST and a press, install the bearing outer race.

SST 09950-60020 (09951-01030), 09950-70010

(09951-07150), 09649-17010 NOTICE:

• Do not apply excessive pressure to the bearing.

• Press-fit the bearing outer race until it contacts the transaxle case.

(c) Using a snap ring expander, install the snap ring. NOTICE:

The white mark side of the snap ring should face upward.

12. INSTALL COUNTER DRIVE GEAR

(a) Coat the couterdrive gear with ATF.

(b) Using SST and a press, install the tapered roller bearing to the counter drive gear.

SST 09950-70010 (09951-07150), 09649-17010 NOTICE:

Do not apply excessive pressure to the bearing.

N C089122E02

(c) Using SST and a press, install the counter drive gear and bearing to the transaxle case. SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) NOTICE:

Do not apply excessive pressure to the counter drive gear.

13. INSTALL 1ST AND REVERSE BRAKE PISTON

(b) Install the 2 O-rings to the 1st and reverse brake piston.

NOTICE:

• Make sure that the O-rings are not twisted or pinched when they are installed.

• Apply sufficient ATF to the O-ring prior to assembling.

(c) Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case. NOTICE:

Be careful not to damage the O-ring.

14. INSTALL 1ST AND REVERSE BRAKE RETURN

SPRING SUB-ASSEMBLY

(a) Place SST on the return spring and compress the return spring with a press.

SST 09387-00070

(b) Using a snap ring expander, install the snap ring to the transaxle case.

NOTICE:

• Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed.

• Do not expand the snap ring excessively.

• Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly.

• The snap ring should be fully engaged in the groove of the cylinder.

• Fix the snap ring to the inside of the claw of the spring seat firmly.

15. INSTALL FRONT PLANETARY RING GEAR

(a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. NOTICE:

Confirm that the snap ring is engaged in the groove of the brake hub correctly.

16. INSTALL FRONT PLANETARY GEAR ASSEMBLY

(a) Install the front planetary gear assembly to the brake hub.

Transaxle -Case

Transaxle -Case

2nd Brake Hub ,w/ Front Planetary Gear Assembly

Counter Drive Gear

*

—M

m/M —

/////W/DHh

(b) Using SST and a press, press-fit the front planetary gear assembly.

SST 09950-60010 (09951-00500), 09950-70010

(09951-07100) NOTICE:

• Do not apply excessive pressure to the planetary gear assembly.

• Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right).

(c) Install a new washer as shown in the illustration.

(d) Using SST, install the nut.

SST 09387-00030, 09387-00080 Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf) NOTICE:

Assemble the washer after pressing each part, then tighten the nut to the minimum tightening torque.

(e) Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not as specified, gradually tighten the nut until it reaches the specified value. SST 09387-00080 Standard:

Turning torque at 60 rpm Bearing: New Bearing:

Y 1 \

/ Lock Washer

D008074E01

0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) Used Bearing: 0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) HINT:

Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

(f) Tighten the nut gradually until the specified turning torque of tapered roller bearing is measured. Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf)

(g) Using a chisel and hammer, stake the front lock washer.

17. INSTALL INPUT SUN GEAR

(a) Coat the 2 thrust bearings with ATF.

(b) Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly.

NOTICE:

• Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race.

• Installing thrust bearing and front sun gears, be careful about the direction of the parts.

• Install the bearing race on the side of the front sun gear. Be careful about the direction of the race.

• Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct.

Thrust bearing and bearing race diameter: mm (in.)

Inside

Outside

Thrust Bearing, A

32.5 (1.28)

56.5 (2.224)

Bearing Race, B

40.2 (1.583)

59.3 (2.335)

Thrust Bearing, C

38.6 (1.520)

59.7 (2.35)

Bearing Race, D

38.6 (1.520)

59.3 (2.335)

18. INSTALL REAR PLANETARY GEAR ASSEMBLY

(a) Install the rear planetary gear assembly to the rear planetary ring gear.

(b) Using a screwdriver, install the snap ring. NOTICE:

Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.

19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC

(a) Coat the 6 discs with ATF.

(b) Install the 7 plates and 6 discs. NOTICE:

Make sure that the plates, discs, and flange are installed as shown in the illustration.

20. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE

(a) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).

(b) Select an appropriate flange so that the pack clearance will meet the specified value. Pack clearance:

Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

1

1.8 (0.071)

5

2.2 (0.087)

2

1.9 (0.075)

6

2.3 (0.091)

3

2.0 (0.079)

7

2.4 (0.094)

4

2.1 (0.083)

8

2.5 (0.098)

(c) Install the flange.

21. INSTALL SECOND BRAKE PISTON ASSEMBLY

(a) Install the second brake piston assembly to the transaxle case.

(b) Install the snap ring and measure the inside diameter. Inside diameter:

Greater than 167 mm (6.57 in.) NOTICE:

• Make sure that the taper snap ring is installed in the correct direction.

• When the diameter does not meet the specified value, replace the snap ring with a new one.

• After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.

22. INSTALL 1-WAY CLUTCH SLEEVE OUTER

(a) Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly.

NOTICE:

Make sure that the outer sleeve is installed in the correct direction.

23. INSTALL 1-WAY CLUTCH ASSEMBLY

(a) Install the 1-way clutch inner race to the 1-way clutch. NOTICE:

• Make sure that the inner race is installed in the correct direction.

• Confirm that the discrimination mark is visible.

(b) Check the rotating direction of 1-way clutch for the lock or free operation as shown in the illustration.

(c) Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer. Bearing diameter: mm (in.)

Inside

Outside

Bearing

53.6 (2.110)

Install the thrust bearing properly so that no-colored race will be visible.

24. INSTALL PLANETARY CARRIER THRUST WASHER NO.1

(a) Coat the planetary carrier thrust washer No.1 with yellow petrolatum, and install the washer onto the planetary sun gear assembly.

NOTICE:

After installing, confirm that the projection should be fixed firmly in the hole of the planetary sun gear assembly.

25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

(a) Coat the planetary carrier thrust washer No.2 with yellow petrolatum, and install the washer onto the rear planetary sun gear.

(b) Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear. Bearing diameter: mm (in.)

Inside

Outside

Race, A

33.0 (1.299)

45.4 (1.787)

Bearing, B

31.85 (1.254)

45.2 (1.78)

(c) Install the rear planetary sun gear assembly to the rear planetary gear. NOTICE:

Installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.

26. INSTALL 2ND BRAKE CLUTCH DISC

(a) Coat the 4 discs with ATF.

(b) Install the 4 discs and 5 plates to the transaxle case.

(c) Temporarily install the snap ring.

27. INSPECT PACK CLEARANCE OF 2ND BRAKE

(a) Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B).

(b) Select an appropriate flange so that the pack clearance will meet the specified value. Clearance:

Piston stroke = Dimension B - Flange thickness -Snap ring thickness 1.6 mm (0.063 in.) Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

1

3.0 (0.118)

5

3.4 (0.134)

2

3.1 (0.122)

6

3.5 (0.138)

3

3.2 (0.126)

7

3.6 (0.142)

4

3.3 (0.130)

8

-

(c) Temporarily remove the snap ring, attach the selected flange and reinstall the snap ring. NOTICE:

Secure the snap ring so that the ends visible through the groove of the transaxle case.

28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY

(a) Install the direct clutch hub to the planetary gear assembly.

NOTICE:

Be careful not to damage the bushing inside the overdrive clutch hub during installation.

(b) Coat the thrust bearing with ATF.

(c) Install the bearing race and the thrust bearing to the direct clutch hub.

NOTICE:

Be careful not to drop the bearing when it is installed.

Bearing and race diameter: mm (in.)

Inside

Outside

Bearing, A

24.7 (0.972)

39.5 (1.555)

Race, B

23.6 (0.929)

38.0 (1.496)

29. INSTALL DIRECT CLUTCH ASSEMBLY

(a) Coat the thrust bearing with ATF.

(b) Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly. NOTICE:

The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed.

(c) Clean the connecting part of the transaxle case and the rear cover.

(d) As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using vernier calipers (Dimension C).

(e) Using vernier calipers and a straightedge, measure the dimension shown in the illustration.

(f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install the selected bearing. End play:

Make sure that the no-colored race side is facing the direct clutch assembly.

HINT:

End play = Dimension D - Dimension C

Bearing th

ckness and diameter : mm (in.)

Thickness

Inside

Outside

3.6 (0.1417)

56.3 (2.217)

75.7 (2.980)

3.8 (0.1496)

56.3 (2.217)

75.7 (2.980)

30. INSTALL GOVERNOR APPLY GASKET NO.1

(a) Install 3 new governor apply gaskets No.1 to the transaxle case.

Brake Apply Tube

31. INSTALL BRAKE APPLY TUBE

(a) Install the clamp to the brake apply tube. NOTICE:

Make sure to install the clamp to the apply tube before installing the apply tube to the transaxle case. This prevents the apply tube from being deformed or damaged.

(b) Install the clutch apply tube.

(c) Install the brake apply tube and a bolt to the transaxle case.

The tube should be securely inserted until it reaches the stopper.

32. INSTALL NEEDLE ROLLER BEARING

(a) Using SST and a press, press the needle roller bearing into the transaxle rear cover.

SST 09950-60010 (09951-00230, 09952-06010) Press fit depth:

• The engraved mark side of the bearing should face upward.

• Repeat the press fit until the specified value is obtained.

(b) Coat a needle roller bearing with ATF.

33. INSTALL REAR CLUTCH OIL SEAL RING OUTER

(a) Coat 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover. NOTICE:

The snap ring should be fully engaged in the groove of the drum.

34. INSTALL TRANSAXLE CASE NO.1 PLUG

(b) Install the 4 O-rings to the 4 transaxle case No.1 plugs.

(c) Install the 4 transaxle case No.1 plugs to the transaxle rear cover.

35. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY

(a) Remove any packing material and be careful not to spill oil on the contact surfaces of the transaxle rear cover or the transaxle case.

(b) Apply FIPG to the cover. FIPG:

Part No. 08826-00090, THREE BOND 1281 or equivalent. NOTICE:

Make sure that the FIPG is applied in a bead (section diameter: ^1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed.

(c) Apply liquid sealer to the "A" bolt threads. Sealant:

Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.

(d) Install the 11 bolts. Torque: Bolt A

36. INSTALL UNDERDRIVE CLUTCH DISC NO.2

(a) Coat the 4 discs with ATF.

(b) Install the 4 discs, 4 plates and flange to the transaxle case.

NOTICE:

Be careful about the order of discs, plate and flange assembly.

(c) Using a screwdriver, install the snap ring. NOTICE:

The snap ring should be fully engaged in the groove of the drum.

37. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

(a) Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2, 57 psi). Pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 in.)

HINT:

Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

1

3.0 (0.118)

4

3.1 (0.122)

2

3.2 (0.126)

5

3.3 (0.130)

3

3.4 (0.134)

-

-

(b) Temporarily remove the snap ring and attach it to the flange.

(c) Reinstall the snap ring.

Free

Free

D003925E01

38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

(a) Install the underdrive clutch assembly to the 1-way clutch.

(b) Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.

39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY

(a) Install the outer race retainer to the 1-way clutch. NOTICE:

Fix the outer race retainer to the external tooth of the 1-way clutch firmly.

(b) Install the 1-way clutch to the transaxle case. NOTICE:

Make sure that the mark on the 1-way clutch outer race is visible.

(c) Using a screwdriver, install the snap ring to the transaxle case. NOTICE:

The snap ring should be fixed fully engaged in the groove of the transaxle case.

40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY

(a) Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch. Bearing and bearing race diameter: mm (in.)

Inside

Outside

Bearing

37.73 (1.4854)

58.0 (2.2835)

Race

29.9 (1.1772)

55.5 (2.185)

Parking Lock Pawl-—

^-Spring

Pawl Pin

N

D009691E01

(b) Install the underdrive clutch assembly to the transaxle case. NOTICE:

Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.

41. INSTALL PARKING LOCK PAWL

(a) Install the pawl pin and spring to the parking lock pawl.

(b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.

42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Install the underdrive planetary gear assembly to the transaxle case. NOTICE:

Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install them securely.

(b) Install the parking lock pawl shaft.

(c) Install the pawl shaft clamp with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

(d) Using a straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E). NOTICE:

Record dimension E for the following process.

Dimension (1) Dimension (2)

Dimension (1) Dimension (2)

D025511E01

D025511E01

(e) As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below. NOTICE:

Recoad dimension F for the following process.

HINT:

43. INSTALL MULTIPLE DISC CLUTCH HUB

(a) Install the thrust bearing race No.1 to the transaxle case while checking its direction. Bearing race diameter: mm (in.)

Inside

Outside

Bearing race

39.5 (1.555)

45.8 (1.803)

(b) Coat the thrust needle roller bearing and race with yellow petrolatum, install them onto the multiple disc clutch hub.

Thrust bearing and race diameter: mm (in.)

Inside

Outside

Thrust Bearing

36.4 (1.433)

52.2 (2.055)

(c) Coat the needle roller bearing with ATF.

(d) Install the needle roller bearing to the multiple clutch hub.

Bearing diameter: mm (in.)

Inside

Outside

Bearing

23.6 (0.929)

44 (1.732)

(e) Install the multiple clutch hub to the transaxle case.

44. INSTALL FORWARD CLUTCH ASSEMBLY

(a) Coat the thrust needle roller bearing with ATF.

(b) Install the thrust needle roller bearing to the forward clutch.

Thrust bearing diameter: mm

(in.)

Inside

Outside

Thrust Bearing

33.58 (1.3220)

Install the thrust bearing properly so that the no-colored race or blue ink jet race will be visible.

(c) Install the forward clutch to the forward clutch assembly.

NOTICE:

• Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely.

• Be careful not to damage the bushing inside of the forward clutch hub during installation.

45. INSTALL OVERDRIVE BRAKE GASKET

(a) Install 2 new overdrive brake gaskets.

Differential

Differential

46. INSTALL DIFFERENTIAL GEAR ASSEMBLY

(a) Install the differential gear assembly to the transaxle case.

Thrust Bearing Underdrive Race No.2

Differential Gear__/ Forward Clutch

Assembly f'r^sS Assembly

Differential Gear__/ Forward Clutch

Assembly f'r^sS Assembly

Do It Yourself Car Diagnosis

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