Automatic Transmission Overhaul - U151E, U151F: Specifications Lexus RX II

SPECIFIED TORQUE FOR STANDARD BOLTS

STANDARD BOLTS TIGHTENING TORQUE SPECIFICATION

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HINT

Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut.

Example: Bolt = 4T

Nut = 4N or more

TORQUE SPECIFICATION

TORQUE SPECIFICATION

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1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY Remove the bolt and speedometer driven hole cover sub-assy from the transaxle assy. Remove the O-ring from the speedometer driven hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY Remove the nut, washer and control shaft lever. Using a screwdriver, unstake the nut stopper, and remove the lock nut and nut stopper. Remove the 2 bolts and pull out the park/neutral position switch.
3. REMOVE BREATHER PLUG HOSE Remove the breather plug hose from the transaxle case.
4. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Remove the union. Remove the O-ring from the union.
5. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Remove the elbow. Remove the O-ring from the elbow.
6. REMOVE SPEED SENSOR Remove the 2 bolts and the 2 speed sensors from the transaxle assy.
7. REMOVE TRANSAXLE CASE NO. 1 PLUG Remove the 4 transaxle case No. 1 plugs from the transaxle case. Remove the 4 O-rings from the 4 transaxle case No. 1 plugs.
8. FIX AUTOMATIC TRANSAXLE ASSY Fix the transaxle assy.
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Remove the 18 bolts, oil pan and gasket. Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle: Steel (magnetic).... bearing, gear and plate wear Brass (non-magnetic).... bushing wear
11. DISCONNECT TRANSMISSION WIRE Remove the 7 connectors from the shift solenoid valves. Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE Remove the bolt and transmission wire from the transaxle case.
13. REMOVE VALVE BODY OIL STRAINER ASSY Remove the 3 bolts and oil strainer. Remove the O-ring from the oil strainer.
14. REMOVE TRANSMISSION VALVE BODY ASSY Support the valve body assy and remove the 17 bolts and valve body assy.
15. REMOVE GOVERNOR APPLY GASKET NO. 1 Remove the governor apply gasket No. 1 from the transaxle case.
16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET Remove the transaxle case 2nd brake gasket from the transaxle case.
17. REMOVE BRAKE DRUM GASKET Remove the brake drum gasket from the transaxle case.
18. REMOVE CHECK BALL BODY Remove the check ball body and spring from the transaxle case.
19. REMOVE C-3 ACCUMULATOR PISTON Remove the spring from the C-3 accumulator piston. Apply compressed air (392 kPa, 4.0 kgf/cm 2,57 psi) to the oil hole and remove the C-3 accumulator piston. NOTE: Blowing off the air may cause the piston to jump-out. When removing the piston, hold it by your hand using a waste cloth. Take care not to splash ATF when air-blowing. Remove the O-ring from the C-3 accumulator piston.
20. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2,57 psi) to the oil hole and remove the reverse accumulator piston and spring. NOTE: Blowing off the air may cause the piston to jump-out. When removing the piston, hold it by your hand using a waste cloth. Take care not to splash ATF when air-blowing. Remove the 2 O-rings from the reverse clutch accumulator piston.
21. REMOVE B-3 ACCUMULATOR PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2,57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs. NOTE: Blowing off the air may cause the piston to jump-out. When removing the piston, hold it by your hand using a waste cloth. Take care not to splash ATF when air-blowing. Remove the O-ring from the B-3 accumulator piston.
22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING Using a needle-nose pliers, remove the manual valve lever shaft retainer spring.
23. REMOVE MANUAL DETENT SPRING SUB-ASSY Remove the 2 bolts, the manual detent spring sub-assy and cover.
24. REMOVE PARKING LOCK PAWL BRACKET Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB-ASSY Using a chisel and hammer, cut off and remove the spacer. Using a pin punch (35 mm) and hammer, drive out the pin. HINT: Slowly drive out the pin so that it will not fall into the transaxle case. Remove the manual valve lever shaft and manual valve lever.
26. REMOVE PARKING LOCK ROD SUB-ASSY Remove the parking lock rod from the manual valve lever.
27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL Using a screwdriver, remove the oil seal from the transaxle case.
28. FIX AUTOMATIC TRANSAXLE ASSY Fix the transaxle case with the oil pump side facing up.
29. INSPECT INPUT SHAFT ENDPLAY Using a dial indicator, measure the input shaft endplay. Endplay: 0.262 - 1.244 mm (0.01 - 0.049 in.)
30. REMOVE TRANSAXLE HOUSING Remove the 16 bolts. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. NOTE: Differential may be accidentally removed when the transaxle housing is removed.
31. REMOVE OIL PUMP ASSY Remove the 7 bolts and oil pump from the transaxle case.
32. REMOVE THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing from the under-drive planetary gear assy.
33. REMOVE THRUST BEARING UNDERDRIVE RACE NO. 2 Remove the thrust bearing underdrive race No. 2 from the underdrive planetary gear assy.
34. REMOVE DIFFERENTIAL GEAR ASSEMBLY Remove the differential gear assy from the transaxle case.
35. REMOVE OVERDRIVE BRAKE GASKET Remove the 2 overdrive brake gaskets from the transaxle case.
36. REMOVE FORWARD CLUTCH ASSY Remove the forward clutch assy from the transaxle case. Remove the thrust needle roller bearing from the forward clutch.
37. REMOVE MULTIPLE DISC CLUTCH HUB Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and thrust bearing race No. 1 from the transaxle case.
38. INSPECT MULTIPLE DISC CLUTCH HUB Using a dial indicator, measure the inside diameter of the forward clutch hub bushing (Scheme 538) Standard inside diameter: 23.025 - 23.046 mm (0.9065 - 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) NOTE: When the diameter is over the maximum, replace the multiple disc clutch hub with new one. Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assy with new one. If the inside diameter is greater than the maximum, replace the forward clutch hub.
39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY Remove the bolt and pawl shaft clamp. Remove the parking lock pawl shaft. Push the parking lock pawl. HINT: Failure to do so will cause interference when the underdrive planetary gear is removed. Remove the underdrive planetary gear assy from the transaxle case. NOTE: Be careful so that the underdrive planetary gear assy will not fall out.
40. REMOVE PARKING LOCK PAWL Remove the spring, pawl pin and parking lock pawl.
41. REMOVE UNDERDRIVE CLUTCH ASSY Remove the underdrive clutch assy, thrust bearing and bearing race from the transaxle case.
42. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY Using a screwdriver, remove the snap ring from the transaxle case. Remove the underdrive 1-way clutch from the transaxle case. Remove the outer race retainer from the 1-way clutch.
43. REMOVE UNDERDRIVE CLUTCH DISC NO. 2 Using a screwdriver, remove the snap ring. Remove the flange, 4 discs and 4 plates from the transaxle case.
44. INSPECT UNDERDRIVE CLUTCH DISC NO. 2 Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. NOTE: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
45. REMOVE TRANSAXLE REAR COVER SUB-ASSY Remove the 11 bolts. Tap in the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
46. REMOVE TRANSAXLE CASE NO. 1 PLUG Remove the 4 transaxle case No. 1 plugs from the transaxle rear cover. Remove the 4 O-rings from the 4 transaxle case No. 1 plugs.
47. REMOVE REAR CLUTCH OIL SEAL RING OUTER Remove the 3 rear clutch oil seal rings from the transaxle rear cover.
48. REMOVE NEEDLE ROLLER BEARING Using SST, remove the needle-roller bearing from the transaxle rear cover. SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)
49. REMOVE GOVERNOR APPLY GASKET NO. 1 Using a screwdriver, remove the 3 apply gaskets.
50. REMOVE BRAKE APPLY TUBE Remove the bolt, clamp and brake apply tube. Remove the clutch apply tube. Remove the brake apply tube from the clamp.
51. REMOVE DIRECT CLUTCH ASSY Remove the thrust bearing and the direct clutch assy from the transaxle case.
52. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub from the planetary gear assy.
53. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY Using a dial indicator, measure the inside diameter of the forward clutch hub bushing. Standard inside diameter: 23.025 - 23.046 mm (0.9065 - 0.9073 in.) Maximum inside diameter: 23.09 mm (0,9091 in.) NOTE: When the diameter is over the maximum, replace the multiple disc clutch hub with new one. Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assy with new one. If the inside diameter is greater than the maximum, replace the forward clutch hub.
54. REMOVE REAR PLANETARY SUN GEAR ASSY Remove the rear planetary sun gear assy from the transaxle case. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assy. Remove the planetary carrier thrust washer No. 2 from the rear planetary sun gear assy.
55. REMOVE 1 WAY CLUTCH ASSY Remove the 1-way clutch assy and the thrust needle roller bearing from the transaxle case. Remove the 1-way clutch inner race from the 1-way clutch assy.
56. REMOVE 1WAY CLUTCH SLEEVE OUTER Remove the 1-way clutch sleeve outer from the transaxle case.
57. REMOVE PLANETARY CARRIER THRUST WASHER NO. 1 Remove the planetary carrier thrust washer No. 1 from the planetary gear assy.
58. REMOVE 2ND BRAKE CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 4 discs and 4 plates from the transaxle case.
59. INSPECT 2ND BRAKE CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. NOTE: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
60. REMOVE SECOND BRAKE PISTON ASSY Using a screwdriver, remove the snap ring. Remove the second brake piston assy from the transaxle case.
61. REMOVE REAR PLANETARY GEAR ASSY Using a screwdriver, remove the snap ring. Remove the rear planetary gear assy from the transaxle case.
62. REMOVE INPUT SUN GEAR Remove the 2 thrust needle roller bearings, thrust bearing race No. 2 and input sun gear from the transaxle case.
63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC Remove the flange, 6 discs and 6 plates from the transaxle case.
64. INSPECT 1 ST & REVERSE BRAKE CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. NOTE: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
65. REMOVE FRONT PLANETARY GEAR ASSY Using a chisel and hammer, unstake the lock washer. NOTE: Push down all claws of the washer. Otherwise SST cannot be fully pressed against the nut, and cannot loosen the nut. Using SST, remove the nut. SST 09387-00030, 09387-00080 Using SST and a press, remove the front planetary gear assy from the counter drive gear. SST 09950-60010 (09951-00450), 09950-70010 (09951-07100) Remove the front planetary gear assy from the brake hub.
66. REMOVE FRONT PLANETARY RING GEAR Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
67. REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY Place SST on the return spring, and compress the return spring with a press. SST 09387-00070 Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring sheet is lowered 1-2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming. Do not expand the snap ring excessively.
68. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.61 mm (0.6933 in.)
69. REMOVE 1 ST & REVERSE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2,57 psi) to the transaxle case to remove 1st & reverse brake piston. NOTE: Blowing off the air may cause the piston to jump-out. When removing the piston, hold it by your hand using a waste cloth. Take care not to splash ATF when air-blowing. Remove the 2 O-rings from the 1st & reverse brake piston.
70. REMOVE COUNTER DRIVE GEAR Using SST and a press, remove the counter drive gear from the transaxle case. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) As shown in the illustration, tighten 2 bolts evenly and make clearance of approx. 20.0 mm (0.797 in.) between the counter drive gear and the inner race. Using SST, remove the tapered roller bearing. SST 09950-60010 (09951-00590), 09950-70010 (09951-07100), 09950-00020, 09950-00030, 09950-40011 (09957-04010)
71. REMOVE COUNTER DRIVE GEAR BEARING Using a snap ring expander, remove the snap ring. Using SST and a press, remove the bearing outer race. SST 09950-60020 (09951-00910), 09950-70010 (09951-07100)
72. REMOVE BREATHER PLUG NO. 2 (ATM)
73. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY Place SST on the return spring, and compress the return spring with a press. SST 09387-00020 Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring sheet is lowered 1-2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming. Do not expand the snap ring excessively.
74. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 13.24 mm (0.5213 in.)
75. REMOVE UNDERDRIVE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2,57 psi) to the transaxle case to remove the underdrive brake piston. Remove the 2 O-rings from the underdrive brake piston.
76. REMOVE NEEDLE ROLLER BEARING Using SST, remove the needle-roller bearing from the transaxle case. SST 09387-00041 (09387-01010, 09387-01030, 09387-01040)
77. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING Remove the 2 oil seal rings from the transaxle case.
78. REMOVE TRANSAXLE CASE NO. 1 PLUG Remove the 2 transaxle case No. 1 plugs. Remove the 2 O-rings from the 2 transaxle case No. 1 plugs.
79. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING Using SST, remove the underdrive cylindrical roller bearing from the transaxle case. SST 09514-35011
80. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Remove the oil seal ring from the transaxle housing.
81. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.
82. BEARING POSITION THRUST BEARING DIAMETER AND FRONT/REAR RACE DIAMETER SPECIFICATION Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.) A - 57.2 (2.252) / 84.96 (3.3449) 56.4 (2.220) / 83.0 (3.268) B - 37.73 (1.4854) / 58.0 (2.283) - C - 33.85 (1.3327) / 52.2 (2.055) - D 24.94 (0.982) 23.5 (0.925)/44.0(1.732) - E - 36.3 (1.429)/51.93 (2.044) 34.5 (1.358) / 48.35 (1.904) F 34.35 (1.352) / 56.57 (2.227) 32.45 (1.278) / 56.48 (2.223) - G 40.15 (1.581)/59.25 (2.333) 38.65 (1.522) / 59.79 (2.354) 38.65 (1.522)/59.25 (2.332) H - 53.6 (2.110)/69.6 (2.740) - I 33.02 (1.3)/45.8 (1.803) 31.85 (1.254)/57.3 (2.256) - J - 24.79 (0.976)/39.5 (1.555) 23.6 (0.929) / 37.95 (1.494) K - 56.3 (2.216)/75.96 (2.991)
83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE Install the differential gear lube apply tube and transaxle apply tube clamp with the bolt to the transaxle housing. Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) NOTE: Make sure to insert the pipe to the stopper.
84. INSTALL TRANSAXLE CASE NO. 1 PLUG Install the 2 new O-rings to the 2 transaxle case No. 1 plugs. Install the 2 transaxle case No. 1 plugs to the transaxle rear cover. Torque: 7.4 N.m (75 kgf.cm, 65 in..lbf)
85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Coat the new oil seal ring with ATF and install it to the transaxle housing.
86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING Coat the underdrive cylindrical roller bearing with ATF. Using SST and a press, install the underdrive cylindrical roller bearing. SST 09950-60020 (09951-00810), 09950-70010 (09951-07100) NOTE: Do not apply excessive pressure to it.
87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING Coat the 2 new oil seal rings with ATF, install them to the transaxle rear cover. NOTE: Do not expand the gap of the oil seal ring too much. Fix the hooks certainly. Confirm the smooth rotation.
88. INSTALL NEEDLE ROLLER BEARING Wind a vinyl tape around SST at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.). NOTE: Clean SST to remove deposited oil, before winding a vinyl tape. Coat the needle roller bearing with ATF. Using SST and a press, install the needle-roller bearing to the transaxle case. SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) NOTE: When the wound vinyl tape contacts the transaxle case, stop press-fitting.
89. INSTALL UNDERDRIVE BRAKE PISTON Coat the 2 new O-rings with ATF, install them to the underdrive brake piston. NOTE: Assemble the O-ring carefully not to have a twist and a pinching. Apply enough ATF to the O-ring prior to assembling. Coat the underdrive brake piston with ATF. Install the underdrive brake piston to the transaxle case. NOTE: Be careful not to damage the O-ring.
90. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Place SST on the return spring and compress the return spring with a press. SST 09387-00020 Using a snap ring expander, install the snap ring to the transaxle case. NOTE: Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove, to prevent the spring sheet from deforming. Do not expand the snap ring excessively. Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. The snap ring should be fixed surely in the groove of the transaxle case.
91. INSTALL BREATHER PLUG NO. 2 (ATM)
92. INSTALL COUNTER DRIVE GEAR BEARING Coat the counterdrive gear bearing with ATF. Using SST and a press, install the bearing outer race. SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010 NOTE: Do not apply excessive pressure to it. Press-fit the bearing outer race until it contacts the transaxle case. Using a snap ring expander, install the snap ring. NOTE: Face the white mark side of the snap ring up.
93. INSTALL COUNTER DRIVE GEAR Coat the couterdrive gear with ATF. Using SST and a press, install the tapered roller bearing to the counter drive gear. SST 09950-70010 (09951-07150), 09649-17010 NOTE: Do not apply excessive pressure to it. Using SST and a press, install the counter drive gear and bearing to the transaxle case. SST 09223-15030, 09527-17011, 09950-60020 (09951-00750), 09950-70010 (09951-07150) NOTE: Do not apply excessive pressure to it.
94. INSTALL 1ST & REVERSE BRAKE PISTON Coat the 2 new O-rings with ATF. Install the 2 O-rings to the 1st & reverse brake piston. NOTE: Assemble the O-ring carefully not to have a twist and a pinching. Apply enough ATF to the O-ring prior to assembling. Coat a 1st & reverse brake piston with ATF, install it to the transaxle case. NOTE: Be careful not to damage the O-ring.
95. INSTALL 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY Place SST on the return spring and compress the return spring with a press. SST 09387-00070 Using a snap ring expander, install the snap ring to the transaxle case. NOTE: Stop the press when the spring sheet is lowered to the place 1--2 mm (0.039 - 0.078 in.) from the snap ring groove, preventing the spring sheet from being deformed. Do not expand the snap ring excessively. Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. The snap ring should be fixed surely in the groove of the cylinder. Fix the snap ring to the inside of the claw of the spring seat surely.
96. INSTALL FRONT PLANETARY RING GEAR Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. NOTE: Confirm the snap ring is fixed in the groove of the brake hub correctly.
97. INSTALL FRONT PLANETARY GEAR ASSY Install the front planetary gear assy to the brake hub. Using SST and a press, press-fit the front planetary gear assy. SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) NOTE: Do not apply excessive pressure to it. Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no pre-load should be applied to one pair of tapered roller bearings (left and right). Install the new washer, as shown. Using SST, install the nut. SST 09387-00030,09387-00080 Torque: 210-350 N.m (2,141 kgf.cm, 155 ft.lbf - 3,569 kgf.cm, 258 ft.lbf) NOTE: Assemble the washer after pressing each part, then tighten the nut to minimum tightening torque. 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 within the specified value, gradually tighten the nut until it reaches the specified value. SST 09387-00080 Turning torque at 60 rpm: New Bearing 0.51 - 1.02 N.m (5.1 - 10.0 kgf.cm, 4.4 - 8.7 in..lbf) Used Bearing 0.26 - 0.51 N.m (2.7 - 5.2 kgf.cm, 2.3 - 4.5 in..lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.). Tighten the nut gradually until the specified rotation torque of tapered roller bearing is measured. Torque: 350 N.m (3,569 kgf.cm, 258 ft.lbf) (a limit) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR Coat the 2 thrust bearings with ATF. Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assy. NOTE: Install the bearing race on the side of the front planetary carrier. Be careful about the orientation of the race. Installing thrust bearing and front sun gears, be careful about the orientation of the parts. Install the bearing race on the side of the front sun gear. Be careful about the orientation of the race. Install the thrust bearing and the race after holding the parts on the rear planetary carrier by applying grease. Be sure the assembling order. Thrust bearing and bearing race diameter: mm (in.) THRUST BEARING AND BEARING RACE DIAMETER SPECIFICATION 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)
99. INSTALL REAR PLANETARY GEAR ASSY Install the rear planetary gear assy to the rear planetary ring gear. Using a screwdriver, install the snap ring. NOTE: Confirm the snap ring is fixed in the groove of the 1st & reverse brake hub correctly.
100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC Coat the 6 discs with ATF. Install the 6 plates and 6 discs. NOTE: Be careful about the order of discs, plates and flange assembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A). Select an appropriate flange so that the pack clearance will meet the specified value. Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 in.) HINT: Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION 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) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY Install the second brake piston assy to the transaxle case. Install the snap ring and measure the inside diameter. Inside diameter: More than 167 mm (6.57 in.) NOTE: Because the taper snap ring has the positioning direction, check it when installing. When the diameter does not meet the specified value, replace the snap ring with new one. After assembling, confirm that there is no clearance between the second brake cylinder and the fitting surface of the cylinder in the transaxle case.
103. INSTALL 1WAY CLUTCH SLEEVE OUTER Install the 1-way clutch sleeve outer to the 2nd brake cylinder assy. NOTE: Check the positioning direction of the outer sleeve.
104. INSTALL 1 WAY CLUTCH ASSY Install the 1-way clutch inner race to the 1-way clutch. NOTE: Check the direction of the inner race. Confirm that the discrimination mark can be seen by the worker. Check the rotating direction of 1-way clutch for the lock or free operation, as shown in the illustration. Install the 1-way clutch and thrust needle roller bearing to the 1-way clutch sleeve outer. Bearing diameter: mm (in.) BEARING DIAMETER SPECIFICATION Inside Outside Bearing 53.6(2.110) 69.4 (2.732) NOTE: Install the thrust bearing properly so that no-colored race will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER NO. 1 Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, install it onto the planetary sun gear assy. NOTE: After assembling, confirm that the projection should be fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY Coat the planetary carrier thrust washer No. 2 with yellow petrolatum, install it onto the rear planetary sun gear. Coat the bearing with yellow petrolatum, install it onto the rear planetary sun gear. Bearing diameter: mm (in.) BEARING DIAMETER SPECIFICATION Inside Outside Race, A 33.0(1.299) 45.4 (1.787) Bearing, B 31.85(1.254) 45.2(1.78) Install the rear planetary sun gear assy to the rear planetary gear. NOTE: Installing the rear planetary sun gear assembly, confirm that the B1 discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC Coat the 4 discs with ATF. Install the 4 discs and 4 plates to the transaxle case. Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE Using a vernier calipers, measure the distance between the disc surface and snap ring surface (Dimension B). Select an appropriate flange so that the pack clearance will meet the specified value. Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.) HINT: Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.) Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION 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 - Temporarily remove the snap ring, attach the selected flange and restore the snap ring. NOTE: Secure the snap ring so that its gap is visible through the groove of the transaxle case.
109. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY Install the direct clutch hub to the planetary gear assy. NOTE: Be careful not to damage the bush inside of the overdrive clutch hub during installing. Coat the thrust bearing with ATF. Install the bearing race and the thrust bearing to the direct clutch hub. NOTE: Installing the bearing, hold the part on the side of the overdrive clutch hub. Bearing and race diameter: mm (in.) BEARING AND RACE DIAMETER SPECIFICATION Inside Outside Bearing, A 24.7 (0.972) 39.5 (1.555) Race, B 23.6 (0.929) 38.0 (1.496)
110. INSTALL DIRECT CLUTCH ASSY Coat the thrust bearing with ATF. Install the direct clutch assy and thrust bearing to the rear planetary sun gear assy. NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed. Clean the connecter part of the transaxle case and the rear cover. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between transaxle case and the straight edge using vernier calipers (Dimension C). Using vernier calipers and a simple straightedge, measure the position shown in the illustration. Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it. End play: 0.244 - 0.901 mm (0.0096 - 0.0355 in.) NOTE: Make sure that the no colored race side is facing the direct clutch assy. HINT: End play = Dimension D - Dimension C Bearing thickness and diameter: mm (in.) BEARING THICKNESS AND DIAMETER SPECIFICATION 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)
111. INSTALL GOVERNOR APPLY GASKET NO. 1 Install the 3 new governor apply gaskets No. 1 to the transaxle case.
112. INSTALL BRAKE APPLY TUBE Install the clamp to the brake apply tube. NOTE: 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. Install the clutch apply tube. Install the brake apply tube and a bolt to the transaxle case. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) NOTE: Each pipe should be securely inserted until it reaches the stopper.
113. INSTALL NEEDLE ROLLER BEARING Using SST and a press, install the needle roller bearing to the transaxle rear cover. SST 09950-60010 (09951-00230, 09952-06010) Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 in.) NOTE: Face the inscribed mark side of the bearing race up. Repeat the press fit until the specified value is obtained. Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER Coat the 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover. NOTE: The snap ring should be fixed certainly in the groove of the drum.
115. INSTALL TRANSAXLE CASE NO. 1 PLUG Install the 4 new O-ring to the 4 transaxle case No. 1 plugs. Install the 4 transaxle case No. 1 plugs to the transaxle rear cover. Torque: 7.4 N.m (75 kgf.cm, 65 in..lbf)
116. INSTALL TRANSAXLE REAR COVER SUB-ASSY Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case. Apply FIPG to the cover. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent. NOTE: Concerning about the amount of the FIPG application, the amount should be controlled to from even sealing film on entire flange surface and have slight protrusion of the FIPG all around of the connecting area. The FIPG shall be applied continuously on the flange. (Reference value of the section diameter: 1.2) Apply liquid sealer to the "A" bolt threads. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. Install the 11 bolts. Torque: Bolt A: 19.0 N.m (190 kgf.cm, 14 ft.lbf) Other bolt: 25.0 N.m (250 kgf.cm, 18 ft.lbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO. 2 Coat the 4 discs with ATF. Install the 4 discs, 4 plates and flange to the transaxle case. NOTE: Be careful about the order of discs, plate and flange assembly. Using a screwdriver, install the snap ring. NOTE: The snap ring should be fixed certainly in the groove of the drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 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 - 2.20 mm (0.0713 - 0.0866 in.) HINT: Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION 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) - - Temporally remove the snap ring and attach to the flange. Restore the snap ring.
119. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY Install the underdrive clutch assy to the 1-way clutch. Rotate the underdrive clutch assy to check the rotating direction for the lock or free operation.
120. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY Install the outer race retainer to the 1-way clutch. NOTE: Fix the outer race retainer to the external tooth of the one way clutch surely. Install the 1-way clutch to the transaxle case. NOTE: Make sure that the mark on the 1-way clutch outer race is visible. Using a screwdriver, install the snap ring to the transaxle case. NOTE: The snap ring should be fixed certainly in the groove of the transaxle case as the gap exists except in the lock of teeth.
121. INSTALL UNDERDRIVE CLUTCH ASSY Coat the bearing and bearing race with petroleum jelly, install them onto the underdrive clutch. Bearing and bearing race diameter: mm (in.) BEARING AND BEARING RACE DIAMETER SPECIFICATION Inside Outside Bearing 37.73 (1.4854) 58.0 (2.2835) Race 29.9(1.1772) 55.5(2.185) Install the underdrive clutch assy to the transaxle case. NOTE: Installing the underdrive clutch drum sub-assy, be sure not to damage the oil seal ring.
122. INSTALL PARKING LOCK PAWL Install the pawl pin and spring to the parking lock pawl. Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration.
123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY Install the underdrive planetary gear assy to the transaxle case. NOTE: Engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assy firmly and assemble them securely. Install the parking lock pawl shaft. Install the pawl shaft clamp with the bolt. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf) Using a straight edge 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 contact surface of the transaxle case and housing (Dimension E). NOTE: Note down the dimension E as it is necessary for the following process. As shown in the illustration, measure the 2 places of the transaxle housing, calculate the dimension F using the formula. NOTE: Write down the dimension F as it is necessary for the following process. HINT: Dimension F = Dimension (1) - Dimension (2)
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB Install the thrust bearing race No. 1 to the transaxle case while checking its direction. Bearing race diameter: mm (in.) BEARING RACE DIAMETER SPECIFICATION Inside Outside Bearing race 39.5 (1.555) 45.8 (1.803) 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.) THRUST BEARING AND RACE DIAMETER SPECIFICATION Inside Outside Thrust Bearing 36.4 (1.433) 52.2 (2.055) Coat the needle roller bearing with ATF. Install the needle roller bearing to the multiple clutch hub. Bearing diameter: mm (in.) BEARING DIAMETER SPECIFICATION Inside Outside Bearing 23.6 (0.929) 44 (1.732) Install the multiple clutch hub to the transaxle case.
125. INSTALL FORWARD CLUTCH ASSY Coat the thrust needle roller bearing with ATF. Install the thrust needle roller bearing to the forward clutch. Thrust bearing diameter: mm (in.) THRUST BEARING DIAMETER SPECIFICATION Inside Outside Thrust Bearing 33.58 (1.3220) 51.9 (2.043) NOTE: Install the thrust bearing properly so that the no colored race or blue ink jet race will be visible. Install the forward clutch to the forward clutch assy. NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely. Be careful not to damage the bush inside of the forward clutch hub during installing.
126. INSTALL OVERDRIVE BRAKE GASKET Install the 2 new overdrive brake gaskets.
127. INSTALL DIFFERENTIAL GEAR ASSEMBLY Install the differential gear assy to the transaxle case.
128. INSTALL THRUST BEARING UNDERDRIVE RACE NO. 2 Install the thrust bearing underdrive race No. 2 to the underdrive planetary gear assy.
129. INSTALL THRUST NEEDLE ROLLER BEARING Coat the thrust needle roller bearing with ATF. Calculate the end play value using the following formula and values of Dimension E and F that ware measured when installing cylindrical roller bearing and underdrive planetary gear. Select an appropriate underdrive planetary gear thrust bearing race No. 2 which satisfies the specified end play value, and install it. End play: 0.498 - 0.993 mm (0.01961 - 0.03909 in.) HINT: End play = Dimension F - Dimension E - thrust bearing thickness 2.5 mm (0.0984 in.) - underdrive thrust bearing race No. 2 thickness. Race thickness: mm (in.) BEARING RACE THICKNESS SPECIFICATION F-E Thickness Less than 7.72 (0.3039) 3.5 (0.138) 7.72 (0.3039) 3.8 (0.150) Bearing and bearing race diameter: mm (in.) BEARING AND BEARING RACE DIAMETER SPECIFICATION Inside Outside Bearing 57.2 (2.252) 84.96 (3.345) Bearing race 56.4 (2.22) 83 (3.268)
130. INSTALL OIL PUMP ASSY Install the oil pump to the transaxle case with the 7 bolts. Torque: 22.0 N.m (226 kgf.cm, 16 ft.lbf) Coat the O-ring of oil pump with ATF. NOTE: Confirm the input shaft rotates smoothly with the manual operation after assembling the oil pump.
131. INSTALL TRANSAXLE HOUSING Remove any parking material and be careful not to get oil on the contacting surface of the transaxle case or transaxle housing. Apply FIPG to the transaxle case. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent Install the transaxle housing and 16 bolts to the transaxle case. Torque: Bolt A: 25 N.m (255 kgf.cm, 18 ft.lbf) Bolt B: 33 N.m (337 kgf.cm, 24 ft.lbf) Bolt C: 29 N.m (295 kgf.cm, 21 ft.lbf) Bolt D: 22 N.m (226 kgf.cm, 16.0 ft.lbf) HINT: Apply seal packing or equivalent to the bolt A and D. Seal packing: THREE BOND 2403 or equivalent Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) Bolt D: 72 mm (2.835 in.) NOTE: Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application.
132. INSPECT INPUT SHAFT ENDPLAY Using a dial indicator, measure the input shaft end play. End play: 0.262 - 1.249 mm (0.0100 - 0.0494 in.)
133. FIX AUTOMATIC TRANSAXLE ASSY Fix the transaxle assy.
134. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL Coat a new oil seal with MP grease. Install the oil seal to the transaxle case. SST 09950-60010 (09951-00230), 09950-70010 (09951-07100) Oil seal drive in depth: 0 +/- 0.5 mm (0 +/- 0.0197 in.)
135. INSTALL PARKING LOCK ROD SUB-ASSY Install the parking lock rod to the manual valve lever.
136. INSTALL MANUAL VALVE LEVER SUB-ASSY Install a new spacer and manual valve lever shaft to the transaxle case. NOTE: Do not damage on the oil seal during assembling the shaft to the transaxle case. Using a pin punch and hammer, drive in a new pin. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft. Using a pin punch, stake the spacer through the small hole. Check that the spacer does not turn.
137. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING Using needle-nose pliers, install the retainer spring. NOTE: Hang the spring on the shaft certainly.
138. INSTALL PARKING LOCK PAWL BRACKET Install the parking lock pawl bracket with the 2 bolts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) Bolt length: 25 mm (0.984 in.) NOTE: Be sure the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is assembled.
139. INSTALL MANUAL DETENT SPRING SUB-ASSY Install the manual detent spring with the 2 bolts. NOTE: Make sure to install the manual detent spring and cover in this order. HINT: Tighten them in the order, A and B. Torque: Bolt A: 20 N.m (205 kgf.cm, 15 ft.lbf) Bolt B: 12 N.m (120 kgf.cm, 9 ft.lbf) Bolt length: Bolt A: 27 mm (1.063 in.) Bolt B: 16 mm (0.630 in.)
140. INSTALL B-3 ACCUMULATOR PISTON Coat a new O-ring with ATF, install it to the B-3 accumulator piston. NOTE: Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston with checking of the identification color or each spring. Accumulator spring: ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION Free length Outer diameter mm (in.) Color Inner 62.00 (2.4409) / 15.50(0.610) Purple Outer 74.23 (2.9224) / 21.70 (0.854) Purple
141. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON Coat the 2 new O-rings with ATF, install them to the reverse accumulator piston. NOTE: Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston with checking of the identification color or each spring. Accumulator spring: ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION Free length Outer diameter mm (in.) Color 60.96 (2.3999) / 14.10(0.555) Yellow
142. INSTALL C-3 ACCUMULATOR PISTON Coat a new O-ring with ATF, install it to the C-3 accumulator piston. NOTE: Install the O-ring to the accumulator piston and the accumulator sleeve not to have a twist and a protrusion. Moreover, apply enough ATF prior to assembling. Be sure to the installed position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston with checking of the identification color or each spring. Accumulator spring: ACCUMULATOR SPRING FREE LENGTH OUTER DIAMETER SPECIFICATION Free length Outer diameter mm (in.) Color 72.20 (2.8425) / 19.0 (0.748) Colorless Install the spring from the C-3 accumulator piston. NOTE: Install the springs to each accumulator piston with checking of the identification color or each spring.
143. INSTALL CHECK BALL BODY Coat the check ball body with ATF. Install the check ball body and spring. NOTE: Regarding the installation of the spring for the check ball body, be sure to place the spring in the hole in the ball body. Be careful about the parts orientation.
144. INSTALL BRAKE DRUM GASKET Coat a new brake drum gasket with ATF, install it to the transaxle case. NOTE: Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling. Also, be careful about the parts orientation.
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET Coat a new transaxle case 2nd brake gasket with ATF, install it to the transaxle case. NOTE: Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling. Also, be careful about the parts orientation.
146. INSTALL GOVERNOR APPLY GASKET NO. 1 Coat a new governor apply gasket No. 1 with ATF, install it to the transaxle case. NOTE: Be sure not to damage the lip portion of the transaxle case brake gasket when inserting the gasket to the case. Moreover, apply enough ATF to the gasket prior to assembling. Also, be careful about the parts orientation.
147. INSTALL TRANSMISSION WIRE Coat a new O-ring with ATF, install it to the transmission wire. NOTE: Be careful about the O-ring not to have a twist, a protrusion and a pinching during installing the wire transmission to the transaxle case. Moreover, apply enough ATF to the O-ring prior to assembling. Install the transmission wire retaining bolt. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
148. CONNECT TRANSMISSION WIRE Coat a O-ring of the ATF temperature sensor with ATF. Install the ATF temperature sensor, with the lock plate and bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in.lbf) Connect the 7 solenoid connectors. NOTE: Connect the connector to A, B, C, D, E, F, G, from shorter one. Apply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY Make sure that the manual valve lever position, install the valve body with 17 bolts to the transaxle case. Torque: 11 N.m (110 kgf.cm, 8 ft.lbf) Bolt length: ( Bolt A: 41 mm (1.614 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 25 mm (0.984 in.) NOTE: Push the valve body against the accumulator piston spring and the check ball body to install it. When installing the valve body to the transaxle case, do not hold the solenoids. Tighten temporarily those bolts marked by in the illustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY Coat a new O-ring with ATF, install it to the oil strainer. NOTE: Assemble the O-ring carefully not to have a twist and a pinching. Moreover, apply enough ATF to the O-ring prior to assembling. Install the oil strainer and 3 bolts to the valve body. Torque: 11 N.m (110 kgf.cm, 8 ft.lbf) NOTE: Apply ATF to the bolts.
151. INSTALL AUTOMATIC TRANSAXLE OIL SUB-ASSY Install the 2 magnets in the oil pan. Apply seal packing or equivalent to new 18 bolts. Seal packing: THREE BOND 2430 or equivalent Install the new oil pan gasket with the 18 bolts to the transaxle case. Torque: 7.8 N.m (80 kgf.cm, 69 in..lbf) NOTE: Because the bolts should be seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application. Remove any oil or grease from the contacting surface of the transaxle case and the oil pan with the gasket completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO. 1 PLUG Coat the 4 new O-rings with ATF, install them to the 4 transaxle case No. 1 plugs. Install the 4 transaxle case No. 1 plugs to the transaxle case. Torque: 7.4 N.m (75 kgf.cm, 65 in..lbf)
153. INSTALL SPEED SENSOR Install them to the 2 sensors. Install the 2 sensors to the transaxle case with the 2 bolts. Torque: 11.0 N.m (115 kgf.cm, 8 ft.lbf)
154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Coat a new O-ring with ATF, install it to the elbow. Install the elbow to the transaxle case. Torque: 27 N.m (276 kgf.cm, 20 ft.lbf)
155. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Coat a new O-ring with ATF, install it to the union. Install the union to the transaxle case. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
156. INSTALL BREATHER PLUG HOSE Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY Install the park/neutral position switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. Install a new nut stopper and nut. Torque: 6.9 N.m (70 kgf.cm, 61 in..lbf) Temporarily install control shaft lever. Turn the lever counterclockwise until it stops, and then turn it clockwise 2 notches. Remove the control shaft lever. Align the groove with neutral basic line. Tighten the 2 bolts. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) Using a screwdriver, stake the nut with the nut stopper. Install the control shaft lever, washer and nut. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY Coat a new O-ring with ATF and install it to the speedometer driven hole cover. Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy. Torque: 6.9 N.m (70 kgf.cm, 61 ft.lbf)

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1. INSPECT OIL PUMP ASSY Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTE: Be careful not to damage the oil seal lip.
2. REMOVE CLUTCH DRUM OIL SEAL RING Remove the 2 clutch drum oil seal rings.
3. REMOVE STATOR SHAFT ASSY Using a torx socket (T30), remove the 11 bolts and stator shaft. Keep the gears in assembling order.
4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: 0.10 - 0.17 mm (0.0039 - 0.0067 in.) Side clearance: 0.02 - 0.05 mm (0.001 - 0.02 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance is greater than the maximum, replace the oil pump body sub-assy. Using a feeler gauge measure the tip clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.07 - 0.15 mm (0.0028 - 0.0059 in.) Maximum tip clearance: 0.15 mm (0.0059 in.) If the tip clearance is greater than the maximum, replace the oil pump body sub-assy. Using a straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 - 0.05 mm (0.0008 - 0.0020 in.) Maximum side clearance: 0.05 mm (0.0020 in.) Drive gear thickness: mm (in.) DRIVE GEAR THICKNESS SPECIFICATION Mark Thickness A 11.690 - 11.699 (0.4602 - 0.4606) B 11.700 - 11.709 (0.4606 - 0.4610) C 11.710 - 11.720 (0.4610 - 0.4614) D 11.721 - 11.730 (0.4615 - 0.4618) E 11.731 - 11.740 (0.4619 - 0.4622) Driven gear thickness: mm (in.) DRIVEN GEAR THICKNESS SPECIFICATION Mark Thickness A 11.690 - 11.699 (0.4602 - 0.4606) B 11.700 - 11.709 (0.4606 - 0.4610) C 11.710 - 11.720 (0.4610 - 0.4614) D 11.721 - 11.730 (0.4615 - 0.4618) E 11.731 - 11.740 (0.4619 - 0.4622)
5. REMOVE FRONT OIL PUMP DRIVE GEAR Remove the front oil pump drive gear.
6. REMOVE FRONT OIL PUMP DRIVEN GEAR Remove the front oil pump driven gear.
7. REMOVE FRONT OIL PUMP BODY O-RING Using a screwdriver, remove the O-ring. HINT: Tape the screwdriver before use.
8. REMOVE FRONT OIL PUMP OIL SEAL Mount oil pump in a soft jaw vise. Using SST, remove the oil seal from the oil pump body. SST 09308-00010
9. INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 38.113 - 38.138 mm (1.50051 - 1.50149 in.) Maximum inside diameter: 38.188 mm (1.50346 in.) If the inside diameter is greater than the maximum, replace the oil pump body sub-assy.
10. INSPECT STATOR SHAFT ASSY Using a dial indicator, measure the inside diameter of the stator shaft. Standard inside diameter: 21.500 - 21.526 mm (0.84646 - 0.84748 in.) Maximum inside diameter: 21.57 mm (0.8492 in.) If the indicator diameter is greater than maximum, replace the stator shaft.
11. INSTALL FRONT OIL PUMP OIL SEAL Using SST and a hammer, install a new oil seal to the oil pump body. SST 09350-32014 (09351-32140) HINT: The seal end should be flat with the outer edge of the oil pump. Coat the lip of the oil seal with MP grease.
12. INSTALL FRONT OIL PUMP BODY O-RING Coat the new O-ring with ATF, install it to the oil pump body. NOTE: Assemble the O-ring carefully not to have a twist and a pinching. Moreover, apply enough ATF to the O-ring prior to assembling.
13. INSTALL FRONT OIL PUMP DRIVEN GEAR Coat the front oil pump driven gear with ATF, install it to the oil pump body with the marked side up.
14. INSTALL FRONT OIL PUMP DRIVE GEAR Coat the front oil pump drive gear with ATF, install it to the oil pump body with the marked side up.
15. INSTALL STATOR SHAFT ASSY Set the stator shaft aligned with each bolt hole. Using a torx socket (T30), install the 11 bolts. Torque: 9.8 N.m (100 kgf.cm, 87 in..lbf)
16. INSTALL CLUTCH DRUM OIL SEAL RING Coat the 2 new clutch drum oil seal rings with ATF. Install the 2 new clutch drum oil seal rings. NOTE: Do not expand the ring ends excessively.
17. INSPECT OIL PUMP ASSY Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTE: Be careful not to damage the oil seal lip.

Scheme 782

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Scheme 793

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Scheme 799

Scheme 800

Scheme 801

1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Install the forward clutch on the oil pump. NOTE: Be careful not to damage the oil seal ring of oil pump. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.) If the clearance is not within standard, inspect the discs, plates and flange. HINT: As the opening is large, cover it with a shop rug to prevent the compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 5 discs and 5 plates from the input shaft assy.
3. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc comes off or discolors, or even if replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSY Place SST on the spring retainer and compress the return spring with a press. SST 09387-00020 Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove, preventing the spring sheet from deforming. Do not expand the snap ring excessively. Remove the clutch balancer from the input shaft. Remove the forward clutch return spring from the input shaft.
5. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.0528 in.)
6. REMOVE FORWARD CLUTCH PISTON SUB-ASSY Place the forward clutch drum onto the oil pump. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil pump to remove the forward clutch piston. HINT: When the piston cannot be removed as it is slanted, either blow the air again with the protruding side pushed, or remove the piston using the needle nose plier with vinyl tape on the tip.
7. REMOVE INPUT SHAFT OIL SEAL RING Remove the input shaft oil seal ring to the input shaft.
8. INSTALL INPUT SHAFT OIL SEAL RING Compress the new input shaft oil seal ring from both sides to reduce dimension A. Dimension A: 5 mm (0.197 in.) Coat the oil seal ring with ATF and install it to the input shaft. NOTE: Do not expand the gap of the oil seal ring too much. Fix the hooks certainly.
9. INSTALL FORWARD CLUTCH PISTON SUB-ASSY Coat the forward clutch piston with ATF, and install it to the input shaft. NOTE: Be careful not to damage the lip seal of the forward clutch piston.
10. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSY Install the return spring to the input shaft. NOTE: Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. Coat the clutch balancer with ATF. Install the clutch balancer to the input shaft. NOTE: Be careful not to damage the lip seal of the forward clutch balancer. Install the clutch balancer carefully not to have a pinching and any other defects at the sealing lip. Apply enough ATF to the sealing lip prior to assembling. Place SST on the clutch balancer, and compress the clutch balancer with a press. SST 09387-00020 Install the snap ring with a snap ring expander. Be sure the end gap of the snap ring is not aligned with (the spring retainer claw. NOTE: Stop the press when the spring sheet is lowered to the place 1--2 mm (0.039 - 0.078 in.) from the snap ring groove. This prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Set the end gap of the snap ring in the piston shown in the illustration. NOTE: The end gap of the snap ring should not coincide with any of the stoppers.
11. INSTALL FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Coat the 5 discs with ATF. Install the 5 plates, 5 discs and flange input shaft. NOTE: Be careful about the order of discs, plates and flange assembly. Using a screwdriver, install the snap ring. Check that the end gap of the snap ring is not aligned with one of the cutouts. NOTE: The snap ring should be fixed certainly in the groove of the drum.
12. INSPECT PACK CLEARANCE OF FORWARD CLUTCH Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kgf.cm 2 , 4.0 kPa, 57 psi). Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.) If the piston stroke is less than the minimum, parts may have been assembled incorrectly. Check and reassemble again. If the clearance is not standard, select another flange. HINT: There are 5 different flanges in thickness. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION No. Thickness No. Thickness 1 3.00 (0.1181) 4 3.45 (0.1358) 2 3.15 (0.1240) 5 3.60 (0.1417) 3 3.30 (0.1299)
13. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Check if the disc lightly rotates when rotating the forward clutch assy after inserting the multiple disc clutch into it. NOTE: Do not place the forward clutch assy in a vise.

Scheme 802

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Scheme 810

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Scheme 813

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Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

Scheme 826

Scheme 827

Scheme 828

Scheme 829

1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Install the intermediate shaft and needle roller bearing on the transaxle rear cover. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 0.60 - 0.82 mm (0.02362 - 0.03228 in.) If the pack clearance is not within standard, inspect the discs, plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH & OVERDRIVE CLUTCH Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 0.61 - 0.83 mm (0.02401 - 0.03268 in.) If the pack clearance is not within standard, inspect the discs, plates and flange.
3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC Using a screwdriver, remove the snap ring from the intermediate shaft. Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.
4. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
5. REMOVE OVERDRIVE DIRECT CLUTCH DISC Using a screwdriver, remove the snap ring from the intermediate shaft. Remove the flange, 4 discs and 4 plates from the intermediate shaft.
6. INSPECT OVERDRIVE DIRECT CLUTCH DISC Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
7. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY Place SST on the clutch balancer and compress the spring with a press. SST 09387-00020 Using a snap ring expander, remove the snap ring from the direct clutch drum. NOTE: Stop the press when the spring sheet is lowered to the place 1-2 mm (0.039 - 0.078 in.) from the snap ring groove. This prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Remove the clutch balancer from the direct clutch drum. Remove the overdrive clutch return spring from the direct clutch drum.
8. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 25.91 mm (1.0201 in.)
9. REMOVE OVERDRIVE DIRECT CLUTCH PISTON Install intermediate shaft on the transaxle rear cover. Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
10. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
11. REMOVE OVERDRIVE DIRECT CLUTCH O-RING Using a screwdriver, remove the O-ring from the direct clutch drum.
12. INSTALL OVERDRIVE DIRECT CLUCH O-RING Coat a O-ring with ATF, and install it to the direct clutch drum. NOTE: Assemble the O-ring carefully not to have a twist and a pinching.
13. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY Coat the direct clutch drum with ATF, and install it to the intermediate shaft. NOTE: Be careful not to damage the O-ring. Be careful not to damage the lip seal of the direct clutch drum.
14. INSTALL OVERDRIVE DIRECT CLUTCH PISTON Apply the overdrive direct clutch piston with ATF, and install it to the direct clutch drum. NOTE: Be careful not to damage the lip seal of the direct clutch piston.
15. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSY Install the piston return spring to the direct clutch drum. NOTE: Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. Coat the clutch balancer with ATF. Install the clutch balancer to the direct clutch drum. NOTE: Be careful not to damage the lip seal of the direct clutch balancer. Install the clutch balancer carefully not to have a pinching and any other defects at the sealing lip. Apply enough ATF to the sealing lip prior to assembling. Place SST on the clutch balancer and compress the piston return spring with a press. SST 09387-00020 Using a snap ring expander, install the snap ring to the direct clutch drum. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring sheet is lowered to the place 1--2 mm (0.039 - 0.078 in.) from the snap ring grove. This prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Set the end gap of the snap ring in the piston shown in the illustration. NOTE: The end gap of the snap ring should not coincide with any of the stoppers.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC Coat the 4 discs with ATF. Install the 4 plates, 4 discs and flange to the intermediate shaft. NOTE: Be careful about the order of discs, plates and flange assembly. Using a screwdriver, install the snap ring. Check that the end gap of the snap ring is not aligned with one of the cutouts. NOTE: The snap ring should be fixed certainly in the groove of the drum.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH DISC Apply the 3 discs with ATF. Install the cushion plate, 3 plates, 3 discs and flange to the intermediate shaft. NOTE: Install the cushion plate with the mark on the white surface facing to plate. Be careful about the order of discs, plates and flange assembly. Using a screwdriver, install the snap ring. Check that the end gap of the snap ring is not aligned with one of the cutouts. NOTE: The snap ring should be fixed certainly in the groove of the drum.
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Install the intermediate shaft on the transaxle rear cover. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 0.60 - 0.82 mm (0.02362 - 0.03228 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the stroke is not within standard, select another flange. HINT: There are 6 flanges of different thickness. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION No. Thickness No. 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)
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH & OVERDRIVE CLUTCH Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 0.61 - 0.83 mm (0.02401 - 0.03268 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the stroke is not within standard, select another flange. HINT: There are 7 flanges in different thickness. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION No. Thickness No. Thickness 0 2.5 (0.098) 4 2.9 (0.114) 1 2.6 (0.102) 5 3.0 (0.118) 2 2.7 (0.106) 6 3.1 (0.122) 3 2.8(0.110) - - Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear. NOTE: Do not place the rear planetary sun gear in a vise.

Scheme 830

Scheme 831

Scheme 832

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Scheme 836

Scheme 837

Scheme 838

1. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSY Place SST on the return spring and compress. SST 09387-00060 Using a screwdriver, remove the snap ring. Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 16.61 mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
4. REMOVE 2ND BRAKE PISTON O-RING Remove the 2 O-rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O-RING Apply the 2 new O-rings with ATF, install them in the 2nd brake piston. NOTE: Assemble the O-ring carefully not to have a twist and a pinching.
6. INSTALL 2ND BRAKE PISTON Apply the 2nd brake piston with ATF, and install it to the 2nd brake cylinder. NOTE: Be careful not to damage the O-ring.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSY Install the 2nd brake piston return spring. NOTE: Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. Place SST on the piston return spring, and compress the piston return spring with a press. SST 09387-00060 Using a screwdriver, install the snap ring. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove. This prevents the spring sheet from being deformed.

Scheme 839

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Scheme 841

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Scheme 849

Scheme 850

Scheme 851

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Scheme 858

1. INSPECT UNDERDRIVE PACK CLEARANCE Install the underdrive clutch to the transaxle case. NOTE: Be careful not to damage the oil seal rings. Install a dial indicator as shown in the illustration. Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.) If the pack clearance is not within standard, inspect the discs, plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO. 2 HOLE SNAP RING Using a screwdriver, remove the underdrive clutch flange No. 2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO. 1 Remove the flange, 4 discs and 4 plates from the underdrive clutch drum.
4. INSPECT UNDERDRIVE CLUTCH DISC NO. 1 Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes.
5. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing. Standard drum bushing: 37.06 - 37.08 mm (1.4591 - 1.4598 in.) Maximum drum bushing: 37.13 mm (1.4618 in.) If the inside diameter is greater than the maximum, replace the underdrive clutch drum.
6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Place SST on the clutch balancer and compress the spring with a press. SST 09350-32014 (09351-32070) Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring groove. This prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Remove the clutch balancer from the underdrive clutch drum. Remove the return spring from the underdrive clutch drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET Install the underdrive clutch to the transaxle case. NOTE: Be careful not to damage the oil seal ring. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O-RING Using a screwdriver, remove the O-ring from the underdrive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING Apply the new O-ring with ATF, install it to the underdrive clutch drum. NOTE: Assemble the O-ring carefully not to have a twist and a pinching.
11. INSTALL UNDERDRIVE CLUTCH PISTON SET Coat the underdrive clutch piston with ATF, install it to the underdrive clutch piston drum. NOTE: Be careful not to damage the O-ring. Be careful not to damage the lip seal of the piston.
12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSY Install the return spring to the underdrive clutch drum. NOTE: Installing the spring sub-assembly, check all of the springs are fit in the piston correctly. Coat the clutch balancer with ATF. Install the clutch balancer to the underdrive clutch drum. NOTE: Be careful not to damage the lip seal of the clutch balancer. Place SST on the clutch balancer and compress the piston return spring with a press. SST 09350-32014 (09351-32070) Using a snap ring expander, install the snap ring to the underdrive clutch drum. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring sheet is lowered to the place 1--2 mm (0.039 - 0.078 in.) from the snap ring grove. This prevents the spring sheet from being deformed. Do not expand the snap ring excessively. Set the end gap of the snap ring in the underdrive clutch drum shown in the illustration. NOTE: The end gap of the snap ring should not coincide with any of the stopper.
13. INSTALL UNDERDRIVE CLUTCH DISC NO. 1 Apply the 4 discs with ATF. Install the 4 plates, 4 discs and flange to the underdrive clutch drum. NOTE: Be careful about the order of discs, plates and flange assembly.
14. INSTALL UNDERDRIVE CLUTCH FLANGE NO. 2 HOLE SNAP RING Using a screwdriver, install the underdrive clutch flange No. 2 hole snap ring. Check that the end gap of snap ring is not aligned with one of the cutouts. NOTE: The snap ring should be fixed certainly in the groove of the drum.
15. INSPECT UNDERDRIVE PACK CLEARANCE Install the underdrive clutch to the transaxle case. NOTE: Be careful not to damage the oil seal ring. Set a dial indicator as shown in the illustration. Measure the underdrive clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.) If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the pack clearance is not within standard, select another flange. HINT: There are 5 flanges in different thickness. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION 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)

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Scheme 882

1. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Using SST, fix the underdrive planetary gear assy. SST 09387-00050 Using SST and a torque wrench, measure the turning torque of underdrive planetary gear assy while rotating the torque wrench at 60 rpm. SST 09387-00050 Turning torque at 60 rpm.: 0.50 - 1.42 N.m (5.1 - 14.5 kgf.cm, 0.06 - 0.17 in..lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT Using SST, loosen the staked part of the lock nut. SST 09930-00010 (09931-00010, 09931-00020), 09387-00050 Clamp the underdrive planetary gear in soft jaw vise. NOTE: Be careful not to damage the differential drive pinion. Using a socket wrench, remove the lock nut.
3. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER Using SST, remove the cylindrical roller bearing race inner. SST 09950-00020, 09950-00030, 09950-60010 (09951-00320), 09950-40011 (09957-04010)
4. REMOVE UNDERDRIVE PLANETARY GEAR ASSY Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with under-drive planetary ring gear and front tapered roller bearing. SST 09950-60010(09951-00320), 09387-00050 Clamp the underdrive planetary gear in soft jaw vise. Using SST, remove the rear tapered roller bearing form the underdrive planetary gear. SST 09950-00020, 09950-00030, 09950-60010 (09951-00320), 09950-40011 (09957-04010)
5. REMOVE UNDERDRIVE PLANETARY RING GEAR Using a snap ring pliers, remove the snap ring. Remove the underdrive planetary ring gear from the counter driven gear.
6. INSTALL UNDERDRIVE PLANETARY RING GEAR Install a new snap ring to the outer race of the tapered roller bearing. HINT: When replacing the bearing, also replace the counter driven gear with a new one. Using a piston ring compressor, squeeze the snap ring. Using SST and a press, press in the outer race of the tapered roller bearing. SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) NOTE: Be sure not to damage on the snap ring during the outer race installation. Install the underdrive planetary ring gear to the counter driven gear. Using a snap ring pliers, install the snap ring.
7. INSTALL UNDERDRIVE PLANETARY GEAR ASSY Using a press, press the rear tapered roller bearing to the underdrive planetary gear. SST 09502-12010, 09950-60010 (09951-00260), 09950-70010 (09951-07100), 09316-20011 NOTE: Press the bearing until it becomes flat at the bottom. Install the counter driven gear with planetary ring gear to the underdrive planetary gear. Using SST and a press, press in the front tapered roller bearing. SST 09502-12010, 09950-60010 (09951-00260), 09950-70010 (09951-07100), 09316-20011 NOTE: Press the counter driven gear while rotating it. Using a press, press in the parking lock gear. SST 09502-12010, 099,50-60010 (09951-00260), 09950-70010 (09951-07100), 09316-20011 NOTE: Press the counter driven gear while rotating it.
8. INSTALL DIFFERENTIAL DRIVE PINION Using a press, press the differential drive pinion. SST 09726-40010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTE: Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE INNER Using a press, press the cylindrical roller bearing race inner. SST 09506-35010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTE: Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT Clamp the underdrive planetary gear in soft jaw vise. NOTE: Be careful not to damage the differential drive pinion. Using a socket wrench, install a new lock nut. Torque: 280 N.m (2,855 kgf.cm, 207 in..lbf) HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Using SST and a torque wrench, measure the turning torque of underdrive planetary gear assy while rotating the torque wrench at 60 rpm. SST 09387-00050 Turning torque at 60 rpm.: 0.5 - 1.42 N.m (5.1 - 14.5 kgf.cm, 0.06 - 0.17 in..lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.). Using a pin punch and hammer, stake the lock nut. NOTE: Make sure that there are no cracks on the nut.

Scheme 883

Scheme 884

Scheme 885

Scheme 886

Scheme 887

Scheme 888

Scheme 889

Scheme 890

Scheme 891

Scheme 892

Scheme 893

Scheme 894

1. REMOVE SHIFT SOLENOID VALVE SL3 Remove the bolt and shift solenoid valve SL3 from the valve body assy.
2. REMOVE LINE PRESSURE CONTROL SOLENOID ASSY Remove the shift solenoid valve SLT from the valve body assy.
3. REMOVE SHIFT SOLENOID VALVE S4 Remove the bolt and shift solenoid valve S4 from the valve body assy.
4. REMOVE SHIFT SOLENOID VALVE SR Remove the shift solenoid valve SR from the valve body assy.
5. REMOVE SHIFT SOLENOID VALVE DSL Remove the bolt and shift solenoid valve DSL from the valve body assy.
6. REMOVE SHIFT SOLENOID VALVE SL2 Remove the bolt and shift solenoid valve SL2 from the valve body assy.
7. REMOVE SHIFT SOLENOID VALVE SL1 Remove the bolt and shift solenoid valve SL1 from the valve body assy.
8. REMOVE MANUAL VALVE Remove the manual valve from the valve body assy.
9. INSTALL MANUAL VALVE Install the manual valve to the valve body assy.
10. INSTALL SHIFT SOLENOID VALVE SL1 Install the shift solenoid valve SL1 to the valve body assy with the bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in.lbf)
11. INSTALL LINE PRESSURE CONTROL SOLENOID ASSY Install the shift solenoid valve SLT to the valve body assy with the bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in.lbf)
12. INSTALL SHIFT SOLENOID VALVE SL3 Install the shift solenoid valve SL3 to the valve body assy with the bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in.lbf)
13. INSTALL SHIFT SOLENOID VALVE SL2 Install the shift solenoid valve SL2 to the valve body assy with the bolt. Torque: 10.8 N.m (110 kgf.cm, 8 ft.lbf)
14. INSTALL SHIFT SOLENOID VALVE DSL Install the shift solenoid valve DSL to the valve body assy with the bolt. Torque: 10.8 N.m (110 kgf.cm, 8 ft.lbf)
15. INSTALL SHIFT SOLENOID VALVE SR Install the shift solenoid valve SR to the valve body assy.
16. INSTALL SHIFT SOLENOID VALVE S4 Install the shift solenoid valve S4 to the valve body assy with the bolt. Torque: 10.8 N.m (110 kgf.cm, 8 ft.lbf)

Scheme 895

Scheme 896

Scheme 897

Scheme 898

Scheme 899

Scheme 900

Scheme 901

Scheme 902

Scheme 903

Scheme 904

Scheme 905

Scheme 906

Scheme 907

Scheme 908

Scheme 909

Scheme 910

Scheme 911

Scheme 912

Scheme 913

Scheme 914

Scheme 915

Scheme 916

Scheme 917

Scheme 918

Scheme 919

Scheme 920

Scheme 921

Scheme 922

Scheme 923

Scheme 924

Scheme 925

1. REMOVE FRONT DIFFERENTIAL RING GEAR Place the match-marks on the front differential ring gear and differential case. Remove the 14 bolts. Using a plastic hammer, tap on the front differential ring gear to remove it from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST, remove the front differential case front differential tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00490), 09950-40011 (09957-04010) Using SST, remove the front differential case front tapered roller bearing outer race. SST 09308-00010
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST, remove the front differential case rear tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00490), 09950-40011 (09957-04010) Using SST, remove the front differential case rear tapered roller bearing outer race. SST 09308-00010
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and hammer, install the straight pin. NOTE: Before removing the straight pin, unstake it with a pin punch.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT NO. 1 Remove the front differential pinion shaft No. 1 from the differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR Remove the 2 front differential pinions, 2 pinion thrust washers, 2 front differential side gears and 2 side gear thrust washers from the differential case.
7. REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, remove the oil seal. SST 09950-70010 (09951-07100), 09215-00013 (09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, remove the oil seal. SST 09950-70010 (09951-07100), 09608-10010
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR Apply the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers with ATF and install them to the differential case.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1 Apply the front differential pinion shaft No. 1 with ATF, install it to the differential case.
11. INSPECT BACKLASH Using a dial indicator, inspect the backlash of the side gear. Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) Thrust washer thickness THRUST WASHER THICKNESS SPECIFICATION Mark Thickness - 1.625 mm (0.0640 in.) - 1.725 mm (0.0679 in.) - 1.825 mm (0.0719 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and hammer, install the pinion shaft straight pin. Using a chisel and hammer, stake the differential case. NOTE: Stake it after adjusting the backlash.
13. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and a press, install the front differential case rear tapered roller bearing to the differential case. SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100) NOTE: Do not make a damage on the bearing cage during the bearing inner race installation. Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing. SST 09550-60010 (09951-00490), 09950-60020 (09951-00910)
14. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST and a press, install the front differential case front tapered roller bearing to the differential case. SST 09316-12010, 09550-60010 (09951-00490), 09950-70010 (09951-07100) NOTE: Do not make a damage on the bearing cage during the bearing inner race installation. Using SST and a hammer, install the front differential case tapered roller bearing front outer race to the transaxle housing. SST 09950-70010 (09951-07150), 09950-60020 (09951-00890)
15. ADJUST DIFFERENTIAL SIDE BEARING RRELOAD Install the differential assy to the transaxle case. Clean the matching surfaces of the transaxle case and transaxle housing. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts. Torque: Bolt A: 25 N.m (255 kgf.cm, 18 ft.lbf) Bolt B: 33 N.m (337 kgf.cm, 24 ft.lbf) Bolt C: 29 N.m (295 kgf.cm, 21 ft.lbf) Bolt D: 22 N.m (226 kgf.cm, 16.0 ft.lbf) HINT: Apply seal packing or equivalent to the A and D. Seal packing: THREE BOND 2403 or equivalent Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) Bolt D: 72 mm (2.835 in.) HINT: Usually, bolt A is a non-reusable bolt. In this case, however, it can be used after cleaning it. Using SST, turn the differential assy right and left 2 or 3 times to settle the bearing. SST 09564-32011 Using SST and a torque wrench, measure the turning torque of the differential. SST 09564-32011 Turning torque at 60 rpm: New bearing 0.20 - 0.69 N.m (2.0 - 7.0 kgf.cm, 1.8 - 6.1 in..lbf) Used bearing 0.10 - 0.35 N.m (1.0 - 3.6 kgf.cm, 0.9 - 3.1 in..lbf) HINT: If the turning torque is not within the specified value, refer to the table below to select a thrust washer which turning torque is within the specified value. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION Mark Thickness Mark Thickness 0 2.00 (0.0787) 9 2.45 (0.0965) 1 2.05 (0.0807) A 2.50 (0.0984) 2 2.10(0.0827) B 2.55(0.1004) 3 2.15(0.0846) C 2.60(0.1024) 4 2.20 (0.0866) D 2.65(0.1043) 5 2.25 (0.0886) E 2.70(0.1063) 6 2.30 (0.0906) F 2.75(0.1083) 7 2.35 (0.0925) G 2.80 (0.1102) 8 2.40 (0.0945) H 2.85 (0.1122) Remove the 16 bolts and the transaxle housing. Remove the differential assy.
16. INSTALL FRONT DIFFERENTIAL RING GEAR Using ATF and heater, heat the front differential ring gear to 90--110°FC (194.0-230.0°FF). NOTE: Do not overheat the ring gear to 110°FC (230.0°FF) or more. Clean the contact surface of the front differential case. Align the match-marks, install the front differential ring gear case quickly. NOTE: Do not install the bolts while the ring gear is hot. Tighten the 14 bolts. Torque: 95.0 N.m (970 kgf.cm, 70 ft.lbf) NOTE: Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, install a new oil seal. Apply the rip of oil seal with a little MP grease. SST 09223-15020, 09950-70010 (09951-07150) Oil seal drive in depth: 0 +/- 0.5 mm (0 +/- 0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive into a new oil seal. Apply the lip of the oil seal with a little MP grease. SST 09710-30050, 09950-70010 (09951-07150) (Oil seal drive in depth: 0 +/- 0.5 mm (0 +/- 0.0197 in.)

Scheme 926

Scheme 927

Scheme 928

Scheme 929

Scheme 930

Scheme 931

Scheme 932

Scheme 933

Scheme 934

Scheme 935

Scheme 936

Scheme 937

Scheme 938

Scheme 939

Scheme 940

Scheme 941

Scheme 942

Scheme 943

Scheme 944

Scheme 945

Scheme 946

Scheme 947

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

Scheme 955

Scheme 956

Scheme 957

Scheme 958

Scheme 959

Scheme 960

Scheme 961

Scheme 962

Scheme 963

Scheme 964

Scheme 965

Scheme 966

Scheme 967

Scheme 968

Scheme 969

Scheme 970

Scheme 971

Scheme 972

Scheme 973

Scheme 974

Scheme 975

Scheme 976

Scheme 977

Scheme 978

Scheme 979

1. REMOVE FRONT DIFFERENTIAL RING GEAR Place the match-marks on the ring gear and differential case. Remove the 16 bolts. Using a plastic hammer, tap on the ring gear to remove it from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR Remove the differential LH case from the differential case assy. Remove the differential case No. 2 from the differential case LH. Remove the front differential side gear, front differential side gear thrust washer, conical spring and center differential side gear thrust washer No. 2 from the differential case LH. Using a snap ring expander, remove the pinion shaft spacer snap ring. Using a pin punch and a hammer, remove 3 straight pins. Remove the center differential pinion shaft and 2 differential pinion shafts. Remove 4 front differential pinions, 4 front differential pinion thrust washers, front differential pinion shaft holder, front differential planetary ring gear and differential side gear thrust washer No. 1.
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST, remove the front differential case rear tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00480) Using SST, remove the front differential case rear tapered roller bearing outer race and differential case washer. SST 09308-00010
4. REMOVE CENTER DIFFERENTIAL PINION Using torx socket (T50), remove the 15 bolts. Place the matchmarks on the differential intermediate case and differential case. Remove the differential intermediate case from the differential case RH. Remove the center differential side gear, conical spring washer and center differential side gear thrust washer No. 1 RH from the differential case RH. Remove the differential spider, 5 center differential pinions and 5 center differential pinion thrust washers from the differential intermediate case.
5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST, remove the front differential case front tapered roller bearing from the differential case. SST 09950-00020, 09950-00030, 09950-60010 (09951-00600) Using SST, remove the front differential case front tapered roller bearing outer race and differential case washer. SST 09308-00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, remove the oil seal. SST 09950-70010 (09951-07100), 09649-17010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, remove the oil seal. SST 09950-70010 (09951-07100), 09608-10010
8. INSTALL DIFFERENTIAL CASE SUB-ASSY NO. 2 Coat the front differential side gear thrust washer No. 1, front differential planetary ring gear, front differential pinion No. 2, front differential pinion thrust washer No. 2, front differential pinion shaft holder, front differential pinion shaft and 2 differential pinion shafts with ATF, install them to the differential case No. 2. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case. Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) NOTE: Do not mount the surface of front differential case which contacts with bushing in a vise. If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value. Thrust washer thickness: mm (in.) THRUST WASHER THICKNESS SPECIFICATION Mark Thickness Mark Thickness A 0.95 (0.0373) F 1.20 (0.0472) B 1.00 (0.0393) G 1.25 (0.0492) C 1.05 (0.0413) H 1.30 (0.0512) D 1.10 (0.0433) J 1.35 (0.0532) E 1.15 (0.0453) K 1.40 (0.0552) Engage the front differential side gear to the above mentioned front differential case. Install the differential case LH to the front differential case and measure its center. After that, remove the differential case LH. Using a straight edge and feeler gauge, measure the clearance between the front differential case and the front differential side gear. t= Thrust washer thickness L= Clearance t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.) If the clearance is not within the specified value, refer to the table below and select a thrust washer which will ensure that the clearance is within the specified value. Thrust washer thickness: mm (in.) THRUST WASHER THICKNESS SPECIFICATION Mark Thickness Mark Thickness A 0.95 (0.0373) F 1.20 (0.0472) B 1.00 (0.0393) G 1.25 (0.0492) C 1.05 (0.0413) H 1.30 (0.0512) D 1.10 (0.0433) J 1.35 (0.0532) E 1.15 (0.0453) K 1.40 (0.0552) If the clearance is not within the specified value, parts may have been assembled incorrectly, so check and reassemble it. Using a pin punch and a hammer, install 3 straight pins. Using a snap ring expander, install the pinion shaft spacer snap ring.
9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR ASSY Install the center differential side gear, conical spring washer and center differential side gear thrust washer No. 2 RH from the differential case RH. HINT: Ensure that the conical washers is installed correctly. Hold the differential case RH by vice. Install the center differential pinion and pinion thrust washer to the differential spider and install them to the differential case RH. NOTE: When holding the differential case RH by vise, be sure to place an aluminum sheet between them and use a minimum force. Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator. (Scheme 914) Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value. Thrust washer thickness: mm (in.) THRUST WASHER THICKNESS SPECIFICATION Mark Thickness Mark Thickness MA 0.80 (0.0313) MH 1.15 (0.0453) MB 0.85 (0.0333) MJ 1.20 (0.0472) MC 0.90 (0.0353) MK 1.25 (0.0492) MD 0.95 (0.0373) ML 1.30 (0.0512) ME 1.00 (0.0393) MM 1.35 (0.0532) MF 1.05 (0.0413) MN 1.40 (0.0552) MG 1.10 (0.0433) - - Temporarily install the differential side gear thrust washer No. 2 LH, center differential side gear conical spring washer and differential case No. 2 to the differential case LH. HINT: Ensure that the conical washers is installed correctly. Install the differential intermediate case to the above and fix them with 4 bolts. Remove the differential spider, 5 center differential pinions and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and fix the case. Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator. Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.) If the backlash is not within the specified value, refer to the table below and select a thrust washer which will ensure that the backlash is within the specified value. Thrust washer thickness: mm (in.) THRUST WASHER THICKNESS SPECIFICATION Mark Thickness Mark Thickness MA 0.80 (0.0313) MH 1.15 (0.0453) MB 0.85 (0.0333) MJ 1.20 (0.0472) MC 0.90 (0.0353) MK 1.25 (0.0492) MD 0.95 (0.0373) ML 1.30 (0.0512) ME 1.00 (0.0393) MM 1.35 (0.0532) MF 1.05 (0.0413) MN 1.40 (0.0552) MG 1.10 (0.0433) - - Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case. Remove the differential case No. 2 from the differential case LH. Install the selected differential side gear thrust washer No. 2 LH and center differential planetary gear to the differential case LH. Install the differential case No. 2 to the differential case LH again. Install the adjusted differential case RH to the intermediate case and tighten the 15 bolts using a torx socket wrench (T50). Torque: 63 N.m (642 kgf.cm, 46 ft.lbf) NOTE: Align the matchmarks.
10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING Using SST and a press, install the front differential case tapered roller bearing FR to the differential case. SST 09950-70010 (09951-07100), 09649-17010 NOTE: Do not make a damage on the bearing cage during the bearing inner race installation. Using SST, install the outer race of the tapered roller bearing FR. SST 09527-17011, 09950-60020 (09951-01030) NOTE: Clearance is not allowed between the plate washer and transaxle housing.
11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING Using SST and a press, install the front differential case tapered roller bearing RR to the differential case. SST 09316-20011, 09214-76011 NOTE: Do not make a damage on the bearing cage during the bearing inner race installation. Install the front differential case shim RR to the transaxle case. If the bearing is new, check to select a front differential case shim RR of proper thickness starting from the thinner ones. If the bearing is reused, check to select a front differential case shim RR starting from the same thickness as one installed before disassembly. Using SST, install the outer race of the front differential case tapered roller bearing RR. SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) NOTE: Clearance is not allowed between the differential case shim and transaxle case.
12. ADJUST TAPERED POLLER BEARING PRELOAD Install the intermediate case to the differential case LH and fix them with 4 bolts. Install the differential assy to the transaxle case. Clean the matching surfaces of the transaxle case and transaxle housing. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts. Torque: Bolt A: 25 N.m (255 kgf.cm, 18 ft.lbf) Bolt B 33 N.m (337 kgf.cm, 24 ft.lbf) Bolt C 29 N.m (295 kgf.cm, 21 ft.lbf) Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) HINT: Usually, bolt A is a non-reusable bolt. In this case, however, it can be used after cleaning it. Using SST, turn the differential assy right and left 2 or 3 times to allow the bearing settle. SST 09564-32011 Using SST and a torque wrench, measure the turning torque of the differential case assy. SST 09564-32011 Turning torque at 60 rpm: New bearing 0.20 - 0.69 N.m (2.0 - 7.0 kgf.cm, 1.8 - 6.1 in..lbf) Used bearing 0.10 - 0.35 N.m (1.0 - 3.6 kgf.cm, 0.9 - 3.1 in..lbf) HINT: If the turning torque is not within the specified value, refer to the table below and select a thrust washer which turning torque is within the specified value. Flange thickness: mm (in.) FLANGE THICKNESS SPECIFICATION Mark Thickness Mark Thickness 0 2.00 (0.0787) 9 2.45 (0.0965) 1 2.05 (0.0807) A 2.50 (0.0984) 2 2.10 (0.0827) B 2.55 (0.1004) 3 2.15 (0.0846) C 2.60 (0.1024) 4 2.20 (0.0866) D 2.65 (0.1043) 5 2.25 (0.0886) E 2.70 (0.1063) 6 2.30 (0.0906) F 2.75 (0.1083) 7 2.35 (0.0925) G 2.80 (0.1102) 8 2.40 (0.0945) H 2.85 (0.1122) Remove the 16 bolts and the transaxle housing. Remove the differential assy.
13. INSTALL FRONT DIFFERENTIAL RING GEAR Using ATF and heater, heat the front differential ring gear to 90--110°FC. (194.0--230.0°FF) NOTE: Do not overheat the ring gear to 110°FC (230.0°FF) or more. Clean the contact surface of the front differential case. Set the match-marks, install the front differential ring gear case quickly. NOTE: Do not install the bolts while the ring gear is hot. Temporarily install the 8 bolts as shown in the illustration. Remove the 4 bolts shown in the illustration. Temporarily install the remaining 8 set bolts. Fully tighten the set bolts. Torque: 95.1 N.m (970 kgf.cm, 70 ft.lbf) NOTE: Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09223-15020, 09950-70010 (09951-07100) Coat the rip of oil seal with a little MP grease.
15. INSTALL TRANSAXLE HOUSING OIL SEAL Wind a vinyl tape around SST at the place 6.0 mm (0.236 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.). SST 09950-60020 (09951-00730) NOTE: Remove foreign matter such as grease on the SST before winding the tape. Coat the rip of oil seal with a little MP grease. Using SST, install a new oil seal. SST 09950-60020 (09951-00730), 09950-70010 (09951-07150) Standard press in depth: 5.5 - 6.5 mm (0.217 - 0.256 in.) NOTE: Stop pressing when the would vinyl tape is contact with the transaxle housing.