Automatic Transmission (U151E): Overview Lexus RX II facelift

SYSTEM DESCRIPTION

1. SYSTEM DESCRIPTION The ECT (Electronic controlled automatic transmission/transaxle) is an automatic transmission/transaxle that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, and controls the shift point, based on driver habits and road conditions. As a result, fuel efficiency and power transmission performance are improved. Shift shock has been reduced by controlling the engine and transmission simultaneously. In addition, the ECT has features such as follows: Diagnostic function. Fail-safe function when a malfunction occurs.

DESCRIPTION

The park/neutral position switch detects the shift lever position and sends signals to the ECM.

DIAGNOSTIC REFERANCE

MONITOR DESCRIPTION

The park/neutral position switch detects the gearshift position and sends a signal to the ECM.

For security, the park/neutral position switch detects the gearshift position so that engine can be started only when the vehicle is in P or N shift position.

When the park/neutral position switch sends more than one signal at a time from switch positions P, R, N, D, 3* 1 or 2* 1 , the ECM interprets this as a fault in the switch. The ECM will turn on the MIL.

HINT

*1: Gate shift lever type

*2: Shift lever with Multi-mode automatic transmission type

The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM.

The ECM applies a voltage to the temperature sensor through ECM terminal THO1.

The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases.

One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher.

The ECM calculates the fluid temperature based on the voltage signal.

Scheme 1

DIAGNOSTIC REFERANCE

These DTCs indicate an open or short in the automatic transmission fluid (ATF) temperature sensor (TFT sensor) circuit. The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an opens or shorts in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 ohms * 1 or more than 156 kohms * 2 , the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC.

*1: 150°C (302°F) or more is indicated regardless of the actual ATF temperature.

*2: -40°C (-40°F) is indicated regardless of the actual ATF temperature.

HINT

The ATF temperature can be checked on the OBD II scan tool or intelligent tester display.

The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM.

DTC DETECTION CONDITION AND TROUBLE AREA

The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an opens or shorts in the ATF temperature circuit.

After running the vehicle for a certain period, the ATF temperature should increase. When the ATF temperature is below 10°C, the ECM interprets this as a fault, turns on the MIL.

This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift.

DTC CHART

Scheme 2

Reference (Using an oscilloscope)

Check the waveform between terminals NT+ and NT- of the ECM connector.

Standard: Refer to the illustration.

OSCILLOSCOPE WAVEFORM REFERANCE CHART

The NT terminal of the ECM detects a revolution signal from the speed sensor (NT) (input RPM). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC).

While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the input shaft revolution is less than 300 rpm * 1 although the output shaft revolution is more than 1,000 rpm * 2 , the ECM detects the trouble, illuminates the MIL and stores the DTC.

*1: Pulse is not output or is irregularly output.

*2: The vehicle speed is 50 km/h (31 mph) or more.

The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition when brakes are suddenly applied.

When the brake pedal is depressed, this switch sends a signals to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress.

DTC DETECTION CONDITION AND TROUBLE AREA

This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during "stop and go" driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) 5 times for two driving cycles in order to detect a malfunction.

The ECM uses the signals from the throttle position sensor, air-flow meter, turbine (input) speed sensor, intermediate (counter) shaft speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch.

Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve DSL, valve body and torque converter clutch.

DTC DETECTION CONDITION AND TROUBLE AREA

Torque converter lock-up is controlled by the ECM based on the speed sensor (NT), speed sensor (NC), engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid DSL. When the DSL is turned on, it applies pressure to the lock-up relay valve and locks the torque converter clutch.

If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve DSL or lock-up system performance. The ECM will turn on the MIL and store the DTC.

HINT

Example

When any of the following is met, the system judges it as a malfunction.

1. There is a difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up. (Engine speed is at least 75 rpm greater than input turbine speed.)
2. There is no difference in rotation between the input side (engine speed) and output side (input turbine speed) of the torque converter when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.)

The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear).

Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL.

HINT

Example

When either condition (a) or (b) is met, the ECM detects a malfunction.

1. The ECM commands the 1st gear, but the actual gear is 2nd.
2. The ECM commands the 2nd gear, but the actual gear is 1st.

Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.)

(See FAIL-SAFE CHART ).

The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear).

Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC.

The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear).

Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC.

The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear).

Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC.

Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.)

(See FAIL-SAFE CHART ).

This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) with the direct clutch speed sensor signal (NT), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus smooth gear shifting is performed.

DTC DETECTION CONDITION AND TROUBLE AREA

Reference (Using an oscilloscope)

Check the waveform between terminals NC+ and NC- of the ECM connector.

Scheme 3

Standard: Refer to the illustration.

OSCILLOSCOPE WAVEFORM REFERANCE CHART

The NC terminal of the ECM detects a revolution signal from the speed sensor (NC) (counter gear rpm). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC).

While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the counter gear revolution is less than 300 rpm * 1 although the output shaft revolution is more than 1,000 rpm * 2 , the ECM detects the trouble, illuminates the MIL and stores the DTC.

*1: Pulse is not output or is irregularly output.

*2: The vehicle speed is 50 km/h (31 mph) or more.

The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear).

Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical troubles of the shift solenoid valves and valve body.

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not the same, the ECM illuminates the MIL and stores the DTC.

Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.) (See FAIL-SAFE CHART ).

Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.)

(See FAIL-SAFE CHART ).

Shifting from 1st to 5th is performed in combination with "ON" and "OFF" operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which are controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valves to allow the vehicle to be operated smoothly (Fail safe function).

DTC DETECTION CONDITION AND TROUBLE AREA

The ECM commands gear shifts by turning the shift solenoid valves "ON/OFF". When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other normal shift solenoid valves "ON/OFF" (In case of an open or short circuit, the ECM stops sending current to the circuit.)

(See FAIL-SAFE CHART ).

The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty cycle of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs.

(*): Duty Ratio

The duty ratio is the ratio of the period of continuity in one cycle.

For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio=A/(A + B) x 100(%)

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 4

When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn on the MIL and store the DTC.

The shift solenoid valve DSL is turned "ON" and "OFF" by signals from the ECM in order to control the hydraulic pressure operation, the lock-up relay valve, which then controls operation of the lock-up clutch.

DTC DETECTION CONDITION AND TROUBLE AREA

Torque converter lock-up is controlled by the ECM based on engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and shift range selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests "lock-up" by applying control voltage to the shift solenoid DSL. When the DSL is opened, it applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects an open or short in the DSL solenoid circuit, the ECM interprets this as a fault in the DSL solenoid or circuit. The ECM will turn on the MIL and store the DTC.

When moving the shift lever into the S position using the transmission control switch, it is possible to switch the shift range position between "1" (first range) and "5" (fifth range).

Shifting up "+" once raises one shift range position, and shifting down "-" lowers one shift range position.

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1. CHECK HARNESS AND CONNECTOR (BATTERY - TRANSMISSION CONTROL SWITCH) Disconnect the transmission control switch connector of shift lock control unit assembly. Measure the voltage according to the value(s) in the table below. Voltage TESTER CONNECTION AND SPECIFIED CONDITION Switch Condition Tester Connection Specified Condition IG switch ON 3 - Body ground 10 to 14 V IG switch OFF Below 1 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
2. CHECK HARNESS AND CONNECTOR (TRANSMISSION@CONTROL SWITCH - BODY GROUND) Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Tester Connection Specified Condition 10 - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
3. INSPECT TRANSMISSION FLOOR SHIFT ASSEMBLY Measure resistance between each terminal of shift lock control unit assembly when the shift lever is moved to each position. Resistance (Check for short) TESTER CONNECTION AND SPECIFIED CONDITION Shift Position Tester Connection Specified Condition S, "+" and "-" 3 - 8 Below 1 ohms Except S, "+" and "-" 10 kohms or higher Press continuously "+" (Up shift) 4 - 10 Below 1 ohms S 10 kohms or higher Press continuously "-" (Down shift) 5 - 10 Below 1 ohms S 10 kohms or higher NG: REPLACE TRANSMISSION FLOOR SHIFT ASSEMBLY OK: Go to next step
4. CHECK HARNESS AND CONNECTOR (TRANSMISSION CONTROL SWITCH - ECM) Connect the transmission control switch connector of shift lock control unit assembly. Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. Voltage TESTER CONNECTION AND SPECIFIED CONDITION Shift Position Tester Connection Specified Condition S, "+" and "-" E6 - 23 (S) - Body ground 10 to 14 V Except S, "+" and "-" Below 1 V Turn the ignition switch to the LOCK position. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Shift Position Tester Connection Specified Condition Press continuously "+" (Up shift) E6 - 22 (SFTU) - Body ground Below 1 ohms S 10 kohms or higher Press continuously "-" (Down shift) E6 - 21 (SFTD) - Body ground Below 1 ohms S 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE

ECT SNOW is the system that operates the throttle motor to control engine output to reduce skidding of the driving wheels, guarantee takeoff acceleration, driving straightness and turning stability.

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1. DRIVING TEST Start the engine. Turn the ECT SNOW switch "OFF" (Normal drive mode). Confirm vehicle response by driving from a parked position to fully depressing the accelerator pedal (*1). Turn the ECT SNOW switch "ON" and perform the same check as (*1). Confirm that there is a difference between ECT SNOW switch "ON" and "OFF". HINT: Driving test should be done on a paved road (a nonskid road). Make sure not to use the TRAC system when testing a vehicle equipped with one. Standard: There is a difference in acceleration between "ON" and "OFF". NG: Go to step 2 OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
2. CHECK HARNESS AND CONNECTOR (PATTERN SELECT SWITCH ASSEMBLY NO. 1 - BODY GROUND) Disconnect the connector of pattern select switch (ECT SNOW switch). Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Tester Connection Specified Condition 4 - Body ground Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
3. INSPECT PATTERN SELECT SWITCH ASSEMBLY NO. 1 Measure the resistance according to the value(s) in the table below. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Switch Condition Tester Connection Specified Condition Press continuously Pattern select switch 3 - 4 Below 1 ohms Release Pattern select switch 10 kohms or higher NG: REPLACE PATTERN SELECT SWITCH ASSEMBLY NO. 1 OK: Go to next step
4. CHECK HARNESS AND CONNECTOR (PATTERN SELECT SWITCH ASSEMBLY NO. 1 - MULTIPLEX NETWORK BODY) Connect the connector of pattern select switch (ECT SNOW switch). Disconnect the instrument panel junction block assembly (multiplex network body ECU) connector. Measure the resistance between terminals SNOW of instrument panel junction block assembly (multiplex network body ECU) and body ground. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Switch Condition Tester Connection Specified Condition Press continuously Pattern select switch B5 - 17 (SNOW) - Body ground Below 1 ohms Release Pattern select switch 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE

Scheme 15

1. CHECK FLUID LEVEL HINT: Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temperature: 70 to 80°C (158 to 176°F) Park the vehicle on a level surface and set the parking brake. With the engine idling and the brake pedal depressed, move the shift lever to all positions from P to L (S1) and return to the P position. Take out the dipstick and wipe it clean. Put the dipstick back all the way. Take out the dipstick again and check that the fluid level is within the HOT range. If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add the proper amount of new fluid and recheck the fluid level. If there are leaks, it is necessary to repair or replace O-rings, FIPGs, oil seals, plugs and/or other parts.

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1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
3. REMOVE AIR CLEANER HOSE NO. 1 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
4. REMOVE AIR CLEANER INLET NO.2 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
5. REMOVE AIR CLEANER BRACKET HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
6. REMOVE AIR CLEANER INLET NO. 1 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
7. REMOVE SPEED SENSOR (NT SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor.
8. REMOVE SPEED SENSOR (NC SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor.

Scheme 19

Scheme 20

1. INSPECT SPEED SENSOR (NT SENSOR) Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION AND SPECIFIED CONDITION Tester Connection Specified Condition 20°C (68°F) 1 - 2 560 to 680 ohms
2. INSPECT SPEED SENSOR (NC SENSOR) Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Resistance: TESTER CONNECTION AND SPECIFIED CONDITION Tester Connection Specified Condition 20°C (68°F) 1 - 2 560 to 680 ohms

Scheme 21

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1. INSTALL SPEED SENSOR (NC SENSOR) Coat the O-ring with ATF. Install the speed sensor with the bolt. Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) HINT: Make sure to install the same manufacturer's sensor. Connect the speed sensor connector.
2. INSTALL SPEED SENSOR (NT SENSOR) Coat the O-ring with ATF. Install the speed sensor with the bolt. Torque: 11 N*m (115 kgf*cm, 8 ft.*lbf) HINT: Make sure to install the same manufacturer's sensor. Connect the speed sensor connector.
3. INSTALL AIR CLEANER INLET NO. 1 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
4. INSTALL AIR CLEANER BRACKET HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
5. INSTALL AIR CLEANER INLET NO. 2 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
6. INSTALL AIR CLEANER HOSE NO. 1 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
7. INSTALL AIR CLEANER ASSEMBLY HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
8. INSTALL BATTERY
9. PERFORM INITIALIZATION HINT: Some systems need initialization when disconnecting the cable from the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

Scheme 23

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1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
3. REMOVE AIR CLEANER HOSE NO. 1 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
4. REMOVE AIR CLEANER HOSE NO.2 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
5. REMOVE AIR CLEANER BRACKET HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
6. REMOVE AIR CLEANER INLET NO. 1 HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
7. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY HINT: (See «REMOVAL»(ref-236009-S19582311542006062900000) )
8. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. Remove the clip and disconnect the control cable from the control cable bracket. NOTE: Do not hold the resin guide pipe.
9. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY Disconnect the park/neutral position switch connector. Remove the nut, washer and control shaft lever. Using a screwdriver, pry up the lock plate. Remove the lock nut and the lock plate. Remove the 2 bolts and pull out the park/neutral position switch.

Scheme 31

1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION Apply the parking brake and turn the ignition switch to the ON position. Depress the brake pedal and check that the engine starts only when the shift lever is in the N or P position and the engine does not start when the shift lever is in other positions. Check that the back up light comes on and the reverse warning buzzer sounds only when the shift lever is in the R position and the light and buzzer do not operate when the shift lever is in other positions. If a failure is found, check the park/neutral position switch for continuity.
2. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Jack up the vehicle. Disconnect the park/neutral position switch connector. Gate shift lever type: Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Shift Position Tester Connection Specified Condition P 2 - 6 and 4 - 5 Below 1 ohms Except P 10 kohms or higher R 2 - 1 Below 1 ohms Except R 10 kohms or higher N 2 - 9 and 4 - 5 Below 1 ohms Except N 10 kohms or higher D and 4 2 - 7 Below 1 ohms Except D and 4 10 kohms or higher 3 2 - 3 Below 1 ohms Except 3 10 kohms or higher 2 and L 2 - 8 Below 1 ohms Except 2 and L 10 kohms or higher Shift lever with Multi-mode automatic transmission type: Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. Resistance TESTER CONNECTION AND SPECIFIED CONDITION Shift Position Tester Connection Specified Condition P 2 - 6 and 4 - 5 Below 1 ohms Except P 10 kohms or higher R 2 - 1 Below 1 ohms Except R 10 kohms or higher N 2 - 9 and 4 - 5 Below 1 ohms Except N 10 kohms or higher D, S, "+" and "-" 2 - 7 Below 1 ohms Except D, S, "+" and "- 10 kohms or higher

Scheme 32

1. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY Loosen the 2 bolts of the park/neutral position switch and move the shift lever to the N position. Align the groove with the neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) After adjustment, perform the inspection described in park/neutral position switch assembly operation.

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1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY Install the park/neutral position switch to the manual valve shaft. Temporarily install the 2 bolts. Place a new lock plate and tighten the nut. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) Temporarily install the control shaft lever. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. Align the groove with the neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Using a screwdriver, bend the tabs of the lock plate. Install the control shaft lever, washer and the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Connect the park/neutral position switch connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Connect the control cable to the control shaft lever with the nut. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Install the control cable with a new clip to the bracket.
3. ADJUST PARK/NEUTRAL POSITION SWITCH ASSEMBLY (See «ADJUSTMENT»(ref-236002-S07874017452006062900000) )
4. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION (See «INSPECTION»(ref-236002-S18212822122006062900000) )
5. INSPECT SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S07547763002006062900000) )
6. ADJUST SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S07547763002006062900000) )
7. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
8. INSTALL AIR CLEANER INLET NO. 1 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
9. INSTALL AIR CLEANER BRACKET HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
10. INSTALL AIR CLEANER HOSE NO.2 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
11. INSTALL AIR CLEANER HOSE NO. 1 HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
12. INSTALL AIR CLEANER ASSEMBLY HINT: (See «INSTALLATION»(ref-236009-S10995122212006062900000) )
13. INSTALL BATTERY
14. PERFORM INITIALIZATION HINT: Some systems need initialization when disconnecting the cable from the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Remove the engine under cover assembly.
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Remove the engine under cover No.2.
5. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain the ATF. Install a new gasket and the drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
6. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Remove the 18 bolts, oil pan and gasket. NOTE: Some fluid will remain in the oil pan. Carefully remove the oil pan so that fluid remaining in the pan does not spill out. Remove the 2 magnets from the oil pan. Examine particles in the pan. Collect any steel chips using the removed magnets. Look carefully at the chips and particles in the pan and on the magnets to see the type of wear which might be found in the transaxle. Result: Steel (magnetic): Wear of the bearing, gear or plate Brass (non-magnetic): Wear of the bearing
7. DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor.
8. REMOVE TRANSMISSION WIRE Disconnect the transmission wire connector. Remove the bolt and transmission wire. Remove the O-ring from the transmission wire.

Scheme 48

Scheme 49

Scheme 50

1. INSTALL TRANSMISSION WIRE Coat the O-ring of the transmission wire connector with ATF and install it. Install the transmission wire with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 ft.*lbf)
2. CONNECT TRANSMISSION WIRE Coat the 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 ft.*lbf) Connect the 7 shift solenoid valve connectors.
3. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Install the 2 magnets in the oil pan. Apply seal packing to the 18 bolts. Seal packing: THREE BOND 2430 or equivalent Using a new gasket, install the oil pan to the transaxle case with the 18 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTE: Apply seal packing to the bolts and tighten them within 10 minutes of application.
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
5. ADD AUTOMATIC TRANSAXLE FLUID
6. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-236002-S15813079702006062900000) )
7. INSTALL ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Install the engine under cover No.2.
8. INSTALL ENGINE UNDER COVER NO. 1
9. INSTALL ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Install the engine under cover assembly.
10. RESET MEMORY HINT: (See «PRECAUTION»(ref-236002-S19443367462006062900000) )
11. PERFORM INITIALIZATION HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

Scheme 51

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Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. REMOVE ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Remove the engine under cover assembly.
2. REMOVE ENGINE UNDER COVER NO. 1
3. REMOVE ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Remove the engine under cover No.2.
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
5. DRAIN AUTOMATIC TRANSAXLE FLUID (See «REMOVAL»(ref-236002-S00360923072006062900000) )
6. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Remove the 18 bolts, oil pan and gasket. NOTE: Some fluid will remain in the oil pan. Carefully remove the oil pan so that the fluid remaining in the pan does not spill out. Remove the 2 magnets from the oil pan. Examine particles in the pan. Collect any steel chips using the removed magnets. Look carefully at the chips and particles in the pan and on the magnets to see the type of wear which might be found in the transaxle. Result: Steel (magnetic): Wear of the bearing, gear or plate Brass (non-magnetic): Wear of the bearing
7. DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor.
8. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 3 bolts and oil strainer. NOTE: Be careful when removing the oil strainer as fluid will come out. Remove the O-ring from the valve body oil strainer assembly.
9. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Support the valve body assembly and remove the 17 bolts and the transmission valve body assembly. Remove the check ball body and the spring. Remove the bolt and lock plate from the valve body assembly. Remove the shift solenoid valve SL3 and SLT from the valve body assembly. Remove the bolt and shift solenoid valve S4 from the valve body assembly. Remove the shift solenoid valve SR from the valve body assembly. Remove the bolt and shift solenoid valve DSL from the valve body assembly. Remove the bolt and shift solenoid valve SL2 from the valve body assembly. Remove the bolt and shift solenoid valve SL1 from the valve body assembly.

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Scheme 73

1. INSTALL TRANSMISSION VALVE BODY ASSEMBLY Install the shift solenoid valve SL1 to the valve body assembly with the bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) Install the shift solenoid valve SL2 to the valve body assembly with the bolt. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) Install the shift solenoid valve DSL to the valve body assembly with the bolt. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) Install the shift solenoid valve SR to the valve body assembly. Install the shift solenoid valve S4 to the valve body assembly with the bolt. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) Install the shift solenoid valve SL3 and SLT to the valve body assembly. Install the lock plate to the valve body assembly with the bolt. Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf) Install the spring and check ball body. Align the groove of the manual valve with the pin of the lever. Install the 17 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf) NOTE: Push the valve body against the accumulator piston springs and check ball body to install the valve body. First, temporarily tighten the bolts marked with (1) in the illustration because they are positioning bolts. Bolt length: Bolt A: 41 mm (1.614 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 25 mm (0.984 in.)
2. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Coat a new O-ring with ATF. Install the O-ring to the oil strainer. Install the oil strainer with the 3 bolts. Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
3. INSTALL TRANSMISSION WIRE Coat the O-ring 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 shift solenoid valve connectors.
4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Install the 2 magnets in the oil pan. Apply seal packing or equivalent to the 18 bolts. Seal packing: THREE BOND 2430 or equivalent Install the oil pan and new gasket with the 18 bolts to the transaxle case. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTE: Tighten the bolts within 10 minutes of sealant application.
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. ADD AUTOMATIC TRANSAXLE FLUID
7. CHECK FLUID LEVEL IN AUTOMATIC TRANSAXLE (See «ON-VEHICLE INSPECTION»(ref-236002-S15813079702006062900000) )
8. INSTALL ENGINE UNDER COVER NO. 2 w/ Engine under cover No.2: Install the engine under cover No.2.
9. INSTALL ENGINE UNDER COVER NO. 1
10. INSTALL ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Install the engine under cover assembly.
11. RESET MEMORY HINT: (See «PRECAUTION»(ref-236002-S19443367462006062900000) )
12. PERFORM INITIALIZATION HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

Scheme 74

Scheme 75

1. CHECK SHIFT LOCK OPERATION Move the shift lever to the P position. Turn the ignition switch to the LOCK position. Check that the shift lever cannot be moved to any position other than P. Turn the ignition switch to the on position, depress the brake pedal and check that the shift lever can be moved to another position. If operation can not be done as specified, inspect the shift lock control unit.
2. CHECK SHIFT LOCK RELEASE BUTTON OPERATION Using a small screwdriver, remove the shift lock release cover. When operating the shift lever with the shift lock release button pressed, check that the lever can be moved to any position other than P. If operation can not be done as specified, check the shift lever assembly installation condition.
3. CHECK KEY INTERLOCK OPERATION Turn the ignition switch to the ON position. )Depress the brake pedal and move the shift lever to any position other than P. Check that the ignition key cannot be turned to the LOCK position. Move the shift lever to the P position, turn the ignition key to the LOCK position and check that the ignition key can be removed. If operation cannot be done as specified, inspect the shift lock control unit.
4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Measure the voltage according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. Voltage VOLTAGE SPECIFICATIONS Terminal Measuring Condition Voltage (V) 6 (ACC) - 8 (E) Ignition switch ACC 10 to 14 6 (ACC) - 8 (E) Ignition switch OFF Below 1 7 (STP) - 8 (E) Depress brake pedal 10 to 14 7 (STP) - 8 (E) Release brake pedal Below 1 12 (KLS+) - 8 (E) Ignition switch ACC and shift lever P position Ignition switch ACC and shift lever except P position Ignition switch ACC and shift lever except P position (After approx. 1 second) Below 1 7.5 to 11 6 to 9 1 (IG) - 8 (E) Ignition switch ON 10 to 14 1 (IG) - 8 (E) Ignition switch OFF Below 1 Measure the resistance according to the value(s) in the table below. HINT: Do not disconnect the shift lock control unit assembly connector. If operation cannot be done as specified, replace the shift lever assembly. Resistance SPECIFIED VALUE Terminal Measuring Condition Specified Value 8 (E) - Body ground Always Below 1 ohms

Scheme 76

Scheme 77

1. REMOVE FRONT BUMPER COVER HINT: (See «REMOVAL»(ref-236022-S32532714882006062900000) )
2. DRAIN AUTOMATIC TRANSAXLE FLUID Remove a drain plug and the gasket, and drain ATF. Install the new gasket and drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
3. REMOVE OIL W/ HOSE COOLER ASSEMBLY Disconnect the 2 oil cooler hoses. Remove the bolt, nut and the oil w/ hose cooler assembly.

Scheme 78

1. INSTALL OIL W/ HOSE COOLER ASSEMBLY Install the oil w/ hose cooler assembly with the bolt and the nut. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) HINT: After temporarily tightening the bolt, fully tighten in order of the nut, bolt. Connect the 2 oil cooler hoses.
2. INSTALL FRONT BUMPER COVER HINT: (See «DISASSEMBLY»(ref-236022-S30875074882006062900000) )
3. ADD AUTOMATIC TRANSAXLE FLUID
4. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-236002-S15813079702006062900000) )

Scheme 79

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Scheme 85

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Remove the engine under cover assembly.
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Remove the engine under cover No.2.
5. REMOVE INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY W/ PASSENGER AIR BAG ASSEMBLY HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
6. REMOVE AIR CONDITIONER UNIT ASSEMBLY HINT: (See «REMOVAL»(ref-236010-S22729450582006062900000) )
7. REMOVE CENTER AIR BAG SENSOR ASSEMBLY HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/airbag/#supplemental-restraint-system) )
8. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY Remove the nut from the control shaft lever. Disconnect the transmission control cable assembly from the control shaft lever. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket. Remove the bolt and transmission control cable bracket No.2. Remove the 3 bolts and disconnect the transmission control cable assembly from the vehicle. Using a screwdriver, disconnect the cable end from the shift lever assembly. Turn the socket of the transmission control cable assembly counterclockwise and remove the stopper cap. Disconnect the transmission control cable assembly from the shift lever assembly.

Scheme 86

Scheme 87

Scheme 88

1. INSPECT SHIFT LEVER POSITION When shifting from the P to R position only with the ignition switch on and brake pedal depressed, make sure that the shift lever moves smoothly and can be moderately operated. Start the engine and make sure that the vehicle moves forward when shifting from the N to D position and moves rearward when shifting to the R position.
2. ADJUST SHIFT LEVER POSITION Loosen the nut on the control shaft lever. Push the control shaft fully downward. Return the control shaft lever 2 notches to the N position. While pushing the control cable end up with the shift lever in the N position, install it to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 10 ft.*lbf) NOTE: If the control cable end is excessively pushed up, the shift lever can not be adjusted. When tightening the nut, confirm that the control cable is properly stretched. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and moves rearward when shifting it to the R position.

Scheme 89

Scheme 90

Scheme 91

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Scheme 93

1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Connect the socket of the transmission control cable assembly to the shift lever assembly. Connect the control cable end to the shift lever assembly. Push the stopper cap to the socket as shown in the illustration. Turn the socket of the transmission control cable assembly clockwise and install the stopper cap. NOTE: To prevent torsion of the inner cable, the end with the eye should face up. Push the cable end to the bottom of the pin. Confirm that the connection between the socket and the shift lock control unit is fixed. Install the transmission control cable assembly with the 3 bolts. Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) Install the transmission control cable bracket No.2 with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Temporarily install the transmission control cable assembly to the control shaft lever with the nut. Connect the transmission control cable assembly with a new clip to the bracket.
2. INSTALL CENTER AIR BAG SENSOR ASSEMBLY HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/airbag/#supplemental-restraint-system) )
3. INSTALL AIR CONDITIONER UNIT ASSEMBLY HINT: (See «INSTALLATION»(ref-236010-S05941525792006062900000) )
4. INSTALL INSTRUMENT PANEL SAFETY PAD SUBASSEMBLY W/ PASSENGER AIR BAG ASSEMBLY HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. INSTALL ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Install the engine under cover No.2.
7. INSTALL ENGINE UNDER COVER NO. 1
8. INSTALL ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Install the engine under cover assembly.
9. INSPECT SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S07547763002006062900000) )
10. ADJUST SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S07547763002006062900000) )
11. INSPECT SRS WARNING LIGHT HINT: (See «DIAGNOSIS SYSTEM»(/lexus/rx/ii-facelift-2006-2009/remont/airbag/#supplemental-restraint-system) )

Scheme 94

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Scheme 96

1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Remove the engine under cover assembly.
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Remove the engine under cover No.2.
5. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and the drain plug. Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
6. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH HINT: (See «REMOVAL»(ref-236015-S40948561722006062900000) ) SST 09520-01010, 09520-24010 (09520-32040)
7. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) HINT: (See «REMOVAL»(ref-236015-S40948561722006062900000) )
8. REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, pull out the oil seal. SST 09308-00010
9. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010

Scheme 97

Scheme 98

1. INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, install a new oil seal. SST 09316-60011 (09316-00011) Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) Coat the lip of the oil seal with MP grease.
2. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09223-15020, 09950-70010 (09951-07150) Oil seal installation depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.) Coat the lip of the oil seal with MP grease.
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH HINT: (See «INSTALLATION»(ref-236015-S26995931032006062900000) )
4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) HINT: (See «INSTALLATION»(ref-236015-S26995931032006062900000) )
5. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
6. ADD AUTOMATIC TRANSAXLE FLUID
7. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-236002-S15813079702006062900000) )
8. INSTALL ENGINE UNDER COVER NO.2 w/ Engine under cover No.2: Install the engine under cover No.2.
9. INSTALL ENGINE UNDER COVER NO. 1
10. INSTALL ENGINE UNDER COVER ASSEMBLY w/ Engine under cover assembly: Install the engine under cover assembly.
11. CHECK ABS SPEED SENSOR SIGNAL HINT: (See «PROBLEM SYMPTOMS TABLE»(ref-236025-S08649415512006062900000) )
12. PERFORM INITIALIZATION HINT: Some systems need initialization when disconnecting the cable from the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

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1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/accessory-drive-belts/#engine-mechanical-3mz-fe) )
2. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH HINT: (See «REMOVAL»(ref-236015-S40948561722006062900000) )
3. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH HINT: (See «REMOVAL»(ref-236015-S40948561722006062900000) )
4. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.2 Remove the bolt and the transmission control cable bracket No.2.
5. REMOVE WIRE HARNESS CLAMP Disconnect the wire harnesses from the clamp. Remove the 4 bolts and 4 clamps.
6. DISCONNECT WIRE HARNESS Remove the bolt and disconnect the wire harness.
7. REMOVE STARTER ASSEMBLY Disconnect the connector (1). Remove the nut (2) and disconnect the starter wire. Remove the 2 bolts (3) and starter assembly.
8. DISCONNECT CONNECTORS Disconnect the transmission wire connector. Disconnect the park/neutral position switch connector. Disconnect the 2 transmission revolution sensor connectors.
9. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 1 Remove the 2 bolts and transmission control cable bracket No. 1.
10. REMOVE TRANSMISSION OIL FILLER TUBE SUBASSEMBLY Remove the ATF level gauge. Disconnect the 2 clamps form the oil filter tube subassembly. Remove the bolt and oil cooler tube clamp. Remove the bolt and transmission oil filter tube subassembly. Remove the O-ring from the oil filter tube subassembly.
11. REMOVE OIL COOLER INLET TUBE NO. 1 Using SST and a wrench, disconnect the oil cooler inlet tube No. 1. SST 09023-12701
12. REMOVE OIL COOLER OUTLET TUBE NO. 1 Using SST and a wrench, disconnect the oil cooler outlet tube No. 1. SST 09023-12701
13. REMOVE ENGINE MOUNTING BRACKET FRONT Remove the 3 bolts and engine mounting bracket front.
14. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Remove the 2 bolts and flywheel housing under cover. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. HINT: There will be one green colored bolt. Remove the 8 bolts. Separate and remove the automatic transaxle.
15. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY
16. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S33378412282006062900000) )

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Scheme 127

1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY Install the torque converter clutch to the automatic transaxle. Using vernier calipers and a straight edge, measure the dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (*1). Using vernier calipers and a straight edge, measure the dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (*1)). Standard: A + 1 mm (0.03937 in.) or more NOTE: Remember to minus the thickness of the straight edge.
2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Install the automatic transaxle to the engine with the 8 bolts. Torque: Bolt A 64 N*m (650 kgf*cm, 47 ft.*lbf) Bolt B 46 N*m (470 kgf*cm, 34 ft.*lbf) Bolt C 37 N*m (377 kgf*cm, 27 ft.*lbf) Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the 6 torque converter clutch mounting bolts. Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) NOTE: First install the green colored bolt, and then the remaining 5 bolts. Install the flywheel housing under cover to the automatic transaxle with the 2 bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
3. INSTALL ENGINE MOUNTING BRACKET FRONT Install the engine mounting bracket front to the automatic transaxle with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
4. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY Coat a new O-ring with ATF, and install it to the transmission oil filler tube sub-assembly. Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) Connect the 2 clamps to the oil filter tube. Install the ATF level gauge.
5. INSTALL OIL COOLER INLET TUBE NO. 1 Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Install the oil cooler tube clamp and bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) HINT: Install them so that the oil cooler tube cushion is positioned as shown in the illustration. Using SST and a wrench, tighten the oil cooler inlet tube No. 1. SST 09023-12701 Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
6. INSTALL OIL COOLER OUTLET TUBE NO. 1 Using SST and a wrench, tighten the oil cooler outlet tube No. 1. SST 09023-12701 Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
7. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 1 Install the control cable bracket No. 1 with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
8. CONNECT CONNECTORS Connect the transmission wire connector. Connect the park/neutral position switch connector. Connect the 2 transmission revolution sensor connectors.
9. INSTALL STARTER ASSEMBLY Install the starter assembly with the 2 bolts (1). Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) Connect the connector (2). Connect the starter wire with the nut (3). Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
10. CONNECT WIRE HARNESS Connect the wire harness with the bolt. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
11. INSTALL WIRE HARNESS CLAMP Install the 4 clamps and 4 bolts. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) Connect the wire harnesses to the clamps.
12. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.2 Install the transmission control cable bracket No.2 with the bolt. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
13. INSTALL LH FRONT DRIVE SHAFT ASSEMBLY HINT: (See «INSTALLATION»(ref-236015-S26995931032006062900000) )
14. INSTALL RH FRONT DRIVE SHAFT ASSEMBLY HINT: (See «INSTALLATION»(ref-236015-S26995931032006062900000) )
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/accessory-drive-belts/#engine-mechanical-3mz-fe) )
16. RESET MEMORY HINT: (See «PRECAUTION»(ref-236002-S19443367462006062900000) )
17. PERFORM INITIALIZATION HINT: Some system need initialization when disconnecting the cable from the negative battery terminal (See «PRECAUTION»(ref-236002-S19443367462006062900000) ).

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Scheme 133

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY Turn the shift lever knob sub-assembly in the direction indication by the arrow and remove it.
3. REMOVE CONSOLE PANEL UPPER FRONT HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
4. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
5. REMOVE FRONT DOOR SCUFF PLATE LH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
6. REMOVE FRONT DOOR SCUFF PLATE RH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
7. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
8. REMOVE COWL SIDE TRIM SUB-ASSEMBLY LH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
9. REMOVE INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
10. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
11. REMOVE FLOOR CARPET COVER CENTER LH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
12. REMOVE FLOOR CARPET COVER CENTER RH HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
13. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER HINT: (See «REMOVAL»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
14. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Using a screwdriver, disconnect the cable end from the shift lever assembly. Turn the socket of the transmission control cable assembly counterclockwise and remove the stopper cap. Disconnect the transmission control cable assembly from the shift lever assembly.
15. REMOVE SHIFT LEVER ASSEMBLY Disconnect the pattern select switch connector, the shift rock control computer connector and the indicator light wire connector. Remove the 4 nuts and disconnect the shift lever assembly from the vehicle.

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1. REMOVE POSITION INDICATOR HOUSING Using a screwdriver, remove the position indicator housing from the shift lever assembly.
2. REMOVE SHIFT LEVER CAP Using a screwdriver, remove the shift lever cap from the position indicator housing.
3. REMOVE PATTERN SELECT SWITCH ASSEMBLY NO. 1 Remove the pattern select switch assembly No. 1 from the position indicator housing.
4. REMOVE SHIFT LOCK RELEASE LINK NO. 1 Remove the shift lock release link, spring and cover from the position indicator housing.
5. REMOVE POSITION INDICATOR LIGHT GUIDE Remove the indicator light wire sub-assembly from the shift lever assembly. Using a screwdriver, remove the position indicator light guide from the shift lever assembly.
6. REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover from the position indicator housing lower.
7. REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover No.2 from the position indicator slide cover.
8. REMOVE POSITION INDICATOR HOUSING LOWER Remove the position indicator housing lower from the shift lock control unit.
9. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY Gate shift lever: Remove the connector from the shift lever assembly. Shift lever with multi-mode automatic transmission: Remove the connector from the shift lever assembly. Using a screwdriver, release the stopper of the connector. Using a screwdriver, disengage the locking lug of terminals (1) and (6), and pull the terminals out from the rear.

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1. INSPECT SHIFT LEVER POSITION When shifting from the P to R position only with the ignition switch on and brake pedal depressed, make sure that the shift lever moves smoothly and can be moderately operated. Start the engine and make sure that the vehicle moves forward when shifting from the N to D position and moves rearward when shifting to the R position.
2. ADJUST SHIFT LEVER POSITION Loosen the nut on the control shaft lever. Push the control shaft fully downward. Return the control shaft lever 2 notches to the N position. While pushing the control cable end up with the shift lever in the N position, install it to the control shaft lever with the nut. Torque: 15 N*m (150 kgf*cm, 10 ft.*lbf) NOTE: If the control cable end is excessively pushed up, the shift lever can not be adjusted. When tightening the nut, confirm that the control cable is properly stretched. Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and moves rearward when shifting it to the R position.

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1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY Shift lever with multi-mode automatic transmission: Connect the 2 terminals of indicator light wire harness to the connector of transmission control switch. Install the connector to the shift lever assembly. Gate shift lever: Install the connector to the shift lever assembly.
2. INSTALL POSITION INDICATOR HOUSING LOWER Install the position indicator housing lower to the shift lock control unit. HINT: Engage the claws securely.
3. INSTALL POSITION INDICATOR SLIDE COVER Install the position indicator slide cover No.2 to the position indicator slide cover.
4. INSTALL POSITION INDICATOR SLIDE COVER Install the position indicator slide cover to the position indicator housing lower. NOTE: Install the position indicator slide cover No.2 with the boss facing the rear of the vehicle.
5. INSTALL POSITION INDICATOR LIGHT GUIDE Install the position indicator light guide to the position indicator housing lower. HINT: Engage the claws securely. Install the indicator light wire sub-assembly to the shift lever assembly.
6. INSTALL SHIFT LOCK RELEASE LINK NO. 1 Apply MP grease to the shift lock release link and spring. Install the shift lock release link, spring and cover.
7. INSTALL PATTERN SELECT SWITCH ASSEMBLY NO. 1 Install the pattern select switch assembly No. 1 to the position indicator housing.
8. INSTALL SHIFT LEVER CAP Install the shift lever cap to the position indicator housing.
9. INSTALL POSITION INDICATOR HOUSING Install the position indicator housing to the shift lever assembly. HINT: Engage the claws securely.

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1. INSTALL SHIFT LEVER ASSEMBLY Install the shift lever assembly with the 4 nuts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) HINT: Tighten them in the order, A, B, C and D. NOTE: Be careful not to put the wirings of the indicator light or the shift lock system between the floor shift assembly and the floor while installing the floor shift assembly. Install the pattern select switch connector, the shift lock control computer connector and the indicator light wire connector.
2. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Connect the socket of the transmission control cable assembly to the shift lever assembly. Connect the control cable end to the shift lever assembly. Push the stopper cap to the socket as shown in the illustration. Turn the socket of the transmission control cable assembly clockwise and install the stopper cap. NOTE: To prevent torsion of the inner cable, the end with the eye should face up. Push the cable end to the bottom of the pin. Confirm that the connection between the socket and the shift rock control unit is fixed.
3. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Install the shift lever knob sub-assembly.
4. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
5. INSTALL FLOOR CARPET COVER CENTER RH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
6. INSTALL FLOOR CARPET COVER CENTER LH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
7. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
8. INSTALL INSTRUMENT PANEL FINISH PANEL SUBASSEMBLY LOWER HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
9. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
10. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
11. INSTALL FRONT DOOR SCUFF PLATE RH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
12. INSTALL FRONT DOOR SCUFF PLATE LH HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
13. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
14. INSTALL CONSOLE PANEL UPPER FRONT HINT: (See «INSTALLATION»(/lexus/rx/ii-facelift-2006-2009/remont/gauges-instrument-panels/#instrument-panel) )
15. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
16. INSPECT SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S21351405642006062900000) )
17. ADJUST SHIFT LEVER POSITION (See «ADJUSTMENT»(ref-236002-S21351405642006062900000) )
18. PERFORM INITIALIZATION HINT: (See «PRECAUTION»(ref-236002-S19443367462006062900000) )

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1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY Inspect the one-way clutch. Set SST into the inner race of the one-way clutch. SST 09350-32014 (09351-32010) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32010, 09351-32020) Stand the torque converter up and turn the SST. Standard: If the one-way clutch is turned clockwise, it rotates freely and if turned counterclockwise, it locks. Determine the condition of the torque converter clutch assembly. If the inspection result of the torque converter clutch assembly satisfies the following conditions, replace the torque converter clutch assembly. Malfunction item: A metallic sound is emitted from the torque converter clutch assembly during the stall test or when the shift lever is moved to the N position. The one-way clutch is free or locked in both directions. The amount of powder in the ATF is greater than the sample shown on the illustration (see the sample). HINT: The sample shows the auto fluid of approximately 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch. Exchange the ATF in the torque converter clutch. If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the torque converter facing up. Clean and check the oil cooler and oil pipe line. If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. If the ATF is cloudy, inspect the oil cooler (radiator). Prevent deformation of the torque converter clutch and damage to the oil pump gear. When there is any damage on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. All of the bolts must be same length. Bolts with washers must be used.
2. INSPECT DRIVE PLATE & RING GEAR SUBASSEMBLY Set up a dial indicator with a roller instrument and measure the drive plate runout. Check for damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If runout is not within specification or ring gear is damaged, replace the drive plate.

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1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 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.
2. REMOVE BREATHER PLUG HOSE Remove the breather plug hose from the transaxle case.
3. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Remove the union. Remove the O-ring from the union.
4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Remove the elbow. Remove the O-ring from the elbow.
5. REMOVE SPEED SENSOR Remove the 2 bolts and the 2 speed sensors from the transaxle assembly.
6. 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.
7. FIX AUTOMATIC TRANSAXLE ASSEMBLY Fix the transaxle assembly.
8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Remove the 18 bolts, oil pan and gasket. Remove the 2 magnets from the oil pan.
9. 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: Result: Steel (magnetic): Wear of the bearing, gear and plate Brass (non-magnetic): Wear of the bushing
10. DISCONNECT TRANSMISSION WIRE Remove the 7 connectors from the shift solenoid valves. Remove the bolt, lock plate and temperature sensor.
11. REMOVE TRANSMISSION WIRE Remove the bolt and transmission wire from the transaxle case.
12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 3 bolts and oil strainer. Remove the O-ring from the oil strainer.
13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Support the valve body assembly and remove the 17 bolts and valve body assembly.
14. REMOVE GOVERNOR APPLY GASKET NO. 1 Remove the governor apply gasket No. 1 from the transaxle case.
15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET Remove the transaxle case 2nd brake gasket from the transaxle case.
16. REMOVE BRAKE DRUM GASKET Remove the brake drum gasket from the transaxle case.
17. REMOVE CHECK BALL BODY Remove the check ball body and spring from the transaxle case.
18. 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: Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth. Take care not to splash ATF when applying compressed air. Remove the O-ring from the C-3 accumulator piston.
19. 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: Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth. Take care not to splash ATF when applying compressed air. Remove the 2 O-rings from the reverse clutch accumulator piston.
20. 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: Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth. Take care not to splash ATF when applying compressed air. Remove the O-ring from the B-3 accumulator piston.
21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING Using needle-nose pliers, remove the manual valve lever shaft retainer spring.
22. REMOVE MANUAL DETENT SPRING SUBASSEMBLY Remove the 2 bolts, the manual detent spring subassembly and cover.
23. REMOVE PARKING LOCK PAWL BRACKET Remove the 2 bolts and parking lock pawl bracket.
24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 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.
25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY Remove the parking lock rod from the manual valve lever.
26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL Using a screwdriver, remove the oil seal from the transaxle case. NOTE: Do not apply excessive force when removing the oil seal.
27. FIX AUTOMATIC TRANSAXLE ASSEMBLY Fix the transaxle case with the oil pump side facing up.
28. INSPECT INPUT SHAFT ENDPLAY HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
29. 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: The differential may be accidentally removed when the transaxle housing is removed.
30. REMOVE OIL PUMP ASSEMBLY Remove the 7 bolts and oil pump from the transaxle case.
31. REMOVE THRUST NEEDLE ROLLER BEARING Remove the thrust needle roller bearing from the underdrive planetary gear assembly.
32. REMOVE THRUST BEARING UNDERDRIVE RACE NO.2 Remove the thrust bearing underdrive race No.2 from the underdrive planetary gear assembly.
33. REMOVE DIFFERENTIAL GEAR ASSEMBLY Remove the differential gear assembly from the transaxle case.
34. REMOVE OVERDRIVE BRAKE GASKET Remove the 2 overdrive brake gaskets from the transaxle case.
35. REMOVE FORWARD CLUTCH ASSEMBLY Remove the forward clutch assembly from the transaxle case. Remove the thrust needle roller bearing from the forward clutch.
36. 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.
37. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
38. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 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 assembly from the transaxle case. NOTE: Be careful so that the underdrive planetary gear assembly will not fall out.
39. REMOVE PARKING LOCK PAWL Remove the spring, pawl pin and parking lock pawl.
40. REMOVE UNDERDRIVE CLUTCH ASSEMBLY Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle case.
41. REMOVE UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Using a screwdriver, remove the snap ring from the transaxle case. NOTE: Do not apply excessive force when removing the snap ring. Remove the underdrive 1-way clutch from the transaxle case. Remove the outer race retainer from the 1-way clutch.
42. REMOVE UNDERDRIVE CLUTCH DISC NO.2 Using a screwdriver, remove the snap ring. NOTE: Do not apply excessive force when removing the snap ring. Remove the flange, 4 discs and 4 plates from the transaxle case.
43. INSPECT UNDERDRIVE CLUTCH DISC NO.2 HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
44. REMOVE TRANSAXLE REAR COVER SUBASSEMBLY Remove the 11 bolts. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
45. 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.
46. REMOVE REAR CLUTCH OIL SEAL RING OUTER Remove the 3 rear clutch oil seal rings from the transaxle rear cover.
47. 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)
48. REMOVE GOVERNOR APPLY GASKET NO. 1 Using a screwdriver, remove the 3 apply gaskets.
49. 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. NOTE: Do not bend the tubes.
50. REMOVE DIRECT CLUTCH ASSEMBLY Remove the thrust bearing and the direct clutch assembly from the transaxle case.
51. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub from the planetary gear assembly.
52. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
53. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY Remove the rear planetary sun gear assembly from the transaxle case. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly. Remove the planetary carrier thrust washer No.2 from the rear planetary sun gear assembly.
54. REMOVE 1-WAY CLUTCH ASSEMBLY Remove the 1-way clutch assembly and the thrust needle roller bearing from the transaxle case. Remove the 1-way clutch inner race from the 1-way clutch assembly.
55. REMOVE 1-WAY CLUTCH SLEEVE OUTER Remove the 1-way clutch sleeve outer from the transaxle case.
56. REMOVE PLANETARY CARRIER THRUST WASHER NO. 1 Remove the planetary carrier thrust washer No. 1 from the planetary gear assembly.
57. REMOVE 2ND BRAKE CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 4 discs and 4 plates from the transaxle case.
58. INSPECT 2ND BRAKE CLUTCH DISC HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
59. REMOVE 2ND BRAKE PISTON ASSEMBLY Using a screwdriver, remove the snap ring. Remove the 2ND brake piston assembly from the transaxle case.
60. REMOVE REAR PLANETARY GEAR ASSEMBLY Using a screwdriver, remove the snap ring. Remove the rear planetary gear assembly from the transaxle case.
61. REMOVE INPUT SUN GEAR Remove the 2 thrust needle roller bearings, thrust bearing race No.2 and the input sun gear from the transaxle case.
62. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC Remove the flange, 6 discs and 6 plates from the transaxle case.
63. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
64. REMOVE FRONT PLANETARY GEAR ASSEMBLY Using a chisel and hammer, unstake the lock washer. NOTE: Push down all claws of the washer. Otherwise the 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 assembly from the counter drive gear. SST 09950-60010 (09951-00450), 09950-70010 (09951-07100) Remove the front planetary gear assembly from the brake hub.
65. REMOVE FRONT PLANETARY RING GEAR Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
66. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 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 seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed. Do not expand the snap ring excessively.
67. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
68. REMOVE 1ST AND REVERSE BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the transaxle case to remove the 1st and reverse brake piston. NOTE: Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth. Take care not to splash ATF when applying compressed air. Remove the 2 O-rings from the 1st and reverse brake piston.
69. 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 the 2 bolts evenly and make clearance of approx. 20.0 mm (0.787 in.) between the counter drive gear and the inner race. Using SST, remove the tapered roller bearing. SST 09950-60010 (09951-00590), 09950-00020, 09950-00030, 09950-40011 (09957-04010)
70. REMOVE TRANSFER DRIVEN PINION FRONT 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)
71. REMOVE BREATHER PLUG NO.2 (ATM)
72. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 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 seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed. Do not expand the snap ring excessively.
73. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S34731799142006062900000) )
74. 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.
75. REMOVE NEEDLE ROLLER BEARING Using SST, remove the needle roller bearing from the transaxle case. SST 09387-00041 (09387-01010, 09387-01030, 09387-01040)
76. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING Remove the 2 oil seal rings from the transaxle case.
77. 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.
78. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING Using SST, remove the underdrive cylindrical roller bearing from the transaxle case. SST 09514-35011
79. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Remove the oil seal ring from the transaxle housing.
80. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing. NOTE: Do not bend the tubes.

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1. INSPECT MULTIPLE DISC CLUTCH HUB Using a dial indicator, measure the inside diameter of the forward clutch hub bushing Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) NOTE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discoloration is found, replace the direct clutch sub-assembly with a new one. If the inside diameter is greater than the maximum, replace the forward clutch hub with a new one.
2. INSPECT UNDERDRIVE CLUTCH DISC NO.2 Check if the sliding surfaces 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY Using a dial indicator, measure the inside diameter of the forward clutch hub bushing. Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) Maximum inside diameter: 23.09 mm (0.9091 in.) NOTE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discoloration is found, replace the direct clutch sub-assembly with a new one. If the inside diameter is greater than the maximum, replace the forward clutch hub with a new one.
4. INSPECT 2ND BRAKE CLUTCH DISC Check 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
5. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC Check 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
6. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 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.) HINT: If the result is not as specified, replace the spring.
7. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 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.) HINT: If the result is not as specified, replace the spring.
8. INSPECT PACK CLEARANCE OF 1ST AND 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 to 1.35 mm (0.0457 to 0.0531 in.) HINT: Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.) FLANGE THICKNESS 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.
9. INSPECT PACK CLEARANCE OF 2ND 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 to 0.91 mm (0.0244 to 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 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
10. 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 to 2.20 mm (0.0713 to 0.0866 in.) HINT: Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.) FLANGE THICKNESS 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) - - Temporarily remove the snap ring and attach it to the flange. Reinstall the snap ring.
11. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive 1-way clutch assembly to check the rotating direction for the lock or free operation. HINT: If the result is not as specified, replace the underdrive 1-way clutch.
12. INSPECT INPUT SHAFT END PLAY Using a dial indicator, measure the input shaft end play. End play: 0.262 to 1.244 mm (0.01 to 0.049 in.) HINT: If the result is not as specified, replace the input shaft or thrust needle roller bearing.

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1. BEARING POSITION THRUST BEARING DIAMETER 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)
2. 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.
3. INSTALL TRANSAXLE CASE NO. 1 PLUG Install 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)
4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING Coat a new oil seal ring with ATF and install it to the transaxle housing.
5. 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 the bearing.
6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING Coat 2 new oil seal rings with ATF, and install them to the transaxle rear cover. NOTE: Do not expand the end gap of the oil seal ring too much. Fix the hooks firmly. Confirm that the oil seal ring rotates freely in its groove.
7. INSTALL NEEDLE ROLLER BEARING Wrap vinyl tape around the SST 4.0 mm (0.157 in.) from the bottom of the SST until the thickness of the tape is about 5.0 mm (0.197 in.). SST 09950-60010 (09951-00320), 09950-70010 (09951-07100) NOTE: Clean SST to remove deposited oil, before wrapping 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 wrapped vinyl tape contacts the transaxle case, stop press-fitting.
8. INSTALL UNDERDRIVE BRAKE PISTON Coat 2 new O-rings with ATF, and install them to the underdrive brake piston. NOTE: Make sure that the O-rings are not twisted or pinched when they are installed. Apply sufficient ATF to the O-ring before installing. 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.
9. INSTALL UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 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 seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed. Do not expand the snap ring excessively. Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly. The snap ring should be fully engaged in the groove of the transaxle case.
10. INSTALL BREATHER PLUG NO. 2 (ATM)
11. INSTALL COUNTER DRIVE GEAR BEARING Coat the counter drive 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 the bearing. Press-fit the bearing outer race until it contacts the transaxle case. Using a snap ring expander, install the snap ring. NOTE: The white mark side of the snap ring should face upward.
12. INSTALL COUNTER DRIVE GEAR Coat the couter drive 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 the bearing. Using SST and a press, install the counter drive gear and bearing to the transaxle case. SST 09950-70010 (09951-07150), 09223-15030, 09527-17011, 09950-60020 (09951-00750) NOTE: Do not apply excessive pressure to the counter drive gear.
13. INSTALL 1ST AND REVERSE BRAKE PISTON Coat 2 new O-rings with ATF. Install the 2 O-rings to the 1st and reverse brake piston. NOTE: Make sure that the O-rings are not twisted or pinched when they are installed. Apply sufficient ATF to the O-ring prior to assembling. Coat the 1st and reverse brake piston with ATF, and install it to the transaxle case. NOTE: Be careful not to damage the O-ring.
14. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 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 seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed. Do not expand the snap ring excessively. Installing the spring sub-assembly, check that all of the springs are fit in the piston correctly. The snap ring should be fully engaged in the groove of the cylinder. Fix the snap ring to the inside of the claw of the spring seat firmly.
15. INSTALL FRONT PLANETARY RING GEAR Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. NOTE: Confirm that the snap ring is engaged in the groove of the brake hub correctly.
16. INSTALL FRONT PLANETARY GEAR ASSEMBLY Install the front planetary gear assembly to the brake hub. Using SST and a press, press-fit the front planetary gear assembly. SST 09950-60010 (09951-00500), 09950-70010 (09951-07100) NOTE: Do not apply excessive pressure to the planetary gear assembly. Press the inner race of LH tapered roller bearing, counter gear and front planetary gear assembly to the position where no preload should be applied to one pair of tapered roller bearings (left and right). Install a new washer as shown in the illustration. Using SST, install the nut. SST 09387-00030, 09387-00080 Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf) NOTE: Assemble the washer after pressing each part, then tighten the nut to the 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 as specified, gradually tighten the nut until it reaches the specified value. SST 09387-00080 Standard: Turning torque at 60 rpm Bearing: New Bearing: 0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7 in.*lbf) Used Bearing: 0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.). Tighten the nut gradually until the specified turning torque of tapered roller bearing is measured. Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf) Using a chisel and hammer, stake the front lock washer.
17. INSTALL INPUT SUN GEAR Coat the 2 thrust bearings with ATF. Install the 2 thrust bearings, the bearing race and the input sun gear to the front planetary gear assembly. NOTE: Install the bearing race on the side of the front planetary carrier. Be careful about the direction of the race. Installing thrust bearing and front sun gears, be careful about the direction of the parts. Install the bearing race on the side of the front sun gear. Be careful about the direction of the race. Install the thrust bearing and the race after holding the parts on the input sun gear by applying grease. Make sure that the assembling order is correct. Thrust bearing and bearing race diameter: mm (in.) THRUST BEARING AND BEARING RACE DIAMETER Inside Outside Thrust Bearing, A 32.5 (1.28) 56.5 (2.224) Bearing Race, B 40.2 (1.583) 59.3 (2.335) Thrust Bearing, C 38.6 (1.520) 59.7 (2.35) Bearing Race, D 38.6 (1.520) 59.3 (2.335)
18. INSTALL REAR PLANETARY GEAR ASSEMBLY Install the rear planetary gear assembly to the rear planetary ring gear. Using a screwdriver, install the snap ring. NOTE: Confirm that the snap ring is fixed in the groove of the 1st and reverse brake hub correctly.
19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC Coat the 6 discs with ATF. Install the 7 plates and 6 discs. NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
20. INSPECT PACK CLEARANCE OF FIRST AND 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 to 1.35 mm (0.0457 to 0.0531 in.) HINT: Piston stroke = Dimension A - Flange thickness Flange thickness: mm (in.) FLANGE THICKNESS 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.
21. INSTALL SECOND BRAKE PISTON ASSEMBLY Install the second brake piston assembly to the transaxle case. Install the snap ring and measure the inside diameter. Inside diameter: Greater than 167 mm (6.57 in.) NOTE: Make sure that the taper snap ring is installed in the correct direction. When the diameter does not meet the specified value, replace the snap ring with a new one. After installing, confirm that there is no clearance between the 2nd brake cylinder and the fitting surface of the cylinder in the transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER Install the 1-way clutch sleeve outer to the 2nd brake cylinder assembly. NOTE: Make sure that the outer sleeve is installed in the correct direction.
23. INSTALL 1-WAY CLUTCH ASSEMBLY Install the 1-way clutch inner race to the 1-way clutch. NOTE: Make sure that the inner race is installed in the correct direction. Confirm that the discrimination mark is visible. 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 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.
24. INSTALL PLANETARY CARRIER THRUST WASHER NO. 1 Coat the planetary carrier thrust washer No. 1 with yellow petrolatum, and install the washer onto the planetary sun gear assembly. NOTE: After installing, confirm that the projection should be fixed firmly in the hole of the planetary sun gear assembly.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY Coat the planetary carrier thrust washer No.2 with yellow petrolatum, and install the washer onto the rear planetary sun gear. Coat the bearing with yellow petrolatum, and install the bearing onto the rear planetary sun gear. Bearing diameter: mm (in.) BEARING DIAMETER 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 assembly to the rear planetary gear. NOTE: Installing the rear planetary sun gear assembly, make sure that the B1 discs are engaged.
26. INSTALL 2ND BRAKE CLUTCH DISC Coat the 4 discs with ATF. Install the 4 discs and 5 plates to the transaxle case. Temporarily install the snap ring.
27. INSPECT PACK CLEARANCE OF 2ND 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. Clearance: 0.62 to 0.91 mm (0.0244 to 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 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 reinstall the snap ring. NOTE: Secure the snap ring so that the ends visible through the groove of the transaxle case.
28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY Install the direct clutch hub to the planetary gear assembly. NOTE: Be careful not to damage the bushing inside the overdrive clutch hub during installation. Coat the thrust bearing with ATF. Install the bearing race and the thrust bearing to the direct clutch hub. NOTE: Be careful not to drop the bearing when it is installed. Bearing and race diameter: mm (in.) BEARING AND RACE DIAMETER Inside Outside Bearing, A 24.7 (0.972) 39.5 (1.555) Race, B 23.6 (0.929) 38.0 (1.496)
29. INSTALL DIRECT CLUTCH ASSEMBLY Coat the thrust bearing with ATF. Install the direct clutch assembly and thrust bearing to the rear planetary sun gear assembly. NOTE: The disc in the direct clutch should completely match with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover cannot be installed. Clean the connecting part of the transaxle case and the rear cover. As shown in the illustration, place a straightedge on the direct clutch drum and measure the distance between the transaxle case and the straightedge using vernier calipers (Dimension C). Using vernier calipers and a straightedge, measure the dimension 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 the selected bearing. End play: 0.244 to 0.901 mm (0.0096 to 0.0355 in.) NOTE: Make sure that the no-colored race side is facing the direct clutch assembly. HINT: End play = Dimension D - Dimension C Bearing thickness and diameter: mm (in.) BEARING AND RACE DIAMETER Thickness Inside Outside 3.6 (0.1417) 56.3 (2.217) 75.7 (2.980) 3.8 (0.1496) 56.3 (2.217) 75.7 (2.980)
30. INSTALL GOVERNOR APPLY GASKET NO. 1 Install 3 new governor apply gaskets No. 1 to the transaxle case.
31. 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: The tube should be securely inserted until it reaches the stopper.
32. INSTALL NEEDLE ROLLER BEARING Using SST and a press, press the needle roller bearing into the transaxle rear cover. SST 09950-60010 (09951-00230, 09952-06010) Press fit depth: 20.55 to 21.25 mm (0.8091 to 0.8366 in.) NOTE: The engraved mark side of the bearing should face upward. Repeat the press fit until the specified value is obtained. Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER Coat 3 new rear clutch oil seal rings with ATF, install them to the transaxle rear cover. NOTE: The snap ring should be fully engaged in the groove of the drum.
34. INSTALL TRANSAXLE CASE NO. 1 PLUG Coat 4 new O-rings with ATF. Install the 4 O-rings 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)
35. INSTALL TRANSAXLE REAR COVER SUBASSEMBLY Remove any packing material and be careful not to spill oil on the contact 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: Make sure that the FIPG is applied in a bead (section diameter: 1.2) so that the entire sealing surface will be evenly sealed. The FIPG should also protrude slightly from the flange after the assembly of the parts has been completed. 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 N*m (190 kgf*cm, 14 ft.*lbf) Other bolts: 25 N*m (250 kgf*cm, 18 ft.*lbf)
36. 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 fully engaged in the groove of the drum.
37. 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 to 2.20 mm (0.0713 to 0.0866 in.) HINT: Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.) FLANGE THICKNESS 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) - - Temporarily remove the snap ring and attach it to the flange. Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY Install the outer race retainer to the 1-way clutch. NOTE: Fix the outer race retainer to the external tooth of the 1-way clutch firmly. 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 fully engaged in the groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY 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 Inside Outside Bearing 37.73 (1.4854) 58.0 (2.2835) Race 29.9 (1.1772) 55.5 (2.185) Install the underdrive clutch assembly to the transaxle case. NOTE: Do not damage the oil seal when installing the underdrive clutch drum sub-assembly.
41. 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.
42. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY Install the underdrive planetary gear assembly to the transaxle case. NOTE: Fully engage all the discs of underdrive clutch and hub splines of the underdrive planetary gear assembly and install 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 straightedge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the underdrive planetary gear and the contact surface of the transaxle case and housing (Dimension E). NOTE: Record dimension E for the following process. As shown in the illustration, measure the 2 places of the transaxle housing, and calculate dimension F using the formula below. NOTE: Record dimension F for the following process. HINT: Dimension F = Dimension (1) - Dimension (2)
43. INSTALL MULTIPLE DISC 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 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 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 Inside Outside Bearing 23.6 (0.929) 44 (1.732) Install the multiple clutch hub to the transaxle case.
44. INSTALL FORWARD CLUTCH ASSEMBLY 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 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 assembly. NOTE: Align the splines of all discs in the forward clutch with those of multiple clutch hub to install them securely. Be careful not to damage the bushing inside of the forward clutch hub during installation.
45. INSTALL OVERDRIVE BRAKE GASKET Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY Install the differential gear assembly to the transaxle case.
47. INSTALL THRUST BEARING UNDERDRIVE RACE NO. 2 Install the thrust bearing underdrive race No.2 to the underdrive planetary gear assembly.
48. 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 are measured when installing the 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 the selected bearing race. End play: 0.498 to 0.993 mm (0.01961 to 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.) RACE THICKNESS 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 Inside Outside Bearing 57.2 (2.252) 84.96 (3.345) Bearing race 56.4 (2.22) 83 (3.268)
49. INSTALL OIL PUMP ASSEMBLY Install the oil pump to the transaxle case with the 7 bolts. Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf) Coat the O-ring of oil pump with ATF. NOTE: Confirm that the input shaft rotates smoothly with the manual operation after installing the oil pump.
50. INSTALL TRANSAXLE HOUSING Remove any packing material and be careful not to spill oil on the contact 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 ft.*lbf) HINT: Apply seal packing or equivalent to bolts 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: Tighten the bolts within 10 minutes of sealant application.
51. INSPECT INPUT SHAFT END PLAY Using a dial indicator, measure the input shaft end play. End play: 0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY Fix the transaxle assembly.
53. 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 installation depth: 0 +- 0.5 mm (0 +- 0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY Install a new spacer and manual valve lever shaft to the transaxle case. NOTE: Do not damage the oil seal when installing 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.
56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER SPRING Using needle-nose pliers, install the retainer spring. NOTE: Hang the spring on the shaft firmly.
57. 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: Make sure that the parking rod is placed between the parking pawl and the guide of the parking bracket when the parking bracket is installed.
58. INSTALL MANUAL DETENT SPRING SUBASSEMBLY Install the manual detent spring and cover with the 2 bolts. NOTE: Make sure to install the manual detent spring and cover in this order. HINT: Tighten bolt A first, and then bolt 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.)
59. INSTALL B-3 ACCUMULATOR PISTON Coat a new O-ring with ATF, install it to the B-3 accumulator piston. NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring: FREE LENGTH OUTER DIAMETER 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
60. INSTALL REVERSE CLUTCH ACCUMULATOR PISTON Coat 2 new O-rings with ATF, install them to the reverse accumulator piston. NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring: FREE LENGTH OUTER DIAMETER Free length Outer diameter mm (in.) Color 60.96 (2.3999) / 14.10 (0.555) Yellow
61. INSTALL C-3 ACCUMULATOR PISTON Coat a new O-ring with ATF, install it to the C-3 accumulator piston. NOTE: Make sure that the O-ring is not twisted and that it does not protrude abnormally from the accumulator piston. Apply sufficient ATF before installing the O-ring. The O-ring must be installed in the correct position. Coat the piston with ATF, install it to the transaxle case. NOTE: Install the springs to each accumulator piston, checking the identification color or each spring. Accumulator spring: FREE LENGTH OUTER DIAMETER Free length Outer diameter mm (in.) Color 72.20 (2.8425) / 19.0 (0.748) Colorless Install the spring to the C-3 accumulator piston. NOTE: Install the springs to each accumulator piston, checking the identification color or each spring.
62. INSTALL CHECK BALL BODY Coat the check ball body with ATF. Install the check ball body and spring. NOTE: Be sure to place the spring in the hole in the check ball body. Be careful about the direction of the parts.
63. 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 of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET Coat a new transaxle case 2nd brake gasket with ATF, and install it to the transaxle case. NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
65. INSTALL GOVERNOR APPLY GASKET NO. 1 Coat a new governor apply gasket No. 1 with ATF, and install it to the transaxle case. NOTE: Be sure not to damage the lip of the transaxle case brake gasket when inserting the gasket to the case. Apply sufficient ATF to the gasket before installation. Be careful about the direction of parts.
66. INSTALL TRANSMISSION WIRE Coat a new O-ring with ATF, and install it to the transmission wire. NOTE: Make sure that the O-ring is not twisted, protruded, or pinched when installing the wire transmission to the transaxle case. Apply sufficient ATF to the O-ring before installation. Install the transmission wire retaining bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
67. CONNECT TRANSMISSION WIRE Coat an 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 connectors A, B, C, D, E, F, G, in the order from shortest to longest. Apply ATF to the bolt.
68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY While positioning the manual valve lever position, install the valve body to the transaxle case with the 17 bolts. 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 the valve body. When installing the valve body to the transaxle case, do not hold the solenoids. Temporarily tighten the bolts marked with (1) in the illustration first because they are positioning bolts.
69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Coat a new O-ring with ATF and install it to the oil strainer. NOTE: Make sure that the O-ring is not twisted or pinched. Apply sufficient ATF to the O-ring before installation. 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.
70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY Install the 2 magnets to the oil pan. Apply seal packing or equivalent to new 18 bolts. Seal packing: THREE BOND 2430 or equivalent Install the oil pan and new oil pan gasket to the transaxle case with the 18 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) NOTE: Tighten the bolts within 10 minutes of sealant application. Completely remove any oil or grease from the contact surface of the transaxle case and the oil pan with the gasket before installing the oil pan to the case.
71. INSTALL TRANSAXLE CASE NO. 1 PLUG Coat 4 new O-rings with ATF, and 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)
72. INSTALL SPEED SENSOR Coat 2 new O-rings with ATF and 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)
73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Coat a new O-ring with ATF, and install it to the elbow. Install the elbow to the transaxle case. Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
74. INSTALL OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Coat a new O-ring with ATF, and install it to the union. Install the union to the transaxle case. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
75. INSTALL BREATHER PLUG HOSE Install the breather plug hose to the transaxle case firmly.
76. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY 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 the 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 the 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)
77. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSEMBLY Coat a new O-ring with ATF and install it to the speedometer driven hole cover. Install the bolt and speedometer driven hoke cover sub assembly to the transaxle assembly. Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)

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1. INSPECT OIL PUMP ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S31841384772006062900000) )
2. REMOVE CLUTCH DRUM OIL SEAL RING Remove the 2 clutch drum oil seal rings.
3. REMOVE STATOR SHAFT ASSEMBLY Using a "torx" socket (T30), remove the 11 bolts and stator shaft.
4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S31841384772006062900000) )
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 the oil pump in a soft jaw vise. Using SST, remove the oil seal from the oil pump body. SST 09308-00010

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1. INSPECT OIL PUMP ASSEMBLY Turn the drive gear with the 2 screwdrivers and make sure that it rotates smoothly. NOTE: Be careful not to damage the oil seal lip.
2. 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 to 0.17 mm (0.0039 to 0.0067 in.) Side clearance: 0.02 to 0.05 mm (0.001 to 0.002 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-assembly. Using a feeler gauge, measure the tip clearance between the driven gear teeth and drive gear teeth. Standard tip clearance: 0.07 to 0.15 mm (0.0028 to 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-assembly. Using a straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 to 0.05 mm (0.0008 to 0.0020 in.) Maximum side clearance: 0.05 mm (0.0020 in.) Drive gear thickness: mm (in.) DRIVE GEAR THICKNESS Mark Thickness A 11.690 to 11.699 (0.4602 to 0.4606) B 11.700 to 11.709 (0.4606 to 0.4610) C 11.710 to 11.720 (0.4610 to 0.4614) D 11.721 to 11.730 (0.4615 to 0.4618) E 11.731 to 11.740 (0.4619 to 0.4622) Driven gear thickness: mm (in.) DRIVEN GEAR THICKNESS Mark Thickness A 11.690 to 11.699 (0.4602 to 0.4606) B 11.700 to 11.709 (0.4606 to 0.4610) C 11.710 to 11.720 (0.4610 to 0.4614) D 11.721 to 11.730 (0.4615 to 0.4618) E 11.731 to 11.740 (0.4619 to 0.4622)
3. INSPECT FRONT OIL PUMP AND GEAR BODY SUBASSEMBLY Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: 38.113 to 38.138 mm (1.50051 to 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-assembly.
4. INSPECT STATOR SHAFT ASSEMBLY Using a dial indicator, measure the inside diameter of the stator shaft. Standard inside diameter: 21.500 to 21.526 mm (0.84646 to 0.84748 in.) Maximum inside diameter: 21.57 mm (0.8492 in.) If the inside diameter is greater than the maximum, replace the stator shaft.

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1. 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.
2. INSTALL FRONT OIL PUMP BODY O-RING Coat new O-ring with ATF, and install it to the oil pump body. NOTE: Make sure that the O-ring is not twisted or pinched. Moreover, apply enough ATF to the O-ring before installation.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR Coat the front oil pump driven gear with ATF, and install it to the oil pump body with the marked side facing upward.
4. INSTALL FRONT OIL PUMP DRIVE GEAR Coat the front oil pump drive gear with ATF, and install it to the oil pump body with the marked side facing upward.
5. INSTALL STATOR SHAFT ASSEMBLY Set the stator shaft and align it with each bolt hole. Using a "torx" socket (T30), install the 11 bolts. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
6. INSTALL CLUTCH DRUM OIL SEAL RING Coat 2 new clutch drum oil seal rings with ATF. Install 2 new clutch drum oil seal rings. NOTE: Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY HINT: (See «INSPECTION»(ref-236002-S31841384772006062900000) )

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1. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Place SST on the return spring and compress the return spring with a press. SST 09387-00060 Using a screwdriver, remove the snap ring. Remove the 2nd brake piston return spring.
2. 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. NOTE: Hold the piston with a shop rag or a piece of cloth when removing the piston. Failure to do so may result in the piston jumping out from the cylinder.
3. REMOVE 2ND BRAKE PISTON O-RING Remove the 2 O-rings from the 2nd brake piston.

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1. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 16.61 mm (0.6539 in.)

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1. INSTALL 2ND BRAKE PISTON O-RING Coat 2 new O-rings with ATF, and install them in the 2nd brake piston. NOTE: Make sure that the O-ring is not twisted or pinched.
2. INSTALL 2ND BRAKE PISTON Coat the 2nd brake piston with ATF, and install it to the 2nd brake cylinder. NOTE: Be careful not to damage the O-ring.
3. INSTALL 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Install the 2nd brake piston return spring. NOTE: Installing the spring sub-assembly, check that 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 that the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed.

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1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH HINT: (See «INSPECTION»(ref-236002-S35055931742006062900000) )
2. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC Using a screwdriver, remove the snap ring. Remove the flange, 5 discs and 5 plates from the input shaft assembly.
3. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Place SST on the spring retainer and compress the return spring with a press. Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring seat from being deformed. Do not expand the snap ring excessively. Remove the clutch balancer from the input shaft. Remove the forward clutch return spring from the input shaft.
4. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 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, blow air again with the protruding side pushed, or remove the piston using the needle nose pliers with vinyl tape on the tip.
5. REMOVE INPUT SHAFT OIL SEAL RING Remove the input shaft oil seal ring from the input shaft.

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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 to 1.25 mm (0.0394 to 0.4921 in.) If the clearance is not as specified, inspect the discs, plates and flange. HINT: If the opening is large, cover it with a shop rug or a piece of cloth to prevent the compressed air from being released.
2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Check 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
3. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 26.74 mm (1.0528 in.)
4. 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 to 1.25 mm (0.0394 to 0.4921 in.) If the piston stroke is less than the minimum, parts may be assembled incorrectly. Check and reassemble the parts again. If the clearance is not as specified, select another flange. HINT: There are 5 different thicknesses of flanges available. Flange thickness: mm (in.) FLANGE THICKNESS 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)
5. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC Check if the disc lightly rotates when rotating the forward clutch assembly after inserting the multiple disc clutch into it. NOTE: Do not place the forward clutch assembly in a vise.

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1. INSTALL INPUT SHAFT OIL SEAL RING Compress a 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 end gap of the oil seal ring too much. Fix the hooks firmly.
2. INSTALL FORWARD CLUTCH PISTON SUBASSEMBLY Coat the forward clutch piston with ATF, and install it to the input shaft. NOTE: Be careful not to damage the lip of the forward clutch piston.
3. INSTALL FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Install the return spring to the input shaft. NOTE: Installing the spring sub-assembly, check that 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 of the forward clutch balancer. Make sure that the clutch balancer is not pinched and that there are no other defects at the lip. Apply sufficient ATF to the sealing lip before installation. 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 that the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. Do not expand the snap ring excessively. Set the end gap of the snap ring in the piston as shown in the illustration. NOTE: The end gap of the snap ring should not align with any of the stoppers.
4. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC Coat the 5 discs with ATF. Install the 5 plates, 5 discs and flange input shaft. NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration. 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 fully engaged in the groove of the drum.
5. INSPECT PACK CLEARANCE OF FORWARD CLUTCH HINT: (See «INSPECTION»(ref-236002-S35055931742006062900000) )
6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC HINT: (See «INSPECTION»(ref-236002-S35055931742006062900000) )

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1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH HINT: (See «INSPECTION»(ref-236002-S12781135702006062900000) )
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH HINT: (See «INSPECTION»(ref-236002-S12781135702006062900000) )
3. REMOVE DIRECT MULTIPLE DISC 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. 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.
5. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 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 seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat 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.
6. REMOVE OVERDRIVE DIRECT CLUTCH PISTON Install the 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.
7. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY 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.
8. REMOVE OVERDRIVE DIRECT CLUTCH O-RING Using a screwdriver, remove the O-ring from the direct clutch drum.

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1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Install the intermediate shaft and needle roller bearing onto 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 to 0.82 mm (0.02362 to 0.03228 in.) If the pack clearance is not as specified, inspect the discs, plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi). Pack clearance: 0.61 to 0.83 mm (0.02401 to 0.03268 in.) If the pack clearance is not as specified, inspect the discs, plates and flange.
3. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC Check if the sliding surfaces 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
4. INSPECT OVERDRIVE DIRECT CLUTCH DISC Check 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
5. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: 25.91 mm (1.0201 in.)
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH Install the intermediate shaft onto 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). Clearance: 0.60 to 0.82 mm (0.02362 to 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 clearance is not as specified, select another flange. HINT: There are 7 flanges of different thickness. Flange thickness: mm (in.) FLANGE THICKNESS 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)
7. INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND 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). Clearance: 0.61 to 0.83 mm (0.02401 to 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 clearance is not as specified, select another flange. HINT: There are 7different thicknesses of flanges available. Flange thickness: mm (in.) FLANGE THICKNESS 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.

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1. INSTALL OVERDRIVE DIRECT CLUTCH O-RING Coat an O-ring with ATF, and install it to the direct clutch drum. NOTE: Make sure that the O-ring is not twisted or pinched when it is installed.
2. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY 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 of the direct clutch drum.
3. INSTALL OVERDRIVE DIRECT CLUTCH PISTON Coat the overdrive direct clutch piston with ATF, and install it to the direct clutch drum.
4. INSTALL OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Install the overdrive clutch return spring to the direct clutch drum. NOTE: Installing the spring sub-assembly, check that all of the springs are fit in 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 of the direct clutch balancer. Make sure that the lip of the seal is not pinched and that it has no other defects. Apply sufficient ATF to the sealing lip before installing the clutch balancer. Place SST on the clutch balancer and compress the overdrive clutch return spring with a press. SST 09387-00020 Using a snap ring expander, install the snap ring to the direct clutch drum. Be sure that the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. Do not expand the snap ring excessively. Overdrive Direct 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 align with any of the stoppers.
5. INSTALL OVERDRIVE DIRECT CLUTCH DISC Coat the 4 discs with ATF. Install the 4 plates, 4 discs and flange to the intermediate shaft. NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration. 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 fully engaged in the groove of the drum.
6. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC Coat the 3 disc with ATF. Install the cushion plate, 3 plates, 3 disc 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, plate and flange assembly. Using a screwdriver, install the snap ling. Check that the end gap of the snap ling is not aligned with one of the cutouts. NOTE: The slap ring should be fixed certainly in the groove of the drum.

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1. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD HINT: (See «INSPECTION»(ref-236002-S38697191442006062900000) )
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 Place the underdrive planetary gear in a 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, 09957-04010)
4. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear and radial ball bearing front. SST 09950-60010 (09951-00320), 09387-00050, 09950-00020, 09950-00030, 09950-40011 (09957-04010) Place the underdrive planetary gear in a soft jaw vise. Using SST, remove the radial ball bearing rear from the underdrive planetary gear. SST 09950-60010 (09951-00320), 09950-00030, 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.

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1. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD Using SST, fix the underdrive planetary gear assembly. Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while rotating the torque wrench at 60 rpm. SST 09387-00050 Turning torque at 60 rpm.: 0.50 to 1.42 N*m (5.1 to 14.5 kgf*cm, 4.4 to 12.6 in.*lbf) HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

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1. INSTALL UNDERDRIVE PLANETARY RING GEAR Install a new snap ring to the outer race of the radial ball bearing rear. 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 radial ball bearing rear. SST 09950-60020 (09951-00890), 09950-70010 (09951-07100) NOTE: Be sure not to damage the snap ring during outer race installation. Install the underdrive planetary ring gear to the counter driven gear. Using a snap ring pliers, install the snap ring.
2. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY Using SST and a press, press the radial ball bearing rear in the underdrive planetary gear. SST 09502-12010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) 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 radial ball bearing front. SST 09502-12010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTE: Press the counter driven gear while rotating it. Using SST and a press, press in the parking lock gear. SST 09502-12010, 09950-60010 (09951-00260), 09950-70010 (09951-07100) NOTE: Press the counter driven gear while rotating it.
3. INSTALL DIFFERENTIAL DRIVE PINION Using SST and 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.
4. INSTALL CYLINDRICAL ROLLER BEARING RACE INNER Using SST and 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.
5. INSTALL FRONT PLANETARY GEAR NUT Place the underdrive planetary gear in a 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 (2,885 kgf*cm, 207 ft.*lbf) HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.). Using a pin punch and hammer, stake the lock nut. CAUTION: Be sure that there are no cracks on the nut.
6. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD HINT: (See «INSPECTION»(ref-236002-S38697191442006062900000) )

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1. INSPECT UNDERDRIVE PACK CLEARANCE HINT: (See «INSPECTION»(ref-236002-S30077159942006062900000) )
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. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Place SST on the clutch balancer and compress the spring with a press. SST 09350-32014 Using a snap ring expander, remove the snap ring. NOTE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat 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.
5. 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.
6. REMOVE UNDERDRIVE CLUTCH DRUM O-RING Using a screwdriver, remove the O-ring from the underdrive clutch drum.

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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 to 1.71 mm (0.0594 to 0.0673 in.) If the pack clearance is not as specified, inspect the discs, plates and flange. HINT: There are 5 flanges in different thickness. Flange thickness: mm (in.) FLANGE THICKNESS Mark Thickness Mark Thickness 1 3.0 (0.118) 4 3.6 (0.122) 2 3.2 (0.126) 5 3.8 (0.130) 3 3.4 (0.134)
2. INSPECT UNDERDRIVE CLUTCH DISC NO. 1 Check 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 if a part of the groove is worn, replace all discs. Before installing new discs, immerse them in ATF for at least 15 minutes.
3. INSPECT UNDERDRIVE CLUTCH DRUM SUBASSEMBLY Using a dial indicator, measure the inside diameter of the underdrive clutch drum bushing. Standard drum bushing: 37.06 to 37.08 mm (1.4591 to 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.
4. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 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.)

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1. INSTALL UNDERDRIVE CLUTCH DRUM O-RING Coat a new O-ring with ATF, and install it to the underdrive clutch drum. NOTE: Make sure that the O-ring is not twisted or pinched.
2. INSTALL UNDERDRIVE CLUTCH PISTON SET Coat the underdrive clutch piston with ATF, and install it to the underdrive clutch piston drum. NOTE: Be careful not to damage the O-ring. Be careful not to damage the lip of the piston.
3. INSTALL UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Install the return spring to the underdrive clutch drum. NOTE: Installing the spring sub-assembly, check that 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 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 that the end gap of the snap ring is not aligned with the spring retainer claw. NOTE: Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove. This prevents the spring seat from being deformed. Do not expand the snap ring excessively. Set the end gap of the snap ring in the underdrive clutch drum as shown in the illustration. NOTE: The end gap of the snap ring should not align with any of the stoppers.
4. INSTALL UNDERDRIVE CLUTCH DISC NO. 1 Coat the 4 discs with ATF. Install the 4 plates, 4 discs and flange to the underdrive clutch drum. NOTE: Make sure that the plates, discs, and flange are installed as shown in the illustration.
5. INSTALL 1ST & REVERSE BRAKE RETURN SPRING SHAFT 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 fully engaged in the groove of the drum.
6. INSPECT UNDERDRIVE PACK CLEARANCE HINT: (See «INSPECTION»(ref-236002-S30077159942006062900000) )

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1. REMOVE FRONT DIFFERENTIAL RING GEAR Place matchmarks 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 FRONT 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 FRONT 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), 09308-00010 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 and a hammer, 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

Scheme 537

1. INSPECT BACKLASH Using a dial indicator, inspect the backlash of the side gear. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Thrust washer thickness THRUST WASHER THICKNESS Mark Thickness - 1.625 mm (0.0640 in.) - 1.725 mm (0.0679 in.) - 1.825 mm (0.0719 in.)

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1. INSTALL FRONT DIFFERENTIAL SIDE GEAR Apply ATF to the 2 front differential side gears, 2 side gear thrust washers, 2 front differential pinions and 2 pinion thrust washers and install them to the differential case.
2. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO. 1 Coat the front differential pinion shaft No. 1 with ATF, and install it to the differential case.
3. INSPECT BACKLASH
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and a hammer, install the pinion shaft straight pin. Using a chisel and a hammer, stake the differential case. NOTE: Stake the differential case after adjusting the backlash.
5. INSTALL FRONT DIFFERENTIAL CASE FRONT 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 damage the bearing cage when installing the bearing inner race. 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)
6. INSTALL FRONT 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, 09951-07150) NOTE: Do not damage the bearing cage when installing the bearing inner race. Using SST and a hammer, install the front differential case tapered roller bearing rear outer race to the transaxle housing. SST 09950-70010 (09951-07100, 09951-07150), 09950-60020 (09951-00890) NOTE: No clearance is allowed between the bearing and transaxle housing.
7. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD Install the differential assembly to the transaxle case. Clean the mating 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 bolts 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 non-reusable. In this case, however, the bolt can be used after cleaning it. Using SST, turn the differential assembly to the 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 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to 6.1 in.*lbf) Used bearing: 0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9 to 3.1 in.*lbf) HINT: If the turning torque is not as specified, refer to the table below to select a thrust washer so that the specified value is achieved. Flange thickness: mm (in.) FLANGE THICKNESS 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 assembly.
8. INSTALL FRONT DIFFERENTIAL RING GEAR Using ATF and heater, heat the front differential ring gear to 90 to 110°C (194.0 to 230.0°F). NOTE: Do not heat the ring gear to more than 110°C (230.0°F). Clean the contact surface of the front differential case. Align the matchmarks, and 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 a diagonal pattern.
9. INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, install a new oil seal. SST 09223-15020, 09950-70010 (09951-07150) Coat the lip of oil seal with a little MP grease. Oil seal installation depth: 0 +- 0.5 mm (0 +- 0.0197 in.)
10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09710-30050, 09950-70010 (09951-07150) Coat the lip of the oil seal with a little MP grease. Oil seal installation depth: 0 +- 0.5 mm (0 +- 0.0197 in.)

See also:
• REGISTRATION
• REMOVAL
• REMOVAL
• REMOVAL