Part 2

34. Apply a coating of petrolatum to the wave spring and attach it to the center support.




35. Install two new O-rings to the center support. Apply a coating of ATF to the O-rings.




36. Install the special tool to the center support, and install within the case.

CAUTION: Be sure that the wave spring is not out of position.




37. Install the snap ring.




38. Install the anchor rod.




39. Assemble a new seal ring (large diameter) and D-ring (small diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.




40. Press the kickdown servo and sleeve in by using the valve spring compressor and special tool, and then install the snap ring.




41. Install the kickdown band.

CAUTION: Install so the direction indicated by the arrow is to the rear.




42. Install kickdown drum with its splines in mesh with sun gear. Place kickdown band on kickdown drum and tighten kickdown servo adjusting screw to keep band in position.




43. Apply a coating of petrolatum to thrust bearing # 8, and then attach to the kickdown drum.




44. Apply a coating of petrolatum to thrust race # 7, and then attach to the rear clutch hub.




45. Install clutch hub to sun gear splines.




46. Attach thrust bearing # 6 onto the hub with petrolatum.




47. Apply a coating of petrolatum to thrust washer # 2 and thrust bearing # 4, and then attach to the rear clutch assembly.




48. Combine the rear clutch assembly and the front clutch assembly.




49. Install the clutch assembly.







50. Install the differential assembly.

51. If end play which was measured and recorded at disassembly is not standard value, adjust end play to specification by selecting thrust race # 3.

Standard value: 0.3-1.0 mm (0.012-0.039 in.)




52. Attach the reused thrust washer # 1, or the one selected in step 51 to the front clutch by using petrolatum.




53. Install special tool to the case.




54. Attach the reused thrust race # 3 or the one selected in step 51 to the oil pump by using petrolatum.




55. Install new oil pump gasket and the oil pump assembly.




56. Install new O-ring in groove of oil pump housing and apply automatic transmission fluid lightly to outside surface of O-ring.
57. Install oil pump assembly by tightening six bolts evenly. When installing this oil pump assembly, be careful that thrust washer will not drop.




58. Check input shaft end play. Readjust if necessary (see step 51).

Standard value: 0.3 - 1.0 mm (0.012 - 0.039 in.)




59. Place chips of solder of 10 mm (0.39 inch) in length and 3 mm (0.12 inch) in diameter on the differential as illustrated. (F4A22)




60. Place chip of solder of 10 mm (0.39 inch) in length and 3 mm (0.12 inch) in diameter on the converter housing as illustrated and assemble the outer lace. (F4A23)




61. Install the converter housing without gasket.

CAUTION: Don't reuse the rubber coated metal gasket which has been used once.

62. Tighten bolts to specification.

Converter housing mounting bolts: 21 Nm (15 ft.lbs.)

63. Loosen the bolts and remove the converter housing in order to remove the pieces of solder. It the solder is not broken, carry out the work in steps 59 to 62 with large diameter solder.




64. Using a micrometer, measure the thickness of the flattened solder.

Select the spacer in the following manner according to measurement.

Add the thickness [0.38 mm (0.0150 in.)] of the rubber coated metal gasket and the end play [0 - 0.15 mm (0 - 0.0059 in.)] of the differential case to the measurement (T). Select a spacer which is in the calculated range. In other words, select a spacer whose thickness is in the range of [T +0.38 mm (.0150 in.)] to [T +0.38 mm (0.0150 in.) -0.15 mm (0.0059 in.)].

65. Install the outer race and spacer to converter housing.




66. Apply silicone grease to hatched area of transaxle case.
67. Install new case gasket on transaxle case.




68. Install converter housing and tighten 14 bolts.

Converter housing mounting bolts: 21 Nm (15 ft.lbs.)




69. Install end clutch shaft. Be sure to install the longest spline toward the front as shown.




70. Fit the thrust washer to the return spring at the end clutch side.




71. Install the end clutch hub to end clutch.




72. Attach, by petrolatum, thrust bearing # 13 to the end clutch hub.




73. Install end clutch assembly.




74. Attach a new O-ring and D-ring to the end clutch cover.

CAUTION:

1. Install so that the D-ring is not twisted.

2. Apply a sufficient amount of automatic transmission fluid to the bearing.




75. Attach the end cover and fasten it with four bolts.

Caution: When installing the end cover, be sure the screw hole is correctly aligned. If the end cover is turned (after it is installed) in order to align with the screw hole, the O-ring and/or the D-ring may be twisted as a result.




76. Install O-ring at center of top of valve body assembly (brake oil pressure passage).

77. Install valve body assembly to case, fitting detent plate (manual control shaft) pin in slot of manual valve.




78. Replace the O-ring of the solenoid valve harness with a new one.

79. Tilt the solenoid valve harness over from the inner side of the transaxle case to the harness grommet installation hole and install the harness grommet securely.

80. Install the harness grommet so that the lead wiring of the solenoid valve harness faces in the direction indicated by the arrow in the illustration.




81. Tighten valve body assembly mounting bolts (10 pieces).

A. 18 mm (0.71 in.) long
B. 25 mm (0.98 in.) long
C. 40 mm (1.57 in.) long

Valve body assembly mounting bolts: 11 Nm (8.0 ft.lbs.)




82. Install oil filter. Tighten four oil filter mounting bolts.

Oil filter mounting bolts: 6.0 Nm (4.0 ft.lbs.)




83. Install the magnets in the five depressions provided on the oil pan.




84. Install new oil pan gasket and oil pan by tightening 12 bolts.

Oil pan mounting bolts: 11 Nm (8.0 ft.lbs.)




85. Install a new D-ring to the kickdown servo switch; then press into the case and secure it by using a snap ring.




86. Install park/neutral position switch and manual lever. Adjust park/neutral position switch.




87. Install the pulse generators A and B.




88. After applying automatic transaxle fluid to outside surface of oil pump-side cylindrical portion of torque converter, install torque converter carefully so as not to damage oil seal lip. Make certain that torque converter is in mesh with oil pump drive gear.

Measure distance between ring gear end and converter housing end. Torque converter has been properly installed when measurement is about 12 mm (0.47 in.).




89. Using special tool, drive two drive shaft oil seals into transaxle case.