Part 2

40. 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 result.





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





42. Apply a coating of petroleum jelly to thrust bearing #8, and then attach to the kickdown drum.





43. Apply a coating of petroleum jelly to thrust race #7, and then attach to the rear clutch hub.





44. Install the clutch hub to the sun gear splines.





45. Attach thrust bearing #6 onto the hub using petroleum jelly.





46. Apply a coating of petroleum jelly to thrust washer #2 and thrust bearing #4. Attach to the rear clutch assembly.





47. Combine the rear clutch and the front clutch assemblies.





48. Install the end clutch assembly.
49. If end play which was measured and recorded at disassembly is not within standard value, adjust to specification by selecting thrust race #3.
Standard value: 0.3 - 1.0 mm (0.012 - 0.040 inch)
When the thrust race is replaced with that of a different thickness, also replace thrust washer #1 located between the oil pump and front clutch. Use a washer of proper corresponding thickness corresponding to thrust race. Find correct pair of thrust races (metal) and thrust washers (fiber) from following table.





Example: When a different thickness thick thrust race is selected, a corresponding thrust washer must be paired with it.





50. Attach the reused thrust washer #1, or the one selected in step 49 to the front clutch by using petroleum jelly.
51. Install the special tool (09452-21401) to the case.





52. Attach the reused thrust race #3 or the one selected in step 50 to the oil pump by using petroleum jelly.





53. Install a new oil pump gasket and the oil pump assembly.





54. Install a new O-ring in the groove of the oil pump housing and lightly apply automatic transaxle fluid to the outside surface of the O-ring.
55. Install the oil pump assembly by tightening the six bolts evenly. When installing this oil pump assembly, be careful that the thrust washer remains in place.





56. Check the input shaft end play. Readjust if necessary (see step 50).
Standard value: 0.3 - 1.0 mm (0.012 - 0.040 inch)





57. Install the O-ring at the center of the top of the valve body assembly (brake oil pressure passage).
Install the valve body assembly to the case, fitting the detent plate (manual control shaft) pin in the slot of the manual valve.





58. Replace the O-ring of the solenoid valve connector with a new one.
59. Tighten the valve body assembly mounting bolts to 10 - 12 Nm (100 - 120 kg.cm, 7 - 9 ft. lbs.)





60. Install the oil filter. Tighten the four oil filter mounting bolts to 5 - 7 Nm (50 - 70 kg.cm, 4 - 5 ft. lbs.)





61. Install five magnets into the five depression provided in the oil pan.





62. Install a new oil pan gasket and oil pan. Tightening 12 bolts to 10 - 12 Nm (100 - 120 kg.cm, 7 - 9 ft. lbs.)





63. Install a new D-ring to the kickdown servo switch. Press into the case and secure using the proper snap ring.





64. Install the transaxle range switch and manual lever. Adjust the transaxle range switch.





65. Install the pulse generator A and B





66. Install the differential assembly.





67. Place two pieces of solder, roughly 10 mm (0.4 inch) long and 3 mm (O.12 inch) in diameter, at the position shown on the differential bearing retainer outer race.





68. Install the differential bearing retainer and tighten the bolt to specified torque.
Standard value: 43 - 55 Nm (430 - 550 kg.cm, 31 - 40 ft. lbs.)





69. Remove the differential bearing retainer
70. Remove the crushed solder from the outer race of the differential bearing.
71. Using a micrometer, measure the thickness of the crushed solder.
Select and install a spacer so that the preload of the differential bearing will be the standard value.
Standard: 0.15 mm (0 - 0.006 inch)





72. Apply the ATF to the new installed O-ring and install the differential bearing retainer.





73. Install the differential bearing cap.
Tightening torque
Standard value: 60 - 80 Nm (600 - 800 kg.cm, 43 - 58 ft. lbs.)





74. Install the differential cover and the rear roll bracket with new gasket.
Tightening torque
Standard value: 10 - 12 Nm (100 - 120 kg.cm, 7 - 9 ft. lbs.)





75. Install the speedometer sleeve.





76. After applying automatic transaxle fluid to the outside surface of the oil pump-side cylindrical portion of the torque converter, install the torque converter carefully so as not to damage the seal lip. Make certain that the torque converter is in mesh with oil pump drive gear.
77. Measure the distance between the ring gear end and the converter housing end. The torque converter has been properly installed when measurement is approximately 12 mm (0.47 inch)