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Transmission Assemble

Tools Required
^ DT 46451 (DW240-020) Brake Clutch Spring Compressor
^ DT 46454 (DW240-050) Overdrive Brake Adapter
^ DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut
^ DT 46456 (DW240-060-02) Brake Spring Compressor Plate
^ DT 46457 DW240-070) 1st/Reverse Brake Adapter
^ DT 46458 (DW240-080) 2nd Brake Adapter
^ DT 46460 (DW240-100) Counter Drive Gear Installation Adapter
^ DT 46461 (DW240-130) Differential Preload Adapter
^ DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter
^ DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter
^ DT 46465 (DW240-170) Adapter Handle
^ DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer
^ DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket
^ DT 47521 (DW260-031-02) Transaxle Case Oil Seal Installer

Assembly Procedure





1. Install 4 new O-rings to the 4 screw plugs.

Notice
Refer to Fastener Notice in Service Precautions.

2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.

Tighten the screw plugs to 7.4 Nm (65 inch lbs.).





3. Install the 2 seal rings to the transaxle rear cover.





4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.
The standard free length is 18.99 mm (0.7476 inch).





5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF). Install the O-rings to the O/D brake piston.





Important
Do not damage the O-rings of the O/D brake piston.

6. Coat the O/D brake piston with ATF. Install the piston to the transaxle rear cover.





Notice
Refer to Transaxle Case Damage Notice in Service Precautions.

7. Using DT 46451 (1), DT 46454 (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover.





8. Using DT 46462 (2) and DT 46465 (1), install a new side bearing outer race into the transaxle housing.





9. Using DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal.
The oil seal depth is 3.1 mm (0.122 inch).





Important
Press-fit the outer tapered roller bearing race until the race contacts the transaxle housing.

10. Install a new outer tapered roller bearing race into the transaxle housing.





11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.
Tighten the bolts to 5.4 Nm (48 inch lbs.).





13. Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.
Tighten the bolts to 5.4 Nm (48 inch lbs.).





Important
First install a shim of the same thickness as the original shim.

14. Install the shim to the transaxle case.
15. Install a new bearing outer race into the transaxle case.





16. Using DT 47521 (1) and a hammer, drive in a new transaxle case oil seal.
The oil seal depth is 4.3 mm (0.169 inch).





Important
First install a shim of the same thickness as the original shim.

17. Install the shim to the transaxle case.

Important
Press-fit the shim until the shim contacts the transaxle case.

17. Using DT 46464 (2) and DT 46465 (1), press in a new outer tapered roller bearing race into the transaxle case.





19. Install the No. 1 transaxle case plate to the transaxle case with the bolt.
Tighten the bolt to 9.8 Nm (87 inch lbs.).





20. Install the differential gear to the transaxle case.





21. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
22. Tighten 8 or 9 bolts of the transaxle housing completely.
Tighten the bolts to 29 Nm (22 ft. lbs.).





23. Using DT 46461, turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.





Important
Note the measured value.

24. Using DT 46461 and a small torque wrench, measure the preload of the differential gear.





25. Remove the transaxle housing and install the counter driven gear.





26. Install the transaxle housing and hand tighten the 16 bolts of the transaxle housing.
27. Tighten 8 or 9 bolts of the transaxle housing completely.
Tighten the bolts to 29 Nm (21 ft. lbs.)





28. Using DT 46461, turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.





29. Using DT 46461 and a small torque wrench, measure the preload of the differential gear. From this value deduct the value measured previously. This new value is the preload of the counter driven gear.
^ The preload for a new bearing is 0.33 - 0.76 Nm (3.21 - 6.77 inch lbs.).
^ The preload for a used bearing is 0.17 - 0.38 Nm (1.48 - 3.39 inch lbs.).

Important
When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.

30. If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the value. Until the value is within the specification, repeat the procedure.





31. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.
The standard free length is 18.053 mm (0.71075 inch).





Important
^ If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
^ Before assembling the new discs, soak the discs in ATF for at least 15 minutes.

32. Inspect the sliding surface of the disc, the plate and the flange of the 1st and reverse brake for wear or burn. Replace the parts, if necessary.





33. Coat 2 new O-rings (1) with ATF, install the O-rings to the 1st and reverse piston.





Important
Do not damage the O-rings of the 1st and reverse brake piston.

34. Install the 1st and reverse brake piston to the transaxle case.





35. Install the return spring to the transaxle case.





36. Install the 4 plates, the 4 discs and the flange in order: 2-1-2-1-2-1-2-1-3, where (2)=Plate, (1)=Disc, and (3)=Flange





Important
Verify that the snap ring is installed correctly in the groove of the transaxle case.

37. Using DT 46457 (2) and DT 46455 (1), install the snap ring.





Important
If the piston stroke is non-standard, inspect the discs, the plates and the flange. The piston stroke is 0.6 - 1.3 mm (0.024 - 0.051 inch).

38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392 - 785 kPa (57 - 114 psi) of compressed air.





Important
Do not apply excessive force to the transaxle case.

39. Using DT 46460 (3), DT 46455 (2) and DT 46456 (1), install the counter drive gear.





40. Coat a new oil seal with ATF.
41. Install the oil seal to the transaxle case.
The oil seal depth is 0.75 - 1.25 mm (0.030 - 0.049 inch).





42. Install the parking lock rod to the manual valve lever.





43. Install a new spacer to the manual valve lever.





44. Install the manual valve lever shaft and the manual valve lever.





45. Using a pin punch and hammer, drive in a new pin.