Part 2

Transmission Assemble Part 2

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


74. Coat the thrust bearing race with petroleum jelly and install the race onto the rear planetary sun gear and the one-way clutch assembly.

* The bearing inner diameter is 42.5 mm (1.673 in).
* The bearing outer diameter is 57.5 mm (2.264 in).




75. Install the rear planetary sun gear and the one-way clutch assembly to the transaxle case.





Important: Verify the direction of the race.

76. Coat the thrust bearing race with petroleum jelly and install the race onto the transaxle case.

* The race inner diameter is 34.95 mm (1.3760 in).
* The race outer diameter is 45.50 mm (1.7913 in).





Important: Verify the direction of the bearing.

77. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward clutch hub.

* The bearing inner diameter is 33.3 mm (1.311 in).
* The bearing outer diameter is 46.5 mm (1.831 in).




78. Install the forward clutch hub to the transaxle case.




79. Coat the thrust bearing race with petroleum jelly and install the race onto the forward clutch hub.

* The race inner diameter is 19.3 mm (0.760 in).
* The race outer diameter is 30.6 mm (1.205 in).




80. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.

* The race inner diameter is 18.1 mm (0.713 in).
* The race outer diameter is 28.2 mm (1.110 in).
* The bearing inner diameter is 18.1 mm (0.713 in).
* The bearing outer diameter is 29.6 mm (1.165 in).




81. Install the forward and reverse clutch assembly to the transaxle case.





Important:
* If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.

* Before assembling new discs, soak the discs in ATF for at least 15 minutes.

If the sliding surface of the disc, the plate and the flange of 2nd coast and O/D brake are worn or burnt, replace the components.





Important: Install the snap ring in the groove of the transaxle case correctly.

82. Using a screwdriver, install the snap ring to the transaxle case.




83. Install the flange, 2 discs and 2 plates to the transaxle case in the following order: 4-2-3-2-1, Flange (4), Non-Selective (3)=Plate, (2)=-Disc, and (1)=Selective Plate.
84. Clean the connected part the transaxle case and the transaxle rear cover.




85. Place a straight edge on the transaxle case and measure the distance between the 2nd coast and the O/D brake flange and the straight edge using vernier calipers (a).




86. Place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
87. Calculate the piston stroke value using the following formula. Piston stroke = Dimension A - Dimension B. Select and install a plate which satisfies the piston stroke value.




88. Install 4 new apply gaskets to the transaxle rear cover.




89. Coat the thrust needle roller bearing with petroleum jelly and install the bearing onto the forward and reverse clutch assembly.

* The bearing inner diameter is 43.2 mm (1.701 in).
* The bearing outer diameter is 62.0 mm (2.441 in).

90. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or transaxle case.




91. Apply a formed in place gasket (FIPG) to the transaxle rear cover.

The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 in).




92. Install the transaxle rear cover to the transaxle case with 9 bolts.

Tighten the bolts to 25 N.m (18 lb ft).




93. Install the counter driven gear assembly to the transaxle case.




94. Install the differential gear assembly to the transaxle case.




95. Install the direct clutch hub to the transaxle case.




96. Install the thrust bearing race and the thrust needle roller bearing to the transaxle case.

* The race inner diameter is 20.5 mm (0.807 in).
* The race outer diameter is 32.6 mm (1.283 in).
* The bearing inner diameter is 17.8 mm (0.701 in).
* The bearing outer diameter is 30.2 mm (1.189 in).




97. Install the clutch assembly to the transaxle case.




98. Install the new apply gasket.





Important: Verify the direction of the bearing.

99. Install the thrust needle roller bearing to the transaxle case.
100. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case.




101. Install the 6 oil pump bolts.

Tighten the bolts to 25 N.m (18 lb ft).





Important: If the end play is not as specified, select and replace the thrust needle roller bearing.

102. Measure the end play in axial direction.

* The end play is 0.3-0.9 mm (0.012-0.035 in).
* The bearing inner diameter is 32.5 mm (1.280 in).
* The bearing outer diameter is 48.5 mm (1.909 in).
* The bearing thickness is 4.21 mm (0.1657 in).
* The bearing inner diameter is 32.9 mm (1.295 in).
* The bearing outer diameter is 48.5 mm (1.909 in).
* The bearing thickness is 3.62 mm (0.1425 in).




103. Confirm that the input shaft rotates smoothly.




104. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or the transaxle case.
105. Apply a formed in place gasket (FIPG) to the transaxle housing.

FIPG: Three bond 1281 or equivalent, seal bend width is 1.2 mm (0.047 in).




106. Install the transaxle housing to the transaxle case with 16 bolts.

Tighten the bolts to 29 N.m (22 lb ft).

107. Apply seal packing or equivalent to the 3 bolts.




108. Coat a new O-ring (1) with ATF, install the O-ring to the transaxle wire.




109. Install the transaxle wire to the transaxle case with the bolt.

Tighten the bolt to 5.4 N.m (48 lb in).




110. Coat new 6 O-rings with ATF and install the O-rings to the pistons (1, 2, 3).
111. Coat the 3 springs and 3 accumulator pistons with ATF and install the components to the holes.




112. Coat a new apply gasket with ATF and install the gasket to the transaxle case.




113. Coat a new brake drum gasket with ATF and install the gasket to the transaxle case.




114. Install the spring and the check valve.




115. Connect the manual valve control rod to the manual valve lever as shown in the illustration.





Important: When installing the valve body to the transaxle case, do not let each of the accumulator pistons incline. When installing the valve body to the transaxle case, do not hold the solenoids.

116. Install the valve body assembly to the transaxle case.

Tighten the bolts to 11 N.m (97 lb in).




117. Connect the transaxle wire connector and harness to the valve body assembly.
118. Connect the 5 connectors.

1. The lock-up control solenoid (5)
2. The pressure control solenoid (1)
3. The No. 2 shift solenoid (2)
4. The No. 1 shift solenoid (3)
5. The timing solenoid (4)

Important: Verify that the transaxle wire does not come out from the oil pan installations surface.

119. Install the TFT sensor with a clamp.




120. Install a new gasket to the oil strainer.




121. Install the oil strainer to the valve body with 3 bolts.

Tighten the bolts to 9.8 N.m (87 lb in).




122. Install 2 magnets in the oil pan.




123. Install a new gasket to the oil pan and install the oil pan to the transaxle case with 18 bolts.

Tighten the bolts to 7 N.m (62 lb in).




124. Install the output shaft speed (OSS) sensor.

Tighten the bolt to 7.4 N.m (65 lb in).




125. Install the No. 1 breather plug.
126. Install the input shaft speed (ISS) sensor with the bolt.

Tighten the bolt to the 5.4 N.m (48 lb in).




127. Coat the new O-ring with ATF and install the O-ring to the screw plug.
128. Install the screw plug to the transaxle case.

Tighten the bolts to 7.4 N.m (65 lb in).




129. Coat 2 new O-rings with ATF and install the O-rings to the unions.
130. Install the 2 unions to the transaxle case.

Tighten the unions to 25 N.m (18 lb ft).




131. Install the PNP switch to the manual valve lever shaft and temporarily install the 2 adjusting bolts.
132. Install a new lock washer and nuts.

Tighten the nuts to 12 N.m (106 lb in).




133. Temporarily install the control lever.




134. Turn the lever counterclockwise until the lever stops, then turn clockwise 2 notches.
135. Remove the control lever.




136. Align the groove with the neutral basic line. Tighten 2 bolts.

Tighten the bolts to 5.4 N.m (48 lb in).




137. Using a screwdriver, stake the nut with the lock washer.




138. Install the control lever, the washer and the nut.

Tighten the nut to 12 N.m (106 lb in).




139. Install the torque converter (2) to the transaxle.
140. Measure the installation depth of the torque converter.

The standard value is 11.1 mm (0.44 in).

141. If the measured value is beyond the standard value, readjust the torque converter within the specified value.