Part 1 of 3
COMPONENT PARTS INSTALLATIONBefore assembly, make sure again that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Recommended ATF: DEXRON II
General Notes:
1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage and affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes.
3. Apply automatic transaxle fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.
U/D GEAR UNIT INSTALLATION
1. INSTALL BEARING TO TRANSAXLE HOUSING
a. Using SST and a press, press the bearing into the transaxle housing.
SST 09350-32014 (09351-32120, 09351-32140)
b. Install the bearing stopper with a bolt.
2. INSTALL NEW GASKET AND OIL TUBE APPLY COVER
Install a new gasket and oil tube apply cover, and tighten the 3 bolts.
3. INSTALL OIL TUBES
a. Using a plastic hammer, install the 3 oil tubes.
NOTICE: Be careful not to bond or damage the tubes.
b. Install the 4 tube clamps.
4. INSTALL BEARING TO TRANSMISSION CASE
Using SST and a press, press the bearing into the transaxle case.
SST 09350-32014 (09351-32090)
5. INSTALL B4 ACCUMULATOR PISTON AND SPRING
6. INSTALL OIL GALLERY COVER AND GASKET
a. Clean the threads of the screws and case with white gasoline.
b. Install a new gasket and oil gallery cover in place.
c. Install and tighten the 3 bolts.
d. Apply seal packing or equivalent to the 6 screws.
Seal packing: Part No.08833-00070, THREE BOND 1324 or equivalent
e. Using a torx wrench, install and tighten the 3 screws.
7. INSTALL MANUAL VALVE SHAFT AND LEVER
a. Install the parking lock rod to the manual valve lever.
b. Slide in the shaft and install the washer, new spacer and manual lever.
c. Install the retaining spring.
HINT: Make sure there is a washer between the retaining spring and case.
8. INSTALL PIN
a. Using a punch and hammer, drive in the pin.
b. Position the spacer and stake it.
9. INSTALL CAM GUIDE BRACKET
Install the cam guide bracket and then insert the parking lock rod into the guide bracket.
10. INSTALL PARKING LOCK SLEEVE
Install the parking lock sleeve protruding portion upward.
11. PLACE STOPPER PLATE
Place the stopper plate on the protruding portion of lock sleeve.
12. INSTALL GUIDE SLEEVE AND SPRING
13. INSTALL PARKING LOCK PAWL, PAWL SHAFT AND SHAFT CLAMP
a. Install the parking lock pawl.
b. Install the parking lock pawl shaft and install the shaft clamp.
14. INSTALL FIRST AND REVERSE BRAKE PISTON
a. Install the 2 new 0- rings to the piston.
b. Coat the O-rings with ATF.
c. Place the piston into the bore of the case, facing the spring seats upward.
d. Using SST, press in the piston.
SST 09350-32014 (09351-32040)
HINT: Be careful not to damage the O-rings.
e. Remove SST.
15. INSTALL PISTON RETURN SPRING AND SNAP RING
a. Install the piston return spring assembly and snap ring in place.
b. Set SST, and tighten the bolt gradually to compress the springs.
SST 09350-32014 (09351-32040)
NOTICE: Avoid bending the spring retainer by over-tightening the bolt.
c. Using a snap ring expander, install the snap ring.
HINT: Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw.
d. Remove SST.
16. INSTALL UNDERDRIVE BRAKE PISTON
a. Coat the O-rings with ATF.
b. Install 2 new O-rings to the piston.
c. Place the piston into the case with the cup side up, being careful not to damage the O-rings.
17. INSTALL RETURN SPRING
18. INSTALL PLATES, DISCS AND FLANGE
a. Install in order: D = Disc P = Plate F = Flange
P-D-P-D-P-D-F
HINT: Install the flange with the flat end facing downward.
b. Place SST on the flange, and compress the flange with a press.
SST 09350-32014 (09351-32070)
c. Install the snap ring.
HINT: Be sure the end gap of the snap ring is not aligned with one of the cutouts.
19. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES
Using compressed air, confirm that the underdrive brake piston moves smoothly.
20. INSTALL OIL SEAL RINGS TO TRANSAXLE CASE
Install the 2 oil seal rings to the transaxle case.
21. INSTALL UNDERDRIVE ONE-WAY CLUTCH
22. INSTALL ANTI-RATTLE CLIP
Push the anti-rattle clip into the space between the one-way clutch outer race and case, until you hear the 'click".
23. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
a. Align the flukes of the discs in the underdrive brake.
b. Install the clutch assembly.
c. Turn the clutch assembly. The clutch assembly should turn freely counterclockwise and should lock clockwise.
24. CHECK HEIGHT OF CLUTCH ASSEMBLY
Using vernier calipers, check the height from the sleeve to the inner race.
Height: 17.3 - 18.2 mm (0.681 - 0.717 inch)
25. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH
a. Set a dial indicator and measuring terminal (SST) together.
SST 09350-32014 (09351-32190)
b. While applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cM2, 57 - 114 psi), measure the underdrive clutch piston stroke.
Piston stroke:
A241E: 1.21 - 1.55 mm (0.0476 - 0.0610 inch)
A244E: 1.50 - 1.86 mm (0.0691 - 0.0762 inch)
If the piston stroke is less than limit, parts may have been misassembled. Check them.
If the piston stroke is non-standard, select another flange.
HINT: There are 3 (A241E) or 2 (A244E) different flange thicknesses.
Flange thickness:
A241E
2.30 mm (0.0906 inch)
2.50 mm (0.0984 inch)
2.70 mm (0.1063 inch)
A244E
2.04 mm (0.0803 inch)
2.40 mm (0.0945 inch)
26. INSTALL BEARING WITH RACE
With the bearing facing upwards, install the bearing with the race.
Bearing:
A241E
Outer diameter 45.2 mm (1.780 inch)
Inner diameter 31.0 mm (1.220 inch)
A244E
Outer diameter 43.7 mm (1.720 inch)
Inner diameter 31.0 mm (1.220 inch)
27. INSTALL SUN GEAR TO CASE
Install the sun gear of the counter shaft to the case.
28. INSTALL COUNTER SHAFT ASSEMBLY
a. Align the flukes of the discs in the underdrive clutch.
b. Install the counter shaft assembly.
29. CHECK HEIGHT OF COUNTER SHAFT
Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.
Height: 33.3 - 33.5 mm (1.311 - 1.398 inch)
30. INSTALL THRUST NEEDLE BEARING
Bearing:
Outer diameter 57.7 mm (2.272 inch)
Inner diameter 41.0 mm (1.614 inch)
31. INSTALL COUNTER DRIVEN GEAR
Using SST and press, press in the driven gear.
SST 09350-32014 (09351-32100, 09351-32140)
32. TIGHTEN NEW LOCK NUT
a. Using SST to hold the driven gear, tighten a new lock nut.
SST 09330-00021 and, 09350-32014 (09351-32032)
Torque: 157 Nm (1,600 kgf-cm. 116 ft. lbs.)
b. Remove SST.
33. CHECK END PLAY OF COUNTER SHAFT
Using a dial indicator, measure the end play of the counter shaft.
End play: 0.23 - 0.89 mm (0.0091 - 0.0350 inch)
34. STAKE LOCK NUT
Using a punch and hammer, stake the lock nut.
35. INSTALL SNAP RING TO TRANSMISSION CASE
Using a snap ring expander, install the snap ring to the transaxle case.
36. INSTALL INTERMEDIATE SHAFT
37. INSTALL TRANSAXLE REAR COVER
a. Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
b. Apply seal packing to the rear cover.
Seal packing: Part No.08833-00090, THREE BOND 1131,LOCTITE 518 or equivalent
c. Install and tighten the 13 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
HINT: Each bolt length (mm) is indicated in the illustration.
38. INSTALL NEW APPLY GASKETS
Install 2 new apply gaskets.
HINT: The oil seal may be inserted with either end up or down.
39. INSTALL GOVERNOR DRIVEN GEAR
a. Install the thrust washer.
b. Install the governor driven gear.