Special Tools

1. Install new O-rings to the bolt plugs.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the bolt plugs with the O-rings to the transaxle rear cover and tighten to 7 N·m (62 lb in).



3. Install the 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.

Specification
The standard free length is 18.99 mm (0.7476 in).




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




Note: 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.



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.

Specification
The oil seal depth is 3.1 mm (0.122 in).





Note: 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 and tighten to 5 N·m (44 lb in).



13. Install the oil reservoir lock plate to the transaxle housing.
14. Install the oil reservoir lock plate bolts and tighten to 5 N·m (44 lb in).




Note: First install a shim of the same thickness as the original shim.

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



17. Using DT 47521  (1) and a hammer, drive in a new transaxle case oil seal.

Specifications
The oil seal depth is 4.3 mm (0.169 in).





Note: First install a shim of the same thickness as the original shim.

18. Install the shim to the transaxle case.

Note: Press-fit the shim until the shim contacts the transaxle case.

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



20. Install the No. 1 transaxle case plate to the transaxle case.
21. Install the transaxle case plate bolt and tighten to 10 N·m (89 lb in).



22. Install the differential gear to the transaxle case.



23. Install the transaxle housing and hand tighten the bolts of the transaxle housing.
24. Tighten 8 bolts of the transaxle housing completely and tighten to 29 N·m (22 lb ft).



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




Note: Note the measured value.

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



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



28. Install the transaxle housing and hand tighten the bolts of the transaxle housing.
29. Tighten 8 bolts of the transaxle housing completely and tighten to 29 N·m (21 lb ft).



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



31. 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.

Specification

•	The preload for a new bearing is 0.33-0.76 N·m (3.21-6.77 lb in).

•	The preload for a used bearing is 0.17-0.38 N·m (1.48-3.39 lb in).

Note: 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.

32. 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.



33. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

Specification
The standard free length is 18.053 mm (0.7107 in).





Note: 

•	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.

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



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




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

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



37. Install the return spring to the transaxle case.



38. 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




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

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




Note: 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 in).

40. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing compressed air.




Note: Do not apply excessive force to the transaxle case.

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



42. Coat a new oil seal with ATF.
43. Install the oil seal to the transaxle case.

Specification
The oil seal depth is 0.75-1.25 mm (0.030-0.049 in).




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



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



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



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



48. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
49. Using a pin punch, stake the spacer through the small hole.
50. Verify that the spacer does not turn.



51. Install the manual detent spring.
52. Install the manual detent spring bolt and tighten to 10 N·m (89 lb in).



53. Install the parking lock shaft, torsion spring, and the parking lock pawl.



54. Verify that the edge of the torsion spring fits into the groove securely.



55. Install the parking lock pawl bracket.
56. Install the parking lock pawl bolts and tighten to 7 N·m (62 lb in).



57. Replace the planetary ring flange of the planetary ring gear.
58. Using DT 46460  (2) and DT 46455  (1), install the planetary ring gear.



59. Fix the counter drive gear with the parking lock pawl.



60. Using DT 46472  (1), install a new nut and tighten to 10 N·m (89 lb in).



61. Using a small torque wrench, turn the counter drive gear 100 turn per minute and measure the preload and tighten to 29 N·m (22 lb ft).

Specification
When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 N·m (0.43-3.12 lb in).

62. Stake the nut.



63. Install the planetary gear to the transaxle case.



64. Coat the planetary carrier thrust washer with petroleum jelly and install the washer onto the planetary gear.



65. Install the No. 2 one-way clutch to the transaxle case.



66. Verify that the planetary gear turns freely counterclockwise and locks clockwise.



67. Install the anti-rattle clip in the space between the No. 2 one-way clutch outer race and transaxle case. Push the anti-rattle clip in place until you hear the click.



68. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

Specification
The standard free length is 15.85 mm (0.6240 in).





Note: 

•	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.

69. If the sliding surface of the disc, the plate and the flange of 2nd brake are worn or burnt, replace the parts.




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

70. Install the flange, 2 discs and 2 plates in order: 2-1-3-1-3, where (1)=Disc, (2)=Flange, and (3)=Plate.
71. Install the 2nd brake return spring.



72. Coat the new O-rings (1) with ATF and install the O-rings to the 2nd brake piston.




Note: Do not damage the O-rings.

73. Install the 2nd brake piston into the 2nd brake clutch cylinder.



74. Install the 2nd brake clutch cylinder to the transaxle case.



75. Using DT 46455  (1) and DT 46458  (2), compress the 2nd brake piston return spring.

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

76. Using a screwdriver, install the snap ring.



77. Coat the thrust bearing race with petroleum jelly and install the race onto the front planetary sun gear.

Specification

•	The race inner diameter is 19.3 mm (0.760 in).

•	The race outer diameter is 29.0 mm (1.142 in).




78. Install the front planetary sun gear to the transaxle case.



79. Install the thrust washer and the one-way clutch assembly to the rear planetary sun gear.




Note: Verify the direction of the bearing.

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

Specification

•	The bearing inner diameter is 42.5 mm (1.673 in).

•	The bearing outer diameter is 57.5 mm (2.264 in).




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




Note: Verify the direction of the race.

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

Specification

•	The race inner diameter is 34.95 mm (1.3760 in).

•	The race outer diameter is 45.50 mm (1.7913 in).





Note: Verify the direction of the bearing.

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

Specification

•	The bearing inner diameter is 33.3 mm (1.311 in).

•	The bearing outer diameter is 46.5 mm (1.831 in).




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



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

Specification

•	The race inner diameter is 19.3 mm (0.760 in).

•	The race outer diameter is 30.6 mm (1.205 in).




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

Specification

•	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).




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




Note: 

•	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.

88. 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.




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

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



90. 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.
91. Clean the connected part the transaxle case and the transaxle rear cover.



92. 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).



93. 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).
94. 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.



95. Install new governor apply gaskets to the transaxle rear cover.



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

Specification

•	The bearing inner diameter is 43.2 mm (1.701 in).

•	The bearing outer diameter is 62.0 mm (2.441 in).

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



98. Apply three bond 1281 or equivalent to the transaxle rear cover.

Specification
The seal bend width is 1.2 mm (0.047 in).




99. Install the transaxle rear cover to the transaxle case.
100. Install the transaxle rear cover bolts and tighten to 25 N·m (18 lb ft).



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



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



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



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

Specification

•	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).




105. Install the clutch assembly to the transaxle case.



106. Install a new governor apply gasket.




Note: Verify the direction of the bearing.

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



109. Install the oil pump bolts and tighten to 25 N·m (18 lb ft).




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

110. Measure the end play in axial direction.

Specification

•	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).




111. Confirm that the input shaft rotates smoothly.



112. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or the transaxle case.
113. Apply three bond 1281 or equivalent to the transaxle housing.

Specification
The seal bend width is 1.2 mm (0.047 in).




114. Install the transaxle housing to the transaxle case.
115. Install the transaxle housing bolts and tighten to 29 N·m (22 lb ft).
116. Apply seal packing or equivalent to the bolts.



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



118. Install the transaxle wire to the transaxle case.
119. Install the transaxle wire bolt and tighten to 5 N·m (44 lb in).



120. Coat the new O-rings with ATF and install the O-rings to the pistons (1, 2, 3).
121. Coat the springs and accumulator pistons with ATF and install the components.



122. Coat a new governor apply gasket with ATF and install the gasket into the transaxle case.



123. Coat a new brake drum gasket with ATF and install the gasket into the transaxle case.



124. Install the spring and the check valve.



125. Connect the manual valve control rod to the manual valve lever.




Note: 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.

126. Install the valve body assembly to the transaxle case.
127. Install the valve body bolts and tighten to 11 N·m (97 lb in).



128. Connect the transaxle wire connector and harness to the valve body assembly.
129. Connect the 5 connectors.

129.1.

The lock-up control solenoid (5)

129.2.

The pressure control solenoid (1)

129.3.

The No. 2 shift solenoid (2)

129.4.

The No. 1 shift solenoid (3)

129.5.

The timing solenoid (4)

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

130. Install the TFT sensor with a clamp.



131. Install a new gasket to the oil strainer.



132. Install the oil strainer to the valve body.
133. Install the oil strainer bolts and tighten to 10 N·m (89 lb in).



134. Install two magnets in the oil pan.



135. Install a new gasket to the oil pan and install the oil pan to the transaxle case.
136. Install the oil pan bolts and tighten to 7 N·m (62 lb in).



137. Install the output shaft speed (OSS) sensor.
138. Install the (OSS) bolt and tighten to 7 N·m (62 lb in).



139. Install the No. 1 breather plug.
140. Install the input shaft speed (ISS) sensor.
141. Install the (ISS) bolt and tighten to 5 N·m (44 lb in).



142. Coat the new O-ring with ATF and install the O-ring to the bolt plug.
143. Install the bolt plug to the transaxle case and tighten to 7 N·m (62 lb in).



144. Coat new O-rings with ATF and install the O-rings to the unions.
145. Install the unions to the transaxle case and tighten to 25 N·m (18 lb ft).



146. Install the PNP switch to the manual valve lever shaft and temporarily install the adjusting bolts.
147. Install a new lock washer and nuts and tighten to 12 N·m (106 lb in).



148. Temporarily install the control lever.



149. Turn the lever counterclockwise until the lever stops, then turn clockwise 2 notches.
150. Remove the control lever.



151. Align the groove with the neutral basic and tighten to 5 N·m (44 lb in).



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



153. Install the control lever.
154. Install the control lever washer and nut and tighten to 12 N·m (106 lb in).



155. Install the torque converter (2) to the transaxle.
156. Measure the installation depth of the torque converter.

Specification
The standard value is 11.1 mm (0.44 in).

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