Page 2553 of 4179
ASSEMBLY
AT-517
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
c. Install low & reverse brake piston and retainer on transaxle
case.
CAUTION:
Align bracket to specified gutter as indicated in the figure.
d. Make sure that each protrusion of low & reverse brake piston is
correctly set to corresponding return spring as follows.
Push low & reverse brake piston and retainer evenly and
confirm they move smoothly.
If they cannot move smoothly, remove low & reverse
brake piston and retainer and align return spring cor-
rectly as instructed in step “a”.
e. Push down low & reverse brake piston and retainer and install
snap ring.
13. Install low one-way clutch to front planetary carrier by turning
carrier in the direction of the arrow shown.
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SAT206F
Page 2554 of 4179
AT-518
[ALL]
ASSEMBLY
14. Install snap ring with flat-bladed screwdriver.
CAUTION:
Forward clutch and bearing must be correctly installed for
snap ring to fit into groove of transaxle case.
15. Install front sun gear according to the following procedures.
a. Install bearing race on front sun gear.
CAUTION:
Apply petroleum jelly to bearing race.
b. Install needle bearing on front sun gear.
CAUTION:
Apply petroleum jelly to needle bearing.
Pay attention to the direction of needle bearing.
c. Install front sun gear on front planetary carrier.
16. Install high clutch hub according to the following procedures.
a. Install needle bearing on front sun gear.
CAUTION:
Apply petroleum jelly to needle bearing.
Pay attention to the direction of needle bearing.
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Page 2555 of 4179
ASSEMBLY
AT-519
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
b. Install high clutch hub on front sun gear.
17. Install input shaft assembly (high clutch assembly) according to the following procedures.
a. Install needle bearing on high clutch hub.
CAUTION:
Apply petroleum jelly.
Pay attention to the direction of needle bearing.
b. Install input shaft assembly (high clutch assembly) on high
clutch hub.
c. Install needle bearing on input shaft assembly (high clutch
drum).
CAUTION:
Apply petroleum jelly to needle bearing.
Be careful with the direction of needle bearing.
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Page 2556 of 4179
AT-520
[ALL]
ASSEMBLY
18. Install reverse clutch assembly on input shaft assembly (high
clutch drum).
Adjustment (2)ECS004MG
When any parts listed below are replaced, adjust total end play and reverse clutch end play.
TOTAL END PLAY
Measure the clearance between reverse clutch drum and needle
bearing for oil pump cover.
Select proper thickness of bearing race so that end play is within
specifications.
1. Measure dimensions “K” and “L” and then calculate dimension
“J”.
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Part name Total end play Reverse clutch end play
transaxle case
Overrun clutch hub
Rear internal gear
Rear planetary carrier
Rear sun gear
Front planetary carrier
Front sun gear
High clutch hub
High clutch drum
Oil pump cover
Reverse clutch drum —
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Page 2557 of 4179
ASSEMBLY
AT-521
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
a. Measure dimension “K”.
b. Measure dimension “L”.
c. Calculate dimension “J”.
2. Measure dimension “M”.
a. Place bearing race and needle bearing on oil pump assembly.
b. Measure dimension “M”.
c. Measure thickness of straightedge “t”.
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“J”: Distance between oil pump fitting surface of
transaxle case and needle bearing mating surface of
high clutch drum.
J = K – L
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SAT378D
“M”: Distance between transaxle case fitting surface of
oil pump cover and needle bearing on oil pump cover.
“M
1 ”: Indication of gauge.
SAT379D
M = M1 – t
SAT443D
Page 2558 of 4179
AT-522
[ALL]
ASSEMBLY
3. Adjust total end play “T1 ”.
Select proper thickness of bearing race so that total end play is within specifications. Refer to AT- 5 3 8 ,
"Total End Play" .
REVERSE CLUTCH END PLAY
Measure the clearance between oil pump cover and thrust
washer for reverse clutch drum.
Select proper thickness of thrust washer so that end play is
within specification.
1. Measure dimensions “O” and “P” and then calculate dimension
“N”.
a. Place thrust washer on reverse clutch drum.
b. Measure dimension “O”.
c. Measure dimension “P”.
d. Calculate dimension “N”.T
1 = J – M
Total end play “T
1 ”:
0.25 - 0.55 mm (0.0098 - 0.0217 in)
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“N”: Distance between oil pump fitting surface of tran-
saxle case and thrust washer on reverse clutch drum.
N = O – P
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Page 2559 of 4179
ASSEMBLY
AT-523
[ALL]
D
E
F
G
H
I
J
K
L
MA
B
AT
2. Measure dimensions “R” and “S” and then calculate dimension
“Q”.
a. Measure dimension “R”.
b. Measure dimension “S”.
c. Calculate dimension “Q”.
3. Adjust reverse clutch end play “T
2 ”.
Select proper thickness of thrust washer so that reverse clutch end play is within specifications. Refer
to AT- 5 3 9 , "
Reverse Clutch End Play" .
Assembly (3)ECS004MH
1. Install anchor end pin and lock nut on transaxle case.
CAUTION:
Do not reuse anchor end pin.
2. Place brake band and strut on outside of reverse clutch drum.
Tighten anchor end pin just enough so that brake band is evenly
fitted on reverse clutch drum.
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SAT385D
“Q”: Distance between transaxle case fitting surface
and thrust washer mating surface.
Q = R – S
SAT386D
T2 = N – Q
Reverse clutch end play:
0.61 - 1.0 mm (0.0240 - 0.039 in)
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Page 2560 of 4179
AT-524
[ALL]
ASSEMBLY
3. Place bearing race selected in total end play adjustment step on
oil pump cover.
CAUTION:
Apply petroleum jelly to bearing race.
4. Place thrust washer selected in reverse clutch end play step on
reverse clutch drum.
CAUTION:
Apply petroleum jelly to thrust washer.
5. Install oil pump assembly and gasket on transaxle case.
CAUTION:
Do not reuse gasket.
6. Tighten oil pump fixing bolts to the specified torque. Refer to AT-
416, "Components"
7. Install O-ring to input shaft assembly (high clutch drum).
CAUTION:
Apply petroleum jelly to O-ring.
Do not reuse O-ring.
8. Adjust brake band.
CAUTION:
Do not reuse anchor end pin.
a. Tighten anchor end pin to the specified torque.
b. Back off anchor end pin two and a half turns.
c. While holding anchor end pin, tighten lock nut. Refer to AT- 5 3 5 ,
"BRAKE BAND" .
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: 4.9 N·m (0.50 kg-m, 43 in-lb)
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