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81. Check to see if the sliding surface of the disc, plate
and flange of 2nd coast & O/D brake are worn or
burnt. If necessary, replace them.
Notice : If the lining of the disc is peeling off or discolored,
or even if a part of the printed mark is defaced, replace all
discs.
Notice : Before assembly new discs, soak them in ATF for
at least 15 minutes.
82. Using a screwdriver, install the snap ring to the
transaxle case.
Notice : Make sure that the snap ring is installed in the
groove of the transaxle case correctly.
83. Install the flange, 2 discs and 2 plates to the trans-
axle case.
S Install in order: P D P D F
(P = Plate, D = Disc, F = Flange)
84. Clean the connected part the transaxle case and
transaxle rear cover.
85. As shown in the illustration, place a straight edge
on the transaxle case and measure the distance
between the 2nd coast & O/D brake flange and
straight edge using vernier calipers. (Dimension A).
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86. As shown in the illustration, place a straight edge
on the O/D brake piston and measure the distance
between the transaxle rear cover and straight edge
using vernier calipers. (Dimension B).
87. Calculate the piston stroke value using the following
formula. Select a flange which satisfies the piston
stroke value and install it.
Piston stroke = Dimension A Dimension B
Piston stroke : 0.65 1.05 mm (0.0256 0.0413
in.)
S Flange thickness : mm (in.)
Piston stroke
value
ThicknessMark
0.738 ~ 0.949
(0.02905 ~
0.03736)3.0
(0.118)0
0.950 ~ 1.149
(0.03740 ~
0.04524)3.2
(0.126)1
1.150 ~ 1.349
(0.04528 ~
0.05311)3.4
(0.134)2
1.350 ~ 1.549
(0.05315 ~
0.06098)3.6
(0.142)3
1.550 ~ 1.702
(0.06102 ~
0.06701)3.8
(0.150)0
88. Install new 4 apply gaskets to the transaxle rear
cover.
89. Coat the thrust neddle roller bearing with petroleum
jelly and install it onto the forward & reverse clutch
assembly.
S Bearig:
Inner diameter: 43.2 mm (1.701 in.)
Outer diameter: 62.0 mm (2.441 in.)
90. Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or transaxle case.
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91. Apply formed in place gasket (FIPG) to the trans-
axle rear cover.
FIPG: three bond 1281 or equivalent
Seal bend width: 1.2 mm (0.047 in.)
92. Install the transaxle rear cover to the transaxle case
with the 9 bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
93. Install the counter driven gear assembly to the
transaxle case.
94. Install the differential gear assembly to the trans-
axle case.
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95. Install the direct clutch hub to the transaxle case.
96. Install the thrust bearing race and thrust needle roll-
er bearing to the transaxle case.
S Race and bearing: mm (in.)
Inner diameterOuter diameter
Race20.5 (0.807)32.6 (1.283)
Bearing17.8 (0.701)30.2 (1.189)
97. Install the direct clutch assembly to the transaxle
case.
98. Install new apply gasket.
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99. Install the thrust needle roller bearing to the trans-
axle case.
Notice : Check the direction of the bearing.
100. Place the oil pump through the input shaft, and
align the bolt holes of the oil pump with the trans-
axle case.
101. Install the 6 oil pump bolts.
Tighten
Tighten the bolts to 25 NSm (18 lb–ft).
102. Measure the end play in axial direction.
Notice : If the end play is not as specified, select and re-
place the thrust needle roller bearing.
S End play 0.3 0.9 mm (0.012 0.035 in.)
S Bearing: mm (in.)
Inner diameter
Outer
diameterThichness
32.5 (1.280)48.5 (1.909)4.21 (0.1657)
32.9 (1.295)48.5 (1.909)3.62 (0.1425)
103. Make sure that the input shaft rotates smooth-
ly.
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104. Remove any packing material and be careful
not to get oil on the contacting surfaces of the
transaxle housing or transaxle case.
105. Apply FIPG (formed in place gasket) to the
transaxle housing.
FIPG: Three bond 1281 or equivalent.
Seal bend width: 1.2 mm (0.047 in.)
106. Install the transaxle housing to the transaxle
case with the 16 bolts.
Tighten
Tighten the bolts to 29 NSm (22 lb–ft).
S Apply seal packing or equivalent to the 3 bolts
indicated by arrows.
107. Coat a new O–ring with ATF, install it to the
transaxle wire.
108. Install the transaxle wire the to the transaxle
case with the bolt.
Tighten
Tighten the bolts to 5.4 NSm (48 lb–in).
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109. Coat new 6 O–rings with ATF and install them
to the pistons.
110. Coat the 3 springs and 3 accumulator pistons
with ATF, install them to the holes.
S Accumulator spring:
Spring
Free length
Outer
diameter
mm(in.)Color
B1(O/D & 2nd
brake)47.13(1.8555)/
16.0(0.630)Pink
C1(Forward
clutch)57.90(2.2795)/
17.2(0.677)–
C2(Direct
clutch)57.20(2.2520)/
17.5(0.689)Green
111. Coat a new apply gasket with ATF, install it to
the transaxle case.
112. Coat a new brake drum gasket with ATF, install
it to the transaxle case.
113. Install the spring and check valve.
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114. Connect the manual valve control rod to the
manual valve lever as shown in the illustration.
115. Install the valve body assembly to the trans-
axle case.
Tighten
Tighten the bolts to 11 NSm (97 lb–in).
Notice : When installing the valve body to the transaxle
case, do not let each of accumulator pistons B1,C1,and
C2 incline. When installing the valve body to the transaxle
case, do not hold the solenoids.
116. Connect the transaxle wire connector and har-
ness to the valve body assembly.
117. Connect the 5 connectors.
a. Lock–up control solenoid
b. Pressure control solenoid.
c. No.2 shift solenoid.
d. No.1 shift solenoid.
e. Timing solenoid
118. Install the TFT sensor with clamp.
Notice : Make sure that the transaxle wire does not come
out from the oil pan installation surface.
119. Install a new gasket to the oil strainer.