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(c) Install the flange.
21. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Install the second brake piston assembly to the
transaxle case.
(b) Install the snap ring and measure the inside
diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
NOTICE:
• Make sure that the taper snap ring is installed
in the correct direction.
• When the diameter does not meet the
specified value, replace the snap ring with a
new one.
• After installing, confirm that there is no
clearance between the 2nd brake cylinder
and the fitting surface of the cylinder in the
transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd
brake cylinder assembly.
NOTICE:
Make sure that the outer sleeve is installed in
the correct direction.
D003815
D026396E03
D008058E01
C092977E01
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23. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the 1-way clutch inner race to the 1-way
clutch.
NOTICE:
• Make sure that the inner race is installed in
the correct direction.
• Confirm that the discrimination mark is
visible.
(b) Check the rotating direction of 1-way clutch for the
lock or free operation as shown in the illustration.
(c) Install the 1-way clutch and thrust needle roller
bearing to the 1-way clutch sleeve outer.
Bearing diameter: mm (in.)
NOTICE:
Install the thrust bearing properly so that no-
colored race will be visible.
24. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No.1 with
yellow petrolatum, and install the washer onto the
planetary sun gear assembly.
NOTICE:
After installing, confirm that the projection
should be fixed firmly in the hole of the
planetary sun gear assembly.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer No.2 with
yellow petrolatum, and install the washer onto the
rear planetary sun gear.
D003909E01
D009638E01
D003588E01
Inside Outside
Bearing 53.6 (2.110) 69.4 (2.732)
D026394E02
D026393E01
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(b) Coat the bearing with yellow petrolatum, and install
the bearing onto the rear planetary sun gear.
Bearing diameter: mm (in.)
(c) Install the rear planetary sun gear assembly to the
rear planetary gear.
NOTICE:
Installing the rear planetary sun gear assembly,
make sure that the B1 discs are engaged.
26. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 5 plates to the transaxle case.
(c) Temporarily install the snap ring.
27. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a vernier calipers, measure the distance
between the disc surface and snap ring surface
(Dimension B).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness -
Snap ring thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
D026404E04
Inside Outside
Race, A 33.0 (1.299) 45.4 (1.787)
Bearing, B 31.85 (1.254) 45.2 (1.78)
D026714E02
D026412E01
D026453E01
Mark Thickness Mark Thickness
1 3.0 (0.118) 5 3.4 (0.134)
2 3.1 (0.122) 6 3.5 (0.138)
3 3.2 (0.126) 7 3.6 (0.142)
4 3.3 (0.130) 8 -
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(c) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
NOTICE:
Secure the snap ring so that the ends visible
through the groove of the transaxle case.
28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-
ASSEMBLY
(a) Install the direct clutch hub to the planetary gear
assembly.
NOTICE:
Be careful not to damage the bushing inside the
overdrive clutch hub during installation.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the
direct clutch hub.
NOTICE:
Be careful not to drop the bearing when it is
installed.
Bearing and race diameter: mm (in.)
29. INSTALL DIRECT CLUTCH ASSEMBLY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assembly and thrust bearing
to the rear planetary sun gear assembly.
NOTICE:
The disc in the direct clutch should completely
match with the hub attached outside the rear
planetary sun gear. Otherwise, the rear cover
cannot be installed.
(c) Clean the connecting part of the transaxle case and
the rear cover.
(d) As shown in the illustration, place a straightedge on
the direct clutch drum and measure the distance
between the transaxle case and the straightedge
using vernier calipers (Dimension C).
D003623E01
D026392E04
Inside Outside
Bearing, A 24.7 (0.972) 39.5 (1.555)
Race, B 23.6 (0.929) 38.0 (1.496)
D026403E02
D026469E01
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(e) Using vernier calipers and a straightedge, measure
the dimension shown in the illustration.
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install the selected bearing.
End play:
0.244 to 0.901 mm (0.0096 to 0.0355 in.)
NOTICE:
Make sure that the no-colored race side is facing
the direct clutch assembly.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
30. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install 3 new governor apply gaskets No.1 to the
transaxle case.
31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube
before installing the apply tube to the transaxle
case. This prevents the apply tube from being
deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the
transaxle case.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
The tube should be securely inserted until it
reaches the stopper.
D026470E01
Thickness Inside Outside
3.6 (0.1417) 56.3 (2.217) 75.7 (2.980)
3.8 (0.1496) 56.3 (2.217) 75.7 (2.980)
D026390
D003923
D026391E03
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32. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, press the needle roller
bearing into the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)
NOTICE:
• The engraved mark side of the bearing
should face upward.
• Repeat the press fit until the specified value
is obtained.
(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
34. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 transaxle case No.1
plugs.
(c) Install the 4 transaxle case No.1 plugs to the
transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove any packing material and be careful not to
spill oil on the contact surfaces of the transaxle rear
cover or the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent.
NOTICE:
Make sure that the FIPG is applied in a bead
(section diameter:
1.2) so that the entire
sealing surface will be evenly sealed. The FIPG
should also protrude slightly from the flange
after the assembly of the parts has been
completed.
D026766E01
D026389E01
D026388
D026454E01
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(c) Apply liquid sealer to the "A" bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent.
(d) Install the 11 bolts.
Torque: Bolt A
19 N*m (190 kgf*cm, 14 ft.*lbf)
Other bolts:
25 N*m (250 kgf*cm, 18 ft.*lbf)
36. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the
transaxle case.
NOTICE:
Be careful about the order of discs, plate and
flange assembly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
37. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Flange thickness: mm (in.)
(b) Temporarily remove the snap ring and attach it to
the flange.
(c) Reinstall the snap ring.
D026387E03
D026414E01
D026466E01
D008082
Mark Thickness Mark Thickness
1 3.0 (0.118) 4 3.1 (0.122)
2 3.2 (0.126) 5 3.3 (0.130)
3 3.4 (0.134) - -
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38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way
clutch.
(b) Rotate the underdrive clutch assembly to check the
rotating direction for the lock or free operation.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth
of the 1-way clutch firmly.
(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(c) Using a screwdriver, install the snap ring to the
transaxle case.
NOTICE:
The snap ring should be fixed fully engaged in
the groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum
jelly, install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
D003925E01
D003907E01
D003627E02
D003581E01
D003580
Inside Outside
Bearing 37.73 (1.4854) 58.0 (2.2835)
Race 29.9 (1.1772) 55.5 (2.185)