Transaxle Reassembly

Fig 1: Identifying Transaxle Components (1 Of 4)

Fig 2: Identifying Transaxle Components (2 Of 4)

Fig 3: Identifying Transaxle Components (3 Of 4)

Fig 4: Identifying Transaxle Components (4 Of 4)

Align bearing cover with guide bolts as shown in Fig 5 , and press it in.
Tightening torque: 96~120 lb-in. (10.8~13.7 N.m, 110~140 kg-cm)

Fig 5: Aligning Bearing Cover With Guide Bolts
Install idler gear and output gear as an assembly by tapping it with a plastic hammer.

Fig 6: Installing Idler Gear & Output Gear Assembly
Install bearing housing.
1. Install bearing housing on converter housing.
2. Align groove on idler shaft with mark on bearing housing.
3. Tap a new roll pin in with a pin punch and hammer.
4. Install 11 mounting bolts.
  Tightening torque: 14~18 lb-ft. (19~25 N.m, 1.9~2.6 kg-m)
  
  Fig 7: Tightening Mounting Bolts
Install parking pawl.
1. Install parking pawl and shaft.
2. Install spring and snap ring.
3. Move manual shaft and verify that parking pawl operates.
  
  Fig 8: Verifying Parking Pawl Operation
Install actuator support with new bolts.
Tightening torque: 11~13 lb-ft. (15~17 N.m, 1.5~1.8 kg-cm)

Fig 9: Installing Actuator Support
Install detent lever and return spring.

Fig 10: Installing Detent Lever & Spring
Install parking assist lever.

Fig 11: Installing Parking Assist Lever
Install lever holder and bolt.
Tightening torque: 69.6~94.8 lb-in. (7.9~10.7 N.m, 80~110 kg-cm)

Fig 12: Installing Lever Holder & Bolt
Install manual shaft and manual plate.
1. Install manual plate, washer, and nut.
2. Tighten nut to specified torque.
Tightening torque: 31~40 lb-ft. (42~54 N.m, 4.2~5.6 kg-cm)

Fig 13: Installing Manual Shaft & Manual Plate
Install differential assembly into converter housing. Install SST(0K201 270 014) or equivalent.
Install a new oil control ring onto output gear assembly.
Install output shell to output gear and install bearing race onto output shell.
Thrust bearing outer diameter: 2.84 in. (72.1 mm)

Fig 14: Installing Output Shell To Output Gear
Apply a thin coat of silicone sealant (TB-1217B) to contact surfaces of converter housing and transaxle case.
Install new O-rings onto converter housing.
NOTE: Insure that sealer will not be forced into oil passages when transaxle case is installed.

Fig 15: Applying Sealant To Contact Surfaces
Mount transaxle case to converter housing.
Tightening torque: 28~38 lb-ft. (38~51 N.m, 3.8~5.3 kg-cm)
Install SST(0K201 190 019) to hold turbine shaft.

Fig 16: Holding Turbine Shaft
Install turbine shaft and 3-4 clutch assembly.
1. Assemble turbine shaft and 3-4 clutch assembly.
  
  Fig 17: Identifying Turbine Shaft & 3-4 Clutch Assembly
2. Verify that thrust bearing is properly installed.
3. Install turbine shaft and 3-4 clutch assembly into transaxle case as an assembly.
  
  Fig 18: Installing Turbine Shaft & 3-4 Clutch Assembly
Install internal gear.
1. Install internal gear to output shell.
2. Install snap ring.
  
  Fig 19: Installing Internal Gear Snap Ring
Install planetary carrier assembly.
1. Verify that thrust bearing and bearing race are properly installed.
  
  Fig 20: Installing Thrust Bearing & Bearing Race
2. Hold turbine shaft with one hand to prevent it from rotating.
  
  Fig 21: Holding Turbine Shaft To Prevent Rotation
3. Install planetary carrier assembly into 3-4 clutch drum by rotating it.
Install low and reverse brake drive and driven plates (four each).
NOTE: Installation order: Driven-Drive-Drive-Drive-Driven-Drive-Driven-Drive

Fig 22: Installing Low & Reverse Brake Plate
Install retaining plate.

Fig 23: Installing Retaining Plate & Snap Ring
Install snap ring.
Install friction plate.
Install one-way clutch No. 2.
1. Hold one-way clutch No. 2 horizontally.
2. Install it by turning planetary carrier counterclockwise.
3. Install snap ring.
  
  Fig 24: Installing One-Way Clutch No. 2 Snap Ring
Install anchor strut and shaft.
NOTE: Interlock 2-4 brake band and anchor strut as shown in Fig 25 .

Fig 25: Installing Anchor Strut & Shaft
Install 2-4 brake band in transaxle case so that it is fully expanded.

Fig 26: Installing 2-4 Brake Band
Install small sun gear and one-way clutch No. 1.
1. Verify that thrust bearing and bearing race are installed in correct position.
  
  Fig 27: Verifying Thrust Bearing & Bearing Race Position
2. Install small sun gear and one-way clutch No. 1 while rotating it.
  
  Fig 28: Installing Small Sun Gear & One-Way Clutch No. 1
Install reverse/forward clutch assembly.
1. Verify that thrust bearing is installed in correct position.
  
  Fig 29: Verifying Thrust Bearing Is Installed Correctly
2. Install reverse/forward clutch assembly while rotating it.
NOTE: Measure height difference between reverse/forward drum and transaxle case.

Maximum: 0.035 in. (0.9 mm)

Fig 30: Measuring Height Difference Between Drum & Case
Install snap ring into bottom ring groove of turbine shaft.

Fig 31: Installing Snap Ring Into Turbine Shaft

Measure total end play and select a suitable bearing race as follows:

Set thrust bearing onto reverse/forward clutch assembly

Fig 32: Installing Thrust Bearing Onto Clutch Assembly
Remove previously used race and gasket.
Set thickest bearing race 0.087 in. (2.2 mm) onto oil pump.
Set oil pump onto clutch assembly.
NOTE: Do not install oil pump gasket at this time.

Fig 33: Installing Thickest Bearing Race On Oil Pump & Removing Gasket
Measure clearance (A) between transaxle case and oil pump.

Select a suitable bearing race from BEARING RACE SPECIFICATIONS table.

BEARING RACE SPECIFICATIONS

Clearance (A) In. (mm)	Select this bearing race - In. (mm)
0.036~0.043 (0.091~1.10)	0.047 (1.2)
0.028~0.035 (0.71~0.90)	0.055 (1.4)
0.020~0.027 (0.51~0.70)	0.063 (1.6)
0.012~0.019 (0.31~0.50)	0.071 (1.8)
0.004~0.011 (0.11~0.30)	0.079 (2.0)
0~0.003 (0~0.10)	0.087 (2.2)

Fig 34: Measuring Clearance Between Transaxle Case & Oil Pump

Remove oil pump.
Place selected bearing race and a new gasket onto oil pump.
Install oil pump onto transaxle assembly.

Tightening torque: 14~18 lb-ft. (19~25 N.m, 190~260 kg-cm)

Fig 35: Tightening Oil Pump Assembly Bolts

Verify 2-4 brake band adjustment as follows:

Install servo piston to SST(0K201 190 021).
Install servo retainer O-ring onto SST(0K201 190 021).
Coat O-ring with ATF, install band servo assembly and SST into transaxle case and secure it with snap ring.

Fig 36: Installing Servo Assembly Snap Ring

NOTE: Insure that 2-4 brake band is correctly positioned against band servo piston stem.
Set a dial indicator against piston stem.

Fig 37: Positioning Dial Indicator Against Piston Stem
Apply compressed air through fluid passage with a rubber-tipped air nozzle as shown and measure piston stem stroke.
Air pressure:
1. 57 psi (392 kPa, 4.0 kg/cm2) maximum
2. Stroke: 0.039~0.067 in. (1.0~1.7 mm)
  
  Fig 38: Applying Compressed Air To Fluid Passage

If not within specification, select proper piston stem from PISTON STEM LENGTH SPECIFICATIONS table.

PISTON STEM LENGTH SPECIFICATIONS

Piston stem length - In. (mm)
3.740 (95.0)	3.760 (95.5)	3.780 (96.0)
3.799 (96.5)	3.819 (97.0)	3.389 (97.5)
3.868 (98.0)	3.878 (98.5)	3.898 (99.0)

Remove band servo assembly and remove SST

NOTE: Do not deform snap ring when removing it.

Install servo into transaxle case
1. Install servo spring and servo assembly.
2. Install snap ring.
3. Position 2-4 brake band onto band servo piston stem.
  
  Fig 39: Installing Servo Assembly Snap Ring

Align manual valve with pin on manual plate and install control valve body.

Tightening torque: 69.6~94.8 lb-in. (7.9~10.7 N.m, 80~110 kg-cm)

CONTROL VALVE BOLT IDENTIFICATION

Bolt

Length - In. (mm)

"A"

1.18 (30)

"B"

1.97 (50)

"C"

0.55 (14)

⁽⁾	For bolt locations, see Fig 40 . Bolt length is measured from below head.

Fig 40: Identifying Control Valve Assembly Bolts

Connect solenoid valve and ATF temperature sensor connectors.
Connect solenoid connector.

Fig 41: Connecting Solenoid Connector

NOTE: Attach magnets inside oil pan in positions shown in Fig 42 (in oil pan).

Fig 42: Attaching Magnets Inside Oil Pan
Install a new gasket and oil pan tighten 19 bolts.
Tightening torque: 74.4~94.8 lb-in. (8.4~10.7 N.m, 80~110 kg-cm)
Install inlet pipe and outlet pipe.
Install driven gear and vehicle speed sensor.
Install crankshaft position sensor.
Install bracket and select bracket.
Install transaxle range switch.
1. Turn manual shaft to N position.
2. Install transaxle range switch.
3. Tighten transaxle range switch mounting bolts.
  Tightening torque: 70~95 lb-in. (7.9~10.7 N.m, 80~110 kg-cm)
4. Verify that the selector lever range position and transaxle range switch correspond.
Remove transaxle from SST(0K 130 990 007/0K130 175 011A).
Install a new O-ring and install oil level gauge and oil filler tube to transaxle case.
Tightening torque: 69.6~94.8 lb-in. (7.9~10.7 N.m, 80~110 kg-cm)
Install input/turbine speed sensor.
Tightening torque: 69.6~94.8 lb-in. (7.9~10.7 N.m, 80~110 kg-cm)
Install oil pump shaft.
Install a new O-ring onto turbine shaft.

Fig 43: Installing Turbine Shaft O-Ring
Fill torque converter with ATF.
ATF type: SK ATF SP-III
NOTE:
- Hold torque converter in an upright position when filling it with ATF. Do not allow fluid to overflow.
- If converter does not fit in easily, do not try to force it: install carefully.
- Do not damage O-ring onto turbine shaft.
Install torque converter in converter housing while rotating it to align splines.

Fig 44: Installing Torque Converter
To ensure that the torque converter is installed accurately, measure distance "A" between face of torque converter and mounting surface of converter housing.
Distance (A): 0.535 in. (13.6 mm)

Fig 45: Measuring Torque Converter Depth