Assembly Procedure

Tightening Torque: 

1. 10.8-13.7 N.m {110-140 kgf.cm, 96-121 in.lbf} 

Fig 1: Installing Bearing Cover

1. Install the bearing housing on the converter housing, and tighten the bolts evenly and gradually.

   Tightening Torque: 

   1. 27.4-34.3 N.m {2.79-3.5 kgf.m, 20.2-25.3 ft.lbf} 

2. Align the slot of the idler shaft with the mark on the bearing housing.
3. Tap a new roll pin in using a pin punch and a hammer.

1. Install the orifice check valve spring and orifice check valve.
2. Apply ATF to new O-rings and install them into the 2-3 accumulator.
3. Install the 2-3 accumulator piston.

Tightening Torque: 

1. 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

Tightening Torque: 

1. 4.0-5.8 N.m {40-60 kgf.cm, 35-52 in.lbf} 

1. Install the manual plate, spacer, washer, and nut.
2. Tighten the nut to the specified torque.

   Tightening Torque: 

   1. 42-54 N.m {4.2-5.6 kgf.m, 31-40 ft.lbf} 

3. Install the detent spring.

   Tightening Torque: 

   1. 15-21 N.m {1.5-2.2 kgf.m, 11-15 ft.lbf} 

4. Move the manual shaft and verify that the parking pawl operates correctly.

Thrust Bearing Outer Diameter: 

1. 71.0 mm {2.80 in} 

Tightening Torque: 

1. 38-51 N.m {3.8-5.3 kgf.cm, 28-38 in.lbf} 

1. Assemble the turbine shaft and 3-4 clutch component.
2. Verify that the thrust bearing and race are properly installed.
3. Install the turbine shaft and 3-4 clutch component into the transaxle case.

1. Install the internal gear to the output shell.
2. Install the snap ring.

1. Verify that the thrust bearing and bearing race are installed in the correct position.
2. Hold the turbine shaft with one hand to prevent it from rotating.
3. Install the carrier hub component into the 3-4 clutch drum by rotating it.

1. Hold the one-way clutch 2 horizontally.
2. Install it by turning the carrier hub component counterclockwise.
3. Install the snap ring.

1. Install the servo return spring and band servo.
2. Compress the servo using the SSTs  .
   Fig 7: Installing Band Servo

   
3. Install the snap ring.
4. Remove the SSTs  .

1. Verify that the thrust bearing and bearing race are installed in the correct position.
2. Install the small sun gear and one-way clutch 1 component by rotating it.

1. Verify that the thrust bearing is installed in the correct position.
2. Install the clutch component by rotating it.

Height Difference: 

1. 0.7-1.9 mm {0.028-0.075 in} 

Fig 9: Measuring Height Difference Between Reverse And Forward Drum & Transaxle Case

1. Set the thrust bearing onto the clutch component.
2. Remove the bearing race and the oil pump gasket.
3. Set the thickest bearing race (2.2 mm {0.084 in}) onto the oil pump.
4. Set the oil pump onto the clutch component.
5. Measure clearance A between the transaxle case and the oil pump. Take several measurements and calculate the average value.
6. Select a suitable bearing race from the chart below.
   BEARING RACE SELECTION
   
   

   Clearance A (mm {in})	Select This Bearing Race (mm {in})
   0.91-1.10 {0.036-0.043}	1.2 {0.047}
   0.71-0.90 {0.028-0.035}	1.4 {0.055}
   0.51-0.70 {0.020-0.027}	1.6 {0.063}
   0.31-0.50 {0.012-0.019}	1.8 {0.071}
   0.11-0.30 {0.004-0.011}	2.0 {0.078}
   0-0.10 {0-0.003}	2.2 {0.087}

   Fig 10: Measuring Clearance A

   
7. Remove the oil pump.
8. Place the selected bearing race and a new gasket onto the oil pump.
9. Install the oil pump onto the clutch component, and tighten the bolts evenly and gradually.

   Tightening Torque: 

   1. 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf} 

10. Install the oil pipe.

1. Loosen the locknut and tighten the piston stem to the specified torque.

   Tightening Torque: 

   1. 11.8-14.7 N.m {120-150 kgf.cm, 105-130 in.lbf} 

2. Install a dial indicator and magnetic base to the oil pump. Set the dial indicator against the piston stem.
   Fig 11: Setting Dial Indicator Against Piston Stem

   
   WARNING:

   • Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
3. While keeping compressed air applied to the 2-4 brake band engagement passage, set the dial indicator to zero.

   Air Pressure: 

   1. 390-400 kPa {3.9-4.1 kgf/cm ²  , 56-58 psi} 
   Fig 12: Locating 2-4 Brake Band Engagement Passage

   
4. Stop applying compressed air, and verify the piston stroke by inspecting the dial gauge. Adjust the piston stem and apply compressed air repeatedly until the stroke is within specification.

   Stroke: 

   1. 0.8-1.2 mm {0.0394-0.0472 in} 

5. Hold the piston stem and tighten the locknut to the specified torque.

   Tightening Torque: 

   1. 25-39 N.m {2.5-4.0 kgf.m, 19-28 ft.lbf} 

Tightening Torque: 

1. 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

Tightening Torque: 

1. 8.4-10.7 N.m {85-110 kgf.cm, 73.8-95.4 in.lbf} 

Fig 13: Tightening Oil Pan Bolts

Tightening Torque: 

1. 10.8-14.7 N.m {110-150 kgf.cm, 96-130 in.lbf} 

Tightening Torque: 

1. 8.4-10.7 N.m {85-110 kgf.cm, 73.8-95.4 in.lbf} 

Tightening Torque: 

1. 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

Tightening Torque: 

1. 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

1. Connect an ohmmeter between the terminals A and H.
   Fig 15: Adjusting TR Switch

   
2. Rotate the manual shaft full counterclockwise, then return it two notches to the N position.
3. Adjust the switch to the point where there is continuity between the terminals.
4. Tighten the switch.

Tightening Torque: 

1. 7.9-10.7 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

Tightening Torque: 

1. 32-46 N.m {3.2-4.7 kgf.m, 24-33 ft.lbf} 

Tightening Torque: 

1. 6.9-9.8 N.m {80-110 kgf.cm, 69.5-95.4 in.lbf} 

ATF Type 

1. M-III Or Equivalent (e.g. Dexron® II) 

Distance A: 

1. 13.96 mm {0.5496 in} 

Fig 16: Measuring Distance A