Necessary equipment
- J-45053 Universal Clamp Press
- DT-47599 Anchor bolt wrench
- DT-47687 Torque transducer
- J-45187 Differential Output Shaft Seal Installer
- J-44809 Output Shaft Seal Installer
- J-45124 Demolition Bridge
- J-45160 Differential bearing race puller
- J-8092 Guide handle
- J-45184 Differential Bearing Race Installer
- J-45161 Manual shift shaft bearing replacement tool
- J-45404 Gearbox Alignment Tool with Pointer
Assembly order
1. Install the countershaft drive gear.
- Install the countershaft drive gear.
- Install the retaining ring with pliers.
2. Install 1st and reverse brake piston (B3).
- Lubricate new o-rings with automatic transmission fluid and install them on the piston.
- Lubricate the inside surface of the transaxle housing with final drive assembly with automatic transmission fluid.
- Press the 1st and reverse brake piston (B3) into the gearbox housing with final drive assembly.
Important: Be careful not to damage the O-ring.
3. Install the brake return spring assembly 1st gear and reverse (B3).
- Install the 1st gear and reverse brake return spring assembly (B3) on piston B3.
- Hand squeezing the 1st gear and reverse brake return spring (B3), use a screwdriver to install the circlip into the groove.
Important: Be careful not to damage the inside surface of the transaxle housing assembly. Make sure that the retaining ring is installed correctly as shown in the figure.
4. Install No. 2 freewheel front epicyclic gear (F2) and flange, disc and brake plate 1st gear and reverse (B3).
- Install the race on the countershaft drive gear.
- Install front epicyclic gear and freewheel No. 2 (F2).
Important: Make sure that the epicyclic gear turns freely counterclockwise and locks when turned clockwise.
- Install flange, disc and plate as shown.
Important: Make sure that their number and order are correct.
- Order: F - D - P - D - R - D - P - D - P - D - F
Clutch and brake
|
Flange (F)
|
plate (P)
|
Disk (D)
|
|
1st gear and reverse brake (B3)
|
2
|
4
|
5
|
- Using a screwdriver, install the circlip.
Important: Make sure that the circlip cut does not line up with one of the cutouts.
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
5. Check 1st gear and reverse brake piston stroke (B3).
- Install the indicator as shown in the figure.
- Apply compressed air (4 kg/cm?) and measure the stroke of the brake piston of 1st gear and reverse (B3).
- Stroke: 1.39-2.21mm (0.055 - 0.087 inches).
6. Install planetary gear assembly.
- Install planetary gear assembly.
Important: Make sure the direction of the thrust bearing is correct.
7. Install the epicyclic wheel of the front planetary gear set.
- Install the epicyclic wheel of the front planetary gear set.
Important: Make sure the direction of the thrust bearing is correct.
8. Install the planetary sun gear assembly.
- Install the planetary sun gear assembly.
Important: Make sure the direction of the thrust bearing is correct.
9. Install forward clutch (C1) and direct transmission (C2).
- Install forward clutch (C1) and direct transmission (C2) assembled.
- Check Distance "A".
- A: 50.850 - 51.825 mm (2.002-2.040 inches)
Important: If the distance is not within specification, adjust again until the specification is reached.
10. Install the supply tube.
- Install the inlet tube with a plastic hammer as shown in the figure.
Important: Be careful not to bend or damage the inlet tube.
- Install 1 clamp and tighten 1 Torx bolt.
Tighten
Tighten the oil supply pipe clamp bolt to 6 Nm (53 lb-in).
11. Install the rear crankcase assembly.
- Lubricate 5 new gaskets and install them in the transaxle housing assembly.
- Install 3 new o-rings and bearing race into the rear crankcase.
- Clean the mating surfaces of the rear crankcase and the gearbox housing with final drive assembly from traces of packaging material and wipe off the automatic transmission fluid from the mating surfaces.
- Apply plastic gasket (FIPG) on the rear crankcase as shown.
Important: Make sure that the mating surfaces of the rear crankcase and transaxle housing assembly are free of oil.
- Install the rear crankcase.
- Install and tighten 13 bolts.
Tighten
Tighten the rear crankcase bolt to 30 Nm (22 lb-ft).
12. Install underdrive brake (B4).
- Lubricate the new O-ring with ATF, install and tighten 1 anchor bolt using the DT-47599 anchor bolt wrench.
Tighten
Tighten the underdrive brake anchor bolt (B4) torque 167 Nm (123 lb-ft).
13. Install the underdrive brake piston (B4).
- Lubricate the inside surface of the transaxle housing with final drive assembly with automatic transmission fluid.
- Install the underdrive brake spring and piston (B4) assembly into the gearbox housing with final drive assembly.
- Lubricate 2 new O-rings with ATF and install them in the underdrive brake cover (B4).
- Pushing the cover of the underdrive brake (B4), install the retaining ring with pliers.
Important: If the circlip is deformed, replace it.
14. Install the rear planetary reduction gear assembly.
- Install the rear planetary gear reduction gear assembly.
Component Name
|
Specifications
|
Designation
|
Washer thickness type
|
0.81 mm (0.032 inch)
|
8
|
0.90 mm (0.035 inch)
|
9
|
|
1.00 mm (0.039 inch)
|
10
|
|
1.10 mm (0.043 inch)
|
11
|
|
1.20 mm (0.047 inch)
|
12
|
|
1.30 mm (0.051 inch)
|
13
|
|
1.40 mm (0.055 inch)
|
14
|
|
1.50 mm (0.059 inch)
|
15
|
|
1.60 mm (0.063 inch)
|
16
|
- Install the rear planetary reduction gear assembly.
15. Install the underdrive brake band (B4).
- Install the underdrive brake band (B4).
16. Install underdrive clutch (C3) assembled.
- Install underdrive clutch (C3) assembled.
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
17. Check the piston stroke of the underdrive brake (B4).
- Mark the piston rod of the downshift brake (B4).
- Measure the B4 piston stroke by supplying and releasing compressed air (4 kg/cm?), as it shown on the picture.
- Stroke: 5.76-6.76mm (0.227-0.266 inch)
If the stroke of the stem does not fit within the norm, select another stem.
stem length
|
R=76.2 mm (3,000 inches)
|
R=76.7 mm (3.020 inches)
|
|
R=77.2 mm (3.039 inches)
|
|
R=77.7 mm (3.059 inches)
|
|
R=78.2 mm (3.079 inches)
|
18. Install the reduction gear assembly.
- Install the reduction gear assembly to the transaxle housing assembly.
- Install thrust bearing and race.
- Check distance E.
Important: Measure from the end surface of the crankcase to the bearing (roller part).
- E: 1.269-1.645mm (0.050-0.065 inch)
If the measured value is out of specification, select a clip "L" for installation.
Component name
|
Specifications
|
Designation
|
Washer thickness type
|
0.80 mm (0.031 inch)
|
(No)
|
0.90 mm (0.035 inch)
|
A
|
|
1.00 mm (0.039 inch)
|
B
|
|
1.10 mm (0.043 inch)
|
C
|
|
1.20 mm (0.047 inch)
|
D
|
|
1.30 mm (0.051 inch)
|
E
|
|
1.40 mm (0.055 inch)
|
F
|
|
1.50 mm (0.059 inch)
|
G
|
And, if the value does not completely fit into the norm when using the above clips, select an adjusting shim "P" according to paragraph "14. Install the rear planetary reduction gear assembly" for installation.
At the same time with a clip "L" thickness = 0.80 mm should be used (0.031 inch).
19. Adjust tapered roller bearing preload.
- Install the differential case assembly to the transaxle case assembly.
- Install the transaxle housing assembly to the transaxle housing assembly.
- Install and tighten 17 bolts as shown.
Tighten
Tighten the gearbox housing mounting bolt with final drive assembly to 30 Nm (22 lb-ft).
- Rotate the differential in both directions to seat the bearing tightly.
- Using a torque converter DT-47687 and a torque gauge, measure the preload (during rotation) side bearing without installing the reduction gear and shaft assembly.
- Torque characteristic (new bearing): 0.70-1.20 Nm (6-11 lb-in).
- If the preload is not within specification, the differential bearing race shim must be replaced.
- Remove the transaxle housing assembly and differential assembly from the transaxle housing assembly.
20. Remove the differential bearing race and shim.
- Install J-45160 into the bearing race, making sure the bottom of the tool is fully down inside the race and sits flat on top of the shim before tightening.
- Use two wrenches to tighten J-45160 until the tool is firmly seated in the bearing race for removal.
- Position the J-45124 axle adjustable mount sections so that they are perpendicular to the top of the housing section around the differential bearing race.
- Attach J-45124 to J-45160 and lightly finger tighten the center bolt to prevent movement of the tool assembly. Recheck the position of the J-45124 axle adjustable feet to ensure that the differential bearing race does not snag on the adjustable feet and that the transaxle housing assembly is not damaged when the bearing race is removed.
- Tighten the bolt on J-45124 to remove the differential bearing race from the transaxle housing assembly.
- Remove the differential bearing race shim from the transaxle housing assembly.
- Measure the differential bearing race shim to determine its size. Based on this measurement value, refer to the following table to determine the correct shim size you will need.
1.00 mm (0.039 inch)
|
1.48 mm (0.058 inch)
|
1.05 mm (0.041 inch)
|
1.51 mm (0.059 inch)
|
1.10 mm (0.043 inch)
|
1.54 mm (0.061 inch)
|
1.15mm (0.045 inch)
|
1.57mm (0.062 inch)
|
1.20 mm (0.047 inch)
|
1.60 mm (0.063 inch)
|
1.25mm (0.049 inch)
|
1.65 mm (0.065 inch)
|
1.30 mm (0.051 inch)
|
1.70 mm (0.067 inch)
|
1.33mm (0.052 inch)
|
1.75mm (0.069 inch)
|
1.36mm (0.053 inch)
|
1.80 mm (0.071 inch)
|
1.39 mm (0.055 inch)
|
1.85 mm (0.073 inch)
|
1.42mm (0.056 inch)
|
1.90 mm (0.075 inch)
|
1.45mm (0.057 inch)
|
-
|
If the resulting torque measurement is below the specifications listed, a larger/thicker shim will be required. If the resulting torque measurement is higher than the specifications listed, then a smaller/thinner shim will be required.
21. Remove the differential bearing race and shim.
- After selecting the correct shim, install a new differential bearing race shim into the transaxle housing assembly.
- Using J-8092 and J-45184, install the differential bearing race into the transaxle housing assembly.
- After correctly installing the differential bearing race into the housing, repeat the measurement to ensure that the shim thickness is correct.
22. Install the manual shift shaft bearing.
- Using J-45161 and a plastic hammer, install the manual shift shaft bearing into the transaxle housing assembly.
23. Install the range select valve gland by pushing the gland into the body.
- Install a new range select valve seal by pressing the seal into the body.
- Install 1 Torx bolt, guide bushing and #2 torsion spring.
Tighten
Tighten the torsion spring mounting bolt No. 2 to 10 Nm (89 lb-in).
- Install the parking lock pin.
- Install the cam plate and park lock pawl.
- Install the park lock pawl shaft and No. 1 torsion spring.
- Install the lock spring.
- Temporarily tighten 2 bolts.
- Install the parking lock bar.
- Install the range select valve lever and attach the park lock rod to it.
- Use a screwdriver to connect the lockout spring to the range select valve lever.
- Fasten with two screws.
Tighten
Tighten bolt (1) lock spring fasteners (16.7mm) torque 10 Nm (89 lb-in).
Tighten bolt (2) lock spring fasteners (14 mm) torque 6 Nm (53 lb-in).
24. Install the downshift brake supply pipe (B4).
- Install 2 new o-rings in the groove of the tube and install the downshift brake feed tube with a plastic hammer (B4).
Important: Be careful not to damage the o-ring or bend or damage the tubing.
- Install clamp and tighten 2 bolts.
Tighten
Tighten the bolt securing the clamp of the supply pipe to the underdrive brake (B4) torque 6 Nm (53 lb-in).
25. Install the oil tank fixing plate (gearbox housing with final drive assy).
- Install the oil tank fixing plate and tighten the 3 bolts.
Tighten
Tighten the oil tank fixing plate bolt (gearbox housing with final drive assy) torque 6 Nm (53 lb-in).
26. Install the transaxle housing plate assembly.
- Install the transaxle housing plate assembly and tighten the 2 bolts.
Tighten
Tighten the transaxle housing plate mounting bolt to 6 Nm (53 lb-in).
27. Install oil filter.
- Install oil filter and tighten 1 bolt.
Tighten
Tighten the oil filter mounting bolt to 6 Nm (53 lb-in).
28. Install differential assembly.
29. Install the oil tank fixing plate (gearbox housing with final drive assy).
- Install 4 magnets on the fixing plate of the oil tank.
- Install the oil tank fixing plate and tighten the 3 bolts.
Tighten
Tighten the oil tank fixing plate bolt (gearbox housing with final drive assy) torque 6 Nm (53 lb-in).
30. Install the lubricant supply pipe to the differential gear.
- Using a plastic mallet, install the grease supply tube to the differential gear.
Important: Be careful not to bend or damage the tubing.
- Install clamp and tighten 1 bolt.
Tighten
Tighten the bolt securing the clamp of the lubricant supply pipe to the differential gear to a torque of 6 Nm (53 lb-in).
31. Install gasket.
- Install 1 new gasket.
32. Assemble the gearbox housing with final drive assembly.
- Clean the parts from traces of packaging material. Do not allow oil to come into contact with the mating surfaces of the transaxle housing assembly and transaxle housing assembly.
- Apply plastic gasket (FIPG) to the transaxle case assembly as shown in the figure.
- Install the transaxle housing assembly to the transaxle housing assembly.
- Install and tighten 17 bolts as shown.
Tighten
Tighten the gearbox housing mounting bolt with final drive assembly to 30 Nm (22 lb-ft).
Important: Be sure to use a new sealing bolt.
33. Install the oil pump assembly.
- Install the thrust washer with grease into the oil pump assembly.
- Install the 2nd gear inertia brake hub (B1) and 2nd gear brakes (B2) and overrunning clutch No. 1 (F1) to the oil pump assembly.
- Check distance B.
- B: 51.09-51.71mm (2.011-2.036 inches)
Important: If the distance is not within specification, adjust again until the specification is reached.
- Install a new O-ring to the oil pump assembly.
- Install the oil pump assembly along the input shaft in a horizontal position and align the bolt holes in the pump housing with the holes in the transaxle housing assembly. Lightly press the oil pump housing.
Important: Be careful not to drop the 2nd gear inertia brake hub (B1) and 2nd gear brakes (B2) and overrunning clutch No. 1 (F1).
- Install and tighten 8 bolts.
Tighten
Tighten the oil pump assembly mounting bolt to 25 Nm (18 lb-ft).
34. Check axial clearance.
- Install the indicator as shown in the figure, move the input shaft and measure the end play.
- Axial clearance: 0.188 - 0.570 mm (0.007 - 0.022 inches).
If the axial clearance is out of specification, select a different bearing race "K" according to paragraph "№ 11, 2) Assembly of the main node" in this section.
Component name
|
Thickness specifications
|
External diameter
|
Inner diameter
|
Designation
|
Washer thickness type
|
0.81 mm (0.032 inch)
|
41.00 mm (1.614 inches)
|
22.00 mm (0.866")
|
(No)
|
0.90 mm (0.035 inch)
|
41.00 mm (1.614 inches)
|
22.00 mm (0.866")
|
9
|
|
1.00 mm (0.039 inch)
|
41.00 mm (1.614 inches)
|
21.70 mm (0.854 inches)
|
10
|
|
1.10 mm (0.043 inch)
|
41.00 mm (1.614 inches)
|
21.50 mm (0.846")
|
11
|
|
1.20 mm (0.047 inch)
|
41.00 mm (1.614 inches)
|
21.30 mm (0.839")
|
12
|
|
1.30 mm (0.051 inch)
|
41.00 mm (1.614 inches)
|
21.20 mm (0.835")
|
13
|
|
1.40 mm (0.055 inch)
|
41.00 mm (1.614 inches)
|
21.00 mm (0.827")
|
14
|
|
1.50 mm (0.059 inch)
|
41.00 mm (1.614 inches)
|
20.80 mm (0.819 in)
|
15
|
35. Install the switch and sensor assembly to the transaxle housing assembly.
- Install a new O-ring using automatic transmission fluid to the transaxle harness assembly.
- Install the switch and sensor assembly to the transaxle housing assembly.
36. Install gasket.
- Install 2 new gaskets to the transaxle housing assembly.
37. Install the valve body.
- While holding the valve block assembly, connect the range select valve connecting rod to the range select valve lever.
Important: Gearshift position - "N".
Important: Be careful not to damage the transaxle harness.
- Install and evenly tighten the 6 bolts.
Tighten
Tighten the valve block assembly bolt to 10 Nm (89 lb-in).
38. Install the cover on the suction side.
- Install new gasket and suction cover, tighten 2 screws evenly.
Tighten
Tighten the suction cover bolt to 10 Nm (89 lb-in).
39. Connect the transmission wire connectors to the final drive assembly.
- Lubricate a new sealing ring with automatic transmission fluid, install in the groove of the gearbox fluid temperature sensor.
- Install clamp and tighten 1 bolt.
Tighten
Tighten the transmission fluid temperature sensor mounting bolt to 10 Nm (89 lb-in).
- Connect the 8 wire connectors of the solenoid valves.
Important: Be careful not to bend the solenoid valve connector pin.
(1) Solenoid valve no. 1 (black)
(2) Solenoid valve no. 2 (grey)
(3) Solenoid valve no. 3 (grey)
(4) Solenoid valve no. 4 (blue)
(5) Solenoid valve No. 5 (brown)
(6) Solenoid valve (blue)
(7) Solenoid valve (green)
(8) Solenoid valve (black)
40. Install the rear transaxle case cover assembly.
- Clean the mating surface of the transaxle housing assembly of packing material and wipe off the oil from the mating surface.
- Apply plastic gasket (FIPG) on the new rear cover of the gearbox housing.
Important: Make sure that the mating surface is free of oil.
- Install the transaxle case rear cover assembly to the transaxle housing assembly.
- Install and evenly tighten 9 new Torx bolts.
Tighten
Tighten the bolts securing the rear cover of the gearbox housing to a torque of 13 Nm (10 lb-ft).
Important: Be sure to use a new sealing bolt.
41. Install the input shaft speed sensor and transmission range switch.
- Install a new O-ring lubricated with automatic transmission fluid to the input shaft speed sensor.
- Install input shaft speed sensor and tighten 1 bolt.
Tighten
Tighten the input shaft speed sensor mounting bolt to 6 Nm (53 lb-in).
Important: Be sure to use a new sealing bolt.
- Install the automatic transmission range switch to the range select valve lever.
- Temporarily tighten 2 bolts.
- Install spring washer with nut and tighten nut.
Tighten
Tighten the automatic transmission range switch nut to 7 Nm (62 lb-in).
- The range select valve lever must be adjusted to the position "N".
- Install J-45404 on the range select valve lever.
- Rotate the AT range switch until the neutral base line on the switch aligns with the pointer line on J-45404.
- Tighten the 2 A/T range switch bolts.
Tighten
Tighten the automatic transmission range switch bolts to 25 Nm (18 lb-ft).
- Use a screwdriver to tighten the spring washer.
42. Install the output shaft speed sensor.
- Install a new O-ring, lubricated with ATF, to the output shaft speed sensor.
- Install the output shaft speed sensor and tighten 1 bolt.
Tighten
Tighten the output shaft speed sensor bolt to 6 Nm (53 lb-in).
Important: Be sure to use a new sealing bolt.
43. Install the oil level sensor.
- Install a new O-ring lubricated with automatic transmission fluid and an oil level sensor.
- Tighten 1 bolt.
Tighten
Tighten the oil level sensor bolt to 10 Nm (89 lb-in).
44. Install the drain plug in place.
- Install a new gasket on the drain plug.
Tighten
Tighten drain plug to 40 Nm (30 pounds per foot).
45. Install the torque converter.
- Install the torque converter.
- Check distance C.
- C=1.35mm (0.053 inch)
Important: If the distance is not within specification, adjust again until the specification is reached.
46. Install the differential seal.
- Install the transaxle case side oil seal with J-45187.
- Install the transaxle housing side oil seal with J-44809.