Necessary equipment
- J-23327 Clutch Spring Remover
- J-23456 Clutch &Booster Pack Remover
- J-45184 Differential Bearing Race Installer
- J-28585 Retaining Ring Remover
1. Install brake piston B5.
- Lubricate new o-rings with automatic transmission fluid and install them on the piston.
- Lubricate the inside of the rear crankcase with automatic transmission fluid.
- Press the piston into the rear crankcase. Care must be taken not to damage the O-rings.
Important: Be careful not to bend the return spring assembly.
2. Install return spring assembly B5.
- Install the return spring assembly to the B5 brake piston.
- Install J-45184 on the center of J-23456.
- Install the transaxle housing cover assembly on J-45184.
- Using J-23327-1, which is the J-23327 bridge piece, compress the return spring assembly.
- Using circlip pliers, install the circlip.
- Remove all tools.
3. Install flange, plate, disc and elastic disc.
- Install elastic disk.
Important: Make sure the orientation of the elastic disc is correct.
- Install flange, plates and discs as shown.
Important: Make sure the number and order of platters and discs are correct.
- Order: F - D - P - D - P - D - P - D - P - D - P - D - P - UD
Clutch and brake
|
Flange (F)
|
plate (P)
|
Disk (D)
|
elastic disk (UD)
|
Brake B5
|
1
|
6
|
6
|
1
|
- Install the circlip into the groove with a screwdriver.
Important: Make sure the circlip is oriented correctly as shown in the illustration.
4. Install the forward clutch accumulator (C1).
- Lubricate the new O-ring with automatic transmission fluid and install the accumulator piston.
- Install the accumulator piston and spring into the accumulator cover.
- Lubricate the new O-ring with automatic transmission fluid and install the battery cover.
- Install the battery cover to the rear crankcase and tighten the 2 Torx bolts.
Tighten
Tighten the forward clutch battery bolt (C1) torque 10 Nm (89 lb-in).
5. Install sealing ring.
- Lubricate 3 new O-rings with automatic transmission fluid and install them in the rear crankcase.
- Install the thrust bearing race into the rear crankcase.
6. Install the inlet pipe to the underdrive clutch (C3).
- Lubricate new O-rings with automatic transmission fluid and install in the inlet pipe to the underdrive clutch (C3).
- Using a plastic mallet, install the C3 inlet pipe into the rear crankcase.
Important: Be careful not to damage the O-rings and the C3 inlet pipe.
- Install 2 clamps and tighten 4 bolts.
Tighten
Tighten the underdrive clutch bolt to 7 Nm (62 lb-in).
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
7. Check brake piston stroke B5.
- Install the indicator as shown in the figure.
- Supplying compressed air (4 kg/cm?) into the lubrication channel as shown in the figure, measure the stroke of the piston and check that the piston moves smoothly.
- Piston: 2.34-2.70mm (0.092-0.106 inch)
If the piston stroke does not fit within the norm, select another flange.
- Flange thickness type: 5.0mm (0.197 inch), 5.1 mm (0.201 inch), 5.2 mm (0.205 inch), 5.3 mm (0.209 inch), 5.5 mm (0.217")