DISASSEMBLY AND ASSEMBLY
CAUTION
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INSTALLATION LOCATION OF ADJUST SHIM, NEEDLE BEARING AND THRUST WASHER
Required special tools:
DISASSEMBLY
CAUTION Do not disassemble parts other than those described in this volume.
1. Remove the transfer from the transaxle. <W6AJ>
2. Remove the RR roll stopper bracket and FR roll stopper bracket from the transaxle.
3. Remove the harness bracket from the transaxle.
4. Remove the oil filler tube and oil level gage from the transaxle.
5. Remove the control cable bracket and breather hose from the transaxle.
6. Remove the torque converter from the transaxle.
7. Remove the vehicle speed sensor from the transaxle case.
8. Remove the O-ring from the vehicle speed sensor.
9. Remove the turbine sensor from the transaxle case.
10.Remove the O-ring from the turbine sensor.
11.Remove the park/neutral position switch.
12.Remove the water-cooled transmission fluid cooler from the transaxle case.
13.Remove the O-ring from the water-cooled transmission fluid cooler.
14.Remove the pressure test port bolt from the transaxle case.
15.Remove the O-ring from the pressure test port bolt.
16.Remove the baffle plate from the converter housing.
17.Remove the O-ring from the baffle plate.
18.Remove stud bolts from the transaxle case.
19.Remove the cooler tube (IN) from the side cover.
20.Remove the cooler tube (OUT) from the side cover.
CAUTION Be careful not to break the terminal body.
21.Remove the snap ring from the terminal body and push the terminal body into the transaxle case.
22.Remove the control valve cover from the transaxle case.
23.Remove the control valve cover gasket from the transaxle case.
CAUTION
24.Remove control valve assembly mounting bolts A and B.
CAUTION Remove the control valve assembly by pulling it straight.
25.Remove the control valve assembly from the transaxle case.
CAUTION Be careful not to drop the manual valve.
26.Remove the manual valve from the control valve.
27.Remove the oil temperature sensor and bracket from the control valve.
28.Remove the bracket from the oil temperature sensor.
29.Remove the terminal assembly from the control valve.
30.Remove the detent spring.
31.Remove lip seals from the transaxle case.
CAUTION Do not damage the manual shaft oil seal mounting surface of the transaxle case when removing the manual shaft oil seal.
32.Using a flat-head screwdriver or equivalent, remove the manual shaft oil seal from the transaxle case.
33.Remove the transmission fluid adjusting bolt from the transaxle case.
34.Remove the O-ring from the ATF adjusting bolt.
CAUTION Mounting bolts are Torx E20 bolts.
35.Remove converter housing mounting bolts.
36.Lightly tap the converter housing with a plastic hammer or equivalent to remove.
CAUTION Do not damage the converter housing when removing the side oil seal.
37.Remove the side oil seal from the converter housing using a pin punch or equivalent. <F6AJ>
38.Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the converter housing.
39.Remove the reduction gear taper bearing shim from the converter housing.
40.Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the converter housing.
41.Remove the differential taper bearing shim from the converter housing.
42.Remove the O-ring from the input shaft.
43.Remove the oil pump assembly and oil strainer as one unit.
44.Remove the oil strainer from the oil pump assembly.
45.Remove the magnet from the oil strainer.
46.Remove the O-ring from the transaxle case.
47.Remove the input shaft.
48.Remove the bearing race and needle bearing from the 3-5 reverse clutch drum.
49.Remove the 3-5 reverse clutch assembly.
50.Remove the needle bearing from the FR sun gear.
51.Remove the FR sun gear.
52.Remove the needle bearing from the FR sun gear.
53.Remove the FR internal gear and FR carrier as one unit.
54.Remove the FR internal gear and needle bearing from the FR carrier.
55.Remove the low clutch assembly.
56.Remove the thrust washer from the drum support.
57.Remove the differential assembly.
58.Remove the pawl shaft plate.
59.Remove the return spring.
60.Remove the parking pawl shaft.
61.Remove the parking pawl.
62.Remove the reduction gear lubrication tube.
63.Remove the reduction gear assembly.
CAUTION Mounting bolts are Torx E16 bolts.
64.Remove the side cover.
65.Remove the spacer and needle bearing from the side cover.
66.Remove the O-ring from the transaxle case.
67.Remove the high clutch assembly.
68.Remove the reduction sun gear.
69.Remove the reduction carrier.
70.Remove the needle bearing from the reduction internal gear.
71.Remove the reduction internal gear from the high clutch hub.
72.Remove the needle bearing from the reduction internal gear.
73.Remove the high clutch hub.
74.Remove the needle bearing from the RR sun gear on the rear side.
75.Remove the RR sun gear on the rear side.
76.Remove the needle bearing from the RR carrier assembly.
CAUTION Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
77.Remove the 2-6 brake retaining plate, drive plate and driven plate from the transaxle case.
78.Using a flat-head screwdriver or equivalent, remove the snap ring.
79.Remove the one-way clutch and RR carrier assembly as one unit.
80.Separate the one-way clutch and RR carrier assembly.
81.Remove the needle bearing from the RR carrier assembly.
82.Using a flat-head screwdriver or equivalent, remove the snap ring.
CAUTION Check the plates for damage, deformation, surface burn or permanent strain. If faulty, replace.
83.Remove the low-reverse brake retaining plate, drive plate and driven plate.
84.Remove the RR sun gear on the front side.
85.Remove the bearing race from the RR sun gear on the front side.
86.Remove the needle bearing.
87.Using the special tool MB992195, remove the snap ring.
88.Remove the diaphragm spring retainer.
89.Remove the diaphragm spring.
CAUTION Do not feed air abruptly. Otherwise, the low-reverse brake piston may become stuck in the clutch drum.
90.Feed air through the oil hole as indicated in the illustration to remove the low-reverse brake piston from the transaxle case.
91.Remove D-rings from the low-reverse brake piston.
CAUTION Mounting bolts are Torx E18 bolts.
92.Remove the Output gear set.
93.Remove the O-ring from the transaxle case.
CAUTION Do not damage the transaxle case when removing the side oil seal.
94.Using a flat-head screwdriver or equivalent, remove the side oil seal from the transaxle case.
95.Using the special tools MB992039 and MB990590, remove the outer race of the reduction gear bearing from the transaxle case equivalent.
96.Using the special tools MB992039 and MB990590, remove the outer race of the differential side bearing from the transaxle case.
ASSEMBLY
CAUTION Never reuse the outer race.
1. Using the special tool MB991550, Install the outer race of the differential side bearing on the transaxle case.
CAUTION Never reuse the outer race.
2. Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the transaxle case.
CAUTION
3. Measure an interference (A) of the reduction gear assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the reduction gear assembly.
L3 = L2 - Height of block
Thickness of reduction gear taper bearing shim = L3 -
L1 + Interference
Standard value: 0.16 − 0.22 mm (0.006 − 0.009 in)
(For reduction gear preload)
CAUTION Never reuse the reduction gear taper bearing shim.
4. Install a selected reduction gear taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the reduction gear taper bearing shim.
CAUTION Never reuse the outer race.
5. Using the special tools MD998812, MD998813 and MD998830, install the outer race of the reduction gear bearing on the converter housing.
CAUTION
6. Measure an interference (A) of the differential assembly in the following procedure. Refer to "SERVICE DATA" for the interference of the differential assembly.
Thickness of differential taper bearing shim = L2 - L1 +
Interference
Standard value: 0.19 − 0.25 mm (0.008 − 0.010 in)
(For differential preload)
CAUTION Never reuse the differential taper bearing shim.
7. Install a selected differential taper bearing shim on the converter housing. Refer to "SERVICE DATA" for selecting the differential taper bearing shim.
CAUTION Never reuse the outer race.
8. Using the special tool MB991550 <F1CJA> or MB991445 <W1CJA>, Install the outer race of the differential side bearing on the converter housing.
CAUTION
9. Install an O-ring on the transaxle case.
CAUTION Mounting bolts are Torx E18 bolts.
10.Install the output gear set. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 41 +- 1 N*m (30 +- 1 ft-lb)
CAUTION
11.Install D-rings on the low-reverse brake piston.
CAUTION Apply transmission fluid to the low-reverse brake piston before installation.
12.Install the low-reverse brake piston on the transaxle case.
13.Install the diaphragm spring.
14.Install the diaphragm spring retainer.
15.Using the special tool MB992195, install the snap ring.
CAUTION Measure the end play at more than two locations and obtain the average of the measurements.
16.Measure the clearance (A) of the low-reverse brake using the following procedure. Refer to "SERVICE DATA" for the specified low-reverse brake clearance.
NOTE: If there is no appropriate plate, use the special tool, MD998917
Standard value: 1.9 − 2.2 mm (0.07 − 0.09 in) (For low-reverse brake clearance)
CAUTION
17.Install the needle bearing.
CAUTION Apply vaseline to the bearing race before installation.
18.Install the bearing race on the RR sun gear on the front side.
19.Install the RR sun gear on the front side.
CAUTION
20.Install the needle bearing on the RR carrier assembly.
21.Install the RR carrier assembly.
CAUTION Ensure that the various plates are installed in the correct order.
22.Install the low-reverse brake drive plate, driven plate and selected retaining plate on the transaxle case.
23.Using a flat-head screwdriver or equivalent, install the snap ring.
24.Install the one-way clutch.
25.Using a flat-head screwdriver or equivalent, install the snap ring.
CAUTION Measure the end play at more than two locations and obtain the average of the measurements.
26.Measure the clearance (A) of the 2-6 brake using the following procedure. Refer to "SERVICE DATA" for the specified 2-6 brake clearance.
NOTE: If there is no appropriate plate, use the special tool, MD998917
CAUTION When measuring L3, use the same straight bar as used when L2 is measured.
Clearance = L2 - (L1 + L3)
Standard value: 1.9 − 2.2 mm (0.07 − 0.09 in) (For 2-6 brake clearance)
CAUTION
27.Install the needle bearing on the RR carrier assembly.
28.Install the RR sun gear on the rear side.
CAUTION
29.Install the needle bearing on the RR sun gear on the rear side.
30.Install the high clutch hub.
CAUTION
31.Install the needle bearing on the reduction internal gear.
32.Install the reduction internal gear on the high clutch hub.
CAUTION
33.Install the needle bearing on the reduction internal gear.
34.Install the reduction carrier.
35.Install the reduction sun gear.
CAUTION Measure the end play at more than two locations and obtain the average of the measurements.
36.Measure the reduction sun gear end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified reduction sun gear end play (A).
End play = L3 - (L1 - L2) - Thickness of straight bar - Thickness of spacer
Standard value: 0.4 − 0.7 mm (0.02 − 0.03 in) (For reduction sun gear end play)
CAUTION Measure the end play at more than two locations and obtain the average of the measurements.
37.Measure the side cover end play (A) in the following procedure. Refer to "SERVICE DATA" for the specified side cover end play (A).
L3 = L5 - (L4 + L6) + Thickness of straight bar
End play = L2 - (L1 + L3) - Thickness of needle bearing
Standard value: 0.70 − 1.05 mm (0.028 − 0.041 in) (For side cover end play)
38.Install the high clutch assembly.
CAUTION Ensure that the various plates are installed in the correct order.
39.Install the 2-6 brake drive plate, driven plate and selected retaining plate on the transaxle case.
CAUTION
40.Install an O-ring on the transaxle case.
CAUTION
41.Install an appropriate spacer and the needle bearing on the side cover.
CAUTION
42.Apply the sealant to the transaxle case mounting surface of the side cover (almost the center line of the surface).
Specified sealant: Three Bond 1216B
CAUTION Mounting bolts are Torx E16 bolts.
43.Install the side cover on the transaxle case. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 27 +- 2 N*m (20 +- 1 ft-lb)
CAUTION Measure the end play at more than two locations and obtain the average of the measurements.
44.Measure the drum support end play (A) using the following procedure. Refer to "SERVICE DATA" for the specified drum support end play (A).
CAUTION
CAUTION
CAUTION
End play = L3 - (L1 - L2) - Thrust washer thickness
Standard value: 0 − 0.35 mm (0 − 0.014 in) (For drum support end play)
45.Install the reduction gear assembly.
46.Install the reduction gear lubrication tube.
47.Install the parking pawl.
48.Install the parking pawl shaft.
49.Install the return spring.
50.Install the pawl shaft plate. Refer to the following or the exploded view for the tightening torque.
Tightening torque: 7.9 N*m (70 in-lb)
51.Install the differential gear assembly.
CAUTION
52.Install an appropriate thrust washer on the drum support.
53.Install the low clutch assembly.
54.Install the FR carrier on the low clutch assembly.
CAUTION
55.Install the needle bearing on the FR carrier.
56.Install the FR internal gear on the FR carrier.
CAUTION
57.Install the needle bearing on the FR sun gear.