AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SYSTEM... COMPONENT PARTS...

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1 SYSTEM COMPONENT PARTS OIL PUMP DIRECT CLUTCH FORWARD CLUTCH SECOND BRAKE UNDERDRIVE PLANETARY GEAR UNDERDRIVE CLUTCH VALVE BODY UPPER VALVE BODY LOWER VALVE BODY DIFFERENTIAL CASE TRANSFER AX1 AX3 AX55 AX59 AX65 AX72 AX76 AX81 AX87 AX94 AX98 AX102 AX118

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3 SYSTEM OPERATION 2nd Brake (B 1 ) SYSTEM 1st & Reverse Brake (B 2 ) Forward Clutch (C 1 ) AX1 AX0AG08 Direct Clutch (C 2 ) No.1 Oneway Clutch (F 1 ) U/D Brake (B 3 ) No.2 Oneway Clutch (F 2 ) U/D Clutch (C 3 ) Shift lever range P R N D 2 L D Operating Gear position C 1 C 2 C 3 B 1 B 2 B 3 F 1 F 2 Parking Reverse Neutral 1st 2nd 3rd O/D 1st 2nd 1st

4 AX2 SYSTEM FUNCTION OF COMPONENTS B1 F 1 B 2 C 1 IN C 2 C 3 OUT B 3 F2 D04090 Component Function C 1 Forward Clutch Connects input shaft and front planetary sun gear. C 2 Direct Clutch Connects input shaft and rear planetary sun gear. C 3 U/D Clutch Connects U/D sun gear and U/D planetary carrier. B 1 B 2 B 3 2nd Brake 1st & Reverse Brake U/D Brake Prevents rear planetary sun gear from turning either clockwise or counterclockwise. Prevents rear planetary carrier and front planetary ring gear from turning either clockwise or counterclockwise. Prevents U/D sun gear from turning either clockwise or counterclockwise. F 1 No.1 Oneway Clutch Prevents rear planetary carrier from turning counterclockwise. F 2 No.2 Oneway Clutch Prevents U/D planetary sun gear from turning clockwise. Planetary Gears These gears change the route through which driving force is transmitted, in accordance with the operation of each clutch and brake, in order to increase or reduce the input and output speed.

5 COMPONENT PARTS AX3 COMPONENT PARTS COMPONENTS AX0AH04 69 (700, 51) Transfer Assembly Counter Gear Speed Sensor Gasket 11.3 (115, 8) 69 (700, 51) x6 Intermediate Shaft Input Turbine Speed Sensor 5.4 (55, 48 in. lbf) 11.3 (115, 8) Solenoid Wire Union 24.5 (250, 18) Oring 7.4 (75, 65 in. lbf) Elbow 27 (276, 20) Oring Gasket 47 (480, 35) N m (kgf cm, ft lbf) : Specified torque Nonreusable part D10703

6 AX4 COMPONENT PARTS Transaxle Rear Cover 7.5 (76, 66 in. lbf) Transaxle Case 24.5 (250, 18) Transaxle Housing Clamp 29 (300, 22) x (100, 7) Apply Pipe x8 x3 Bolt A 18.6 (190, 14) Transaxle Rear Cover Plate Apply Gasket x5 Bolt A 22 (225, 16) Valve Body 10.8 (110, 8) x17 ORing Oil Strainer 11 (110, 8) Gasket Magnet Spacer Manual Valve Lever Parking Lock Rod Cover 20 (205, 15) Retainer Spring Pin Manual Valve Lever Shaft Parking Lock Pawl Bracket Oil Seal 20 (205, 15) Neutral Start Switch Nut Stopper C 3 Accumulator Piston Spring 5.4 (55, 48 in. lbf) 6.9 (70, 61 in. lbf) Control Shift Lever Washer 12.7 (130, 9) Spring Oil Pan x (77, 67 in. lbf) 10.3 (102, 7) Manual Detent Spring C 1 Accumulator Piston Oring Spring B 3 Accumulator Piston N m (kgf cm, ft lbf) : Specified torque Nonreusable part Precoated part D09654

7 COMPONENT PARTS AX5 Forward Clutch Thrust Bearing Thrust Bearing Counter Drive Gear Oil Pump Apply Gasket 22 (226, 16) x7 Multiple Clutch Hub Tapered Roller Bearing 1st & Reverse Brake Piston Washer Needle Roller Bearing Bearing Race 280 (2,855, 207) Piston Return Spring Plate Bearing Outer Race Snap Ring Tapered Roller Bearing Flange Oring Disc Snap Ring Plate Flange Snap Ring Bearing Outer Race 2nd Brake Assembly Front Planetary Sun Gear Front Planetary Ring Gear Snap Ring Bearing Race Disc Thrust Bearing Rear Planetary Gear Snap Ring Direct Clutch Thrust Bearing Front Planetary Gear Thrust Bearing Bearing Race Snap Ring Brake Hub Rear Planetary Sun Gear 24.5 (250, 18) Washer No.1 Oneway Clutch Outer Race N m (kgf cm, ft lbf) : Specified torque Nonreusable part Washer No.2 Oneway Clutch No.1 Oneway Clutch Inner Race Thrust Bearing Oil Seal Ring Needle Roller Bearing x11 Transaxle Rear Cover D10709

8 AX6 COMPONENT PARTS U/D Clutch Assembly U/D Planetary Gear Assembly Thrust Bearing Snap Ring Bearing Race Bearing Race Oneway Clutch No.2 U/D Brake Piston Oring Needle Roller Bearing Disc Thrust Bearing Flange Oil Seal Ring Piston Return Spring Snap Ring Plate Parking Lock Pawl Shaft Parking Lock Pawl Clamp Parking Lock Pawl Spring 9.8 (100, 7) Pawl Pin Differential Assembly Apply Pipe N m (kgf cm, ft lbf) : Specified torque Nonreusable part Clamp Apply Gasket 5.4 (55, 48 in. lbf) D10704

9 D03082 COMPONENT PARTS DISASSEMBLY AX7 AX11L01 1. REMOVE TRANSFER ASSEMBLY (a) Remove the 2 bolts and 6 nuts. (b) Using a plastic hummer, remove the transfer assembly from the transaxle assembly. Pull the transfer straight up and remove it from the transaxle. Pulling up the transfer case by inserting your fingers into the holes on both sides may cause damage to the oil seal lip. Be careful not to damage it. 2. REMOVE GASKET AND INTERMEDIATE SHAFT D REMOVE NEUTRAL START SWITCH (a) Remove the nut, washer and control shaft lever. (b) Using a screwdriver, unstake the nut stopper. (c) Remove the 2 bolts, nut stopper, nut, and neutral start switch. D REMOVE UNION AND ELBOW (a) Remove the union and elbow. (b) Remove the 2 Orings from the union and elbow. D03805

10 AX8 COMPONENT PARTS 5. REMOVE SPEED SENSOR (a) Remove the 2 bolts and 2 speed sensors from the transaxle. (b) Remove the 2 Orings from the sensors. D REMOVE TRANSAXLE CASE PLUG NO.1 (a) Remove the transaxle case plug No.1 from the transaxle case. (b) Remove the Oring from the transaxle case plug No.1. D REMOVE SOLENOID WIRE RETAINING BOLT Remove the bolt only and do not remove the solenoid wire. D PLACE TRANSAXLE ON WOODEN BLOCKS Be careful not to damage the oil seal. D REMOVE OIL PAN AND GASKET (a) Remove the 18 bolts. (b) Remove the oil pan and gasket. D09177

11 COMPONENT PARTS AX9 10. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle: Steel (magnetic)... bearing, gear and plate wear Brass (nonmagnetic)... bushing wear AT REMOVE SOLENOID WIRE (a) Remove the 5 connectors from the shift solenoid valves. (b) Remove the bolt, the clamp and the ATF temperature sensor. (c) Remove the solenoid wire from the transaxle case. D09637 (d) Remove the Oring from the solenoid wire. D REMOVE OIL STRAINER (a) Remove the 3 bolts and oil strainer. D09179 (b) Remove the gasket from the oil strainer. D09180

12 AX10 COMPONENT PARTS 13. REMOVE VALVE BODY ASSEMBLY Support the valve body assembly and remove the 17 bolts and valve body assembly. D REMOVE 3 APPLY GASKETS D REMOVE CHECK BALL BODY Remove the check ball body and spring. D REMOVE ACCUMULATOR SPRING AND PISTON (a) Remove the spring from the C 3 accumulator piston. D03555 (b) Apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the oil hole and remove the C 3 accumulator piston. Blowing off the air may cause the piston s jumpout. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when airblowing. D03556

13 COMPONENT PARTS AX11 (c) Remove the Oring from the piston. D03902 (d) Apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the oil hole and remove the C 1 accumulator piston and spring. Blowing off the air may cause the piston s jumpout. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when airblowing. D03557 (e) Remove the 2 Orings from the piston. D03903 (f) Apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the oil hole and remove the B 3 accumulator piston and 2 springs. Blowing off the air may cause the piston s jumpout. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when airblowing. D03558 (g) Remove the Oring from the piston. D03904

14 AX12 COMPONENT PARTS 17. REMOVE MANUAL VALVE LEVER SHAFT (a) Using needlenose pliers, remove the retainer spring. D03559 (b) Remove the 2 bolts, manual detent spring and cover. D03560 (c) Remove the 2 bolts and parking lock pawl bracket. D03561 (d) Using a chisel and hammer, unstake and remove the spacer. D03563 (e) Using a pin punch and hammer, drive out the pin. HINT: Slowly drive out the pin so that it will not fall into the transaxle case. D03564

15 COMPONENT PARTS AX13 (f) Remove the manual valve lever shaft and manual valve lever. D03565 (g) Remove the parking lock rod from the manual valve lever shaft. D03905 (h) Using a screwdriver, remove the oil seal. 18. PLACE TRANSAXLE CASE Fix the transaxle case with the oil pump side facing up. D INSPECT INPUT SHAFT END PLAY Using a dial indicator, measure the input shaft end play. End play: mm ( in.) D REMOVE TRANSAXLE HOUSING (a) Remove the 16 bolts. (b) Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case. Differential may be accidentally removed when the transaxle housing is removed. D03568

16 AX14 COMPONENT PARTS 21. REMOVE OIL PUMP (a) Remove the 7 bolts and oil pump. D03569 (b) Remove the Oring from the oil pump. D REMOVE THRUST BEARING AND BEARING RACE Remove the thrust bearing and bearing race from the U/D planetary gear assembly. D REMOVE DIFFERENTIAL ASSEMBLY D REMOVE 2 APPLY GASKETS D03573

17 COMPONENT PARTS AX REMOVE FORWARD CLUTCH (a) Remove the forward clutch from the transaxle case. D03574 (b) Remove the thrust bearing from the forward clutch. D03906 (c) Remove the thrust bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle case. D REMOVE U/D PLANETARY GEAR ASSEMBLY (a) Remove the bolt and parking pawl shaft clamp. D03576 (b) Remove the parking lock pawl shaft. D09652

18 AX16 COMPONENT PARTS (c) Push the parking lock pawl. HINT: Failure to do so will cause interference when the U/D planetary gear is removed. D09689 (d) Remove the U/D planetary gear assembly from the transaxle case. Be careful that the U/D planetary gear assembly do not fall out. D03579 (e) Remove the spring, pawl pin and parking lock pawl. D REMOVE U/D CLUTCH ASSEMBLY Remove the U/D clutch assembly, thrust bearing and bearing race from the transaxle case. D REMOVE ONEWAY CLUTCH NO.2 (a) Using a screwdriver, remove the snap ring. D03581

19 COMPONENT PARTS AX17 (b) Remove the oneway clutch No.2 from the transaxle case. D03627 (c) Remove the outer race retainer from the oneway clutch No.2. D REMOVE U/D BRAKE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange, 4 discs and 4 plates from the transaxle case. D03582 (c) Using, a snap ring expander and press, remove the snap ring and piston return spring D REMOVE TRANSAXLE REAR COVER (a) Remove the 11 bolts. (b) Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case. D10706

20 AX18 COMPONENT PARTS (c) (d) Remove the 2 oil seal rings from the transaxle rear cover. Remove the 2 screws and transaxle rear cover plate. D03584 (e) Using, remove the needleroller bearing ( , , ) D REMOVE BRAKE APPLY PIPE (a) Remove a bolt, clamp and 2 brake apply pipes. D REMOVE TRANSAXLE CASE APPLY GASKET Using a screwdriver, remove the 2 apply gaskets. D REMOVE DIRECT CLUTCH ASSEMBLY (a) Remove the thrust bearing and direct clutch from the transaxle case. D03586

21 COMPONENT PARTS AX19 (b) Remove the bearing race from the direct clutch. D REMOVE REAR PLANETARY SUN GEAR ASSEMBLY (a) Remove the rear planetary sun gear assembly from the transaxle case. D03587 (b) Remove the thrust bearing from the rear planetary sun gear. D03791 (c) Remove the thrust washer No.1 from the rear planetary sun gear. D REMOVE ONEWAY CLUTCH NO.1 (a) Remove the oneway clutch No.1 and thrust bearing from the transaxle case. D03588

22 AX20 COMPONENT PARTS (b) Remove the inner race from the oneway clutch No.1. D REMOVE ONEWAY CLUTCH OUTER SLEEVE D REMOVE 2ND BRAKE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange, 4 discs and 4 plates from the transaxle case. D REMOVE REAR PLANETARY GEAR (a) Using a screwdriver, remove the snap ring. D03616 (b) Remove the rear planetary gear from the transaxle case. D03592

23 COMPONENT PARTS AX21 (c) Remove the thrust washer No.2 from the rear planetary gear. D03910 (d) Remove the bearing race from the rear planetary gear. D REMOVE FRONT PLANETARY SUN GEAR (a) Remove the 2 thrust bearings, bearing race and front planetary sun gear from the transaxle case. D REMOVE FRONT PLANETARY GEAR ASSEMBLY AND BRAKE HUB (a) Using a chisel and hammer, unstake the lock washer. Push down all claws of the washer. Otherwise can not be fully pressed again the nut and can not loosen the nut. D03595 (b) Using, remove the nut , D03596

24 AX22 COMPONENT PARTS (c) Using and a press, remove the front planetary gear assembly from the counter drive gear ( ) D REMOVE 2ND BRAKE ASSEMBLY AND FRONT PLANETARY RING GEAR (a) Using a screwdriver, remove the snap ring and brake hub with 2nd brake cylinder assembly. D03598 (b) Remove the brake hub from the 2nd brake cylinder assembly. D REMOVE FRONT PLANETARY RING GEAR Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub. D REMOVE 1ST & REVERSE BRAKE (a) Remove the flange, 7 discs and 7 plates from the transaxle case. D03599

25 COMPONENT PARTS AX23 (b) Using, a press and snap ring expander, remove the snap ring and piston return spring Stop the press when the spring sheet is lowered 1 2 mm ( in.) from the snap ring groove, preventing the spring sheet from deforming. Do not expand the snap ring excessively. D03600 (c) Apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the transaxle case to remove 1st & reverse brake piston. Blowing off the air may cause the piston jumpout. When removing the piston, hold it with your hand using a waste cloth. Take care not to splash ATF when airblowing. D03800 (d) Remove the 2 Orings from the 1st & reverse brake piston. D REMOVE COUNTER DRIVE GEAR (a) Using and a press, remove the counter drive gear from the transaxle case ( ), ( ) D03601 (b) As shown in the illustration, tighten 2 bolts evenly and make clearance of approx mm (0.797 in.) between the counter drive gear and the inner race. D03602

26 AX24 COMPONENT PARTS (c) Using, remove the tapered roller bearing RH , , ( ) D03603 (d) Using a brass bar and hammer, remove the 2 bearing outer races. D03798 (e) Using a screwdriver, remove the snap ring from the transaxle case. D REMOVE U/D BRAKE PISTON (a) Apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the transaxle case and remove the U/D brake piston. D03799 (b) Remove the 2 Orings from the U/D brake piston. D03794

27 COMPONENT PARTS AX25 (c) Using, remove the needleroller bearing from the transaxle case , ( , , ) D03605 (d) Remove the 2 oil seal rings from the transaxle case. D REMOVE U/D CYLINDRICAL ROLLER BEARING (a) Using, remove the cylindrical roller bearing from the transaxle case D03606 (b) Remove the oil seal ring from the transaxle housing. D REMOVE APPLY PIPE Remove the bolt, clamp and apply pipe from the transaxle case. D03607

28 AX26 REASSEMBLY COMPONENT PARTS The automatic transaxle is composed of highly precisionfinished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similarlooking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended ATF: ATF TYPE TIV All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. Dry all parts with compressed airnever use shop rags. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face. The recommended ATF or kerosene should be used for cleaning. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly. When disassembling a valve body, be sure to match each valve together with the corresponding spring. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. All gaskets and rubber Orings should be replaced. Do not apply adhesive cements to gaskets and similar parts. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. If a worn bushing is to be replaced, the subassembly containing the bushing must also be replaced. Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts in place. When working with FIPG material, you must observe the following. Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a nonresidue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. AX11M01

29 COMPONENT PARTS AX27 BEARING AND RACES INSTALLATION POSITION AND DIRECTION B A E C D F G I J H D03839

30 AX28 COMPONENT PARTS Mark Front Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Race Diameter Inside / Outside mm (in.) A 57.2 (2.252) / (3.3449) 56.4 (2.220) / 83.0 (3.268) B (1.4854) / 58.0 (2.283) 29.9 (1.177) / 55.5 (2.185) C (1.3327) / 52.2 (2.055) D 23.5 (0.925) / 44.0 (1.732) E 36.3 (1.429) / 52.2 (2.055) 34.5 (1.358) / 48.5 (1.909) F 34.6 (1.362) / 52.2 (2.055) G 40.3 (1.587) / 58.0 (2.283) 38.6 (1.520) / 60.0 (2.362) 38.6 (1.520) / 58.0 (2.283) H 53.6 (2.110) / 69.6 (2.740) I 33.7 (1.327) / 48.2 (1.898) 30.3 (1.193) / 46.0 (1.811) J 53.6 (2.110) / (2.763) or 69.6 (2.740)

31 COMPONENT PARTS AX29 1. INSTALL APPLY PIPE Install the apply pipe and clamp with the bolt to the transaxle case. Torque: 9.8 N m (100 kgf cm, 7 ft lbf) Make sure to insert the pipe to the stopper. D INSTALL U/D CYLINDRICAL ROLLER BEARING (a) Install the oil seal ring to the transaxle housing. D03915 (b) Using and a press, install the U/D cylindrical roller bearing , ( ), , ( ) Do not apply excessive pressure to it. D CHECK U/D BRAKE PISTON RETURN SPRING Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: mm ( in.) D INSTALL U/D BRAKE (a) Install the 2 oil seal rings to the transaxle case. D03914

32 AX30 COMPONENT PARTS Vinyl Tape (b) Wind a vinyl tape around at the place 4.0 mm (0.157 in.) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 in.) ( ) Clean to remove deposited oil, before winding a vinyl tape. D03809 (c) Using and a press, install the needleroller bearing to the transaxle case , ( ), ( ) When the wound vinyl tape contacts the transaxle case, stop pressfitting. D03810 (d) Coat 2 new Orings with ATF, install them to the U/D brake piston. D03794 (e) Install the U/D brake piston to the transaxle case. D03609 (f) Using, a snap ring expander and press, install the piston return spring and snap ring to the transaxle case Pressfit the bearing race RH until it contacts the snap ring. Do not apply excessive pressure to it. D03610

33 COMPONENT PARTS AX31 5. INSTALL COUNTER DRIVE GEAR (a) Using a screwdriver, install the snap ring to the transaxle case. D03604 Counter Drive Gear Side: (b) Using and a press, install the 2 bearing outer races to the transaxle case ( ), ( ) Pressfit the bearing race until it contacts the snap ring. Do not apply excessive pressure to it. Front Planetary Gear Side: D03611 (c) Using and a press, install the tapered roller bearing to the counter drive gear Pressfit the bearing inner race until it contacts the counter drive gear. Do not apply excessive pressure to it. D03613 (d) Using and a press, install the counter drive gear and bearing to the transaxle case ( ), ( ) Do not apply excessive pressure to it. D03614

34 AX32 COMPONENT PARTS 6. CHECK 1ST & REVERSE BRAKE PISTON RETURN SPRING Using vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: mm ( in.) D INSTALL 1ST & REVERSE BRAKE PISTON (a) Coat 2 new Orings with ATF. (b) Install the 2 Orings to the 1st & reverse brake piston. D03913 (c) Coat a 1st & reverse brake piston with ATF, install the 1st & reverse brake piston to the transaxle case. D03813 (d) Using, a press and snap ring pliers, install the piston return spring and snap ring to the transaxle case Stop the press when the spring sheet is lowered to the place 1 2 mm ( in.) from the snap ring groove, preventing the spring sheet from deforming. Do not expand the snap ring excessively. D INSTALL FRONT PLANETARY GEAR ASSEMBLY (a) Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub. D03615

35 COMPONENT PARTS AX33 (b) Install the front planetary gear to the brake hub. (c) Using, a press and pressfit the front planetary gear ( ) Do not apply excessive pressure to it. 2nd Brake Hub w/ Front Planetary Gear Counter Drive Gear Transaxle Case D03916 (d) Install the washer, as shown in the illustration. D03917 (e) Using, install the nut , Torque: 280 N m (2,855 kgf cm, 207 ft lbf) D03596 (f) Using and a torque wrench, measure the starting torque of the bearing. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value Starting torque: N m ( kgf cm, in. lbf) D03918

36 AX34 COMPONENT PARTS (g) Install the 2 bearings, 2 races and front planetary sun gear to the front planetary gear. Bearing and race diameter: mm (in.) Inside Out side Bearing 34.6 (1.362) 52.2 (2.055) Race 40.3 (1.587) 58.0 (2.283) Bearing 38.6 (1.520) 60.0 (2.362) D INSTALL REAR PLANETARY GEAR (a) Coat a bearing race with ATF, install it to the rear planetary gear assembly. Bearing race diameter: mm (in.) Inside Out side Race 38.6 (1.520) 58.0 (2.283) D03593 (b) Install the thrust washer No.2. D03910 (c) Install the rear planetary gear from the rear planetary ring gear. D03592 (d) Using a screwdriver, install the snap ring. D03616

37 COMPONENT PARTS AX35 D INSPECT DISC AND FLANGE OF 1ST & REVERSE BRAKE Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 11. INSTALL 1ST & REVERSE BRAKE (a) Install the 7 plates and 7 discs. D03599 A D03618 (b) Using vernier calipers, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case.(dimension A) (c) Select an appropriate flange so that the piston stroke will meet the specified value. Piston stroke: mm ( in.) HINT: Piston stroke = Dimension A Flange thickness Flange thickness: mm (in.) Mark Thickness Mark Thickness (0.071) (0.087) (0.075) (0.091) (0.079) (0.094) (0.083) (0.098) (d) Install the flange. D03815

38 AX36 COMPONENT PARTS D INSTALL 2ND BRAKE CYLINDER ASSEMBLY, ONE WAY CLUTCH NO.1 AND REAR PLANETARY SUN GEAR ASSEMBLY (a) Install the 2nd brake cylinder assembly to the transaxle case. (b) Install the snap ring and measure the inside diameter. Inside diameter: More than 167 mm (6.57 in.) Because the taper snap ring has the positioning direction, check it when installing. When the diameter does not satisfy the specified value, replace the snap ring with new one. (c) Install the oneway clutch outer race sleeve to the 2nd brake cylinder assembly. Check the positioning direction of the outer sleeve. D03589 (d) Install the inner race to the oneway clutch. Check the direction of the inner race. D03909 (e) Check the rotating direction of oneway clutch for the lock or free operation, as shown in illustration. D03920

39 COMPONENT PARTS AX37 (f) Install the oneway clutch No.1 and bearing to the one way clutch outer race sleeve. Bearing diameter: mm (in.) D03588 Inside Outside Bearing 53.6 (2.110) 69.6 (2.740) Install the thrust bearing properly so that the black race will be risible. (g) Coat the thrust washer No.1 with petroleum jelly install it onto the rear planetary sun gear. D03908 (h) Coat the bearing with petroleum jelly and install it onto the rear planetary sun gear. Bearing diameter: mm (in.) Inside Outside Bearing 33.7 (1.327) 48.2 (1.898) D03791 (i) Install the rear planetary sun gear assembly to the rear planetary gear. D INSPECT DISC AND FLANGE OF 2ND BRAKE Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. D04083

40 AX38 COMPONENT PARTS 14. INSTALL 2ND BRAKE (a) Install the 4 discs and 4 plates to the transaxle case. (b) Temporarily install the snap ring. D03621 D03622 (c) Using vernier calipers, measure the distance between the disk surface and snap ring surface. (d) Select an appropriate flange so that the piston stroke will meet the specified value. Piston stroke: mm ( in.) HINT: Piston stroke = Clearance Flange thickness Snap ring thickness 1.6 mm (0.063 in.). Flange thickness: mm (in.) Mark Thickness Mark Thickness (0.118) (0.134) (0.122) (0.138) (0.126) (0.142) (0.130) (e) Temporarily remove the snap ring, attach the selected flange and restore the snap ring. Secure the snap ring so that its end gap is visible through the groove of the transaxle case. D INSTALL DIRECT CLUTCH ASSEMBLY (a) Install the bearing race to the direct clutch. Bearing race diameter: mm (in.) Inside Outside Bearing race 30.3 (1.193) 46.0 (1.811) D03802

41 COMPONENT PARTS AX39 (b) Install direct clutch assembly and thrust bearing to the rear planetary sun gear assembly. The disk in the direct clutch should completely mate with the hub attached outside the rear planetary sun gear. Otherwise, the rear cover can not be installed. D03586 B (c) (d) Clean the connected part of the transaxle case and rear cover. As shown in the illustration, place a straight edge on the direct clutch drum and measure the distance between the transaxle case and the straight edge using vernier calipers (Dimension B). D03624 Dimension (1) Dimension (2) D03922 (e) Measure the 2 places of the rear cover as shown in the illustration and calculate a dimension C using the following formula. HINT: Dimension C = Dimension (1) Dimension (2) (f) Calculate the end play value using the following formula. Select a thrust bearing which satisfies the end play value and install it. End play: mm ( in.) Make sure that the black race side is facing the rear cover. HINT: End play = Dimension C Dimension B Bearing thickness and diameter: mm ( in.) Thickness Inside Outside 3.55 (0.1397) 53.6 (2.110) 69.6 (2.740) 3.85 (0.1515) 53.6 (2.110) (2.763) 16. INSTALL 2 NEW APPLY GASKETS D03591

42 AX40 COMPONENT PARTS 17. INSTALL APPLY PIPE (a) Install the clamp to the apply pipe. Make sure to install the clamp to the apply pipe before installing the apply tube to the transaxle case. This prevents the apply pipe from being deformed or damaged. D03923 (b) Install the 2 apply pipe and a bolt to the transaxle case. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) Each pipe is securely inserted until it reaches the stopper. D INSTALL TRANSAXLE REAR COVER (a) Using and a press, install the bearing ( , ) Press fit depth: mm ( in.) Face the inscribed mark side of the bearing race up. Repeat the press fit and the measurement until the specified value above is obtained. (b) Apply liquid sealer to the 2 screws. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent. (c) Install the transaxle rear cover plate with the 2 screws. Torque: 7.5 N m (76 kgf cm, 66 in. lbf) D09193 (d) Coat the 2 oil seal rings with ATF, install them to the transaxle rear cover. D03584

43 COMPONENT PARTS AX41 Seal Bend Width 1.2 mm (0.047 in.) D10707 D10706 (e) (f) (g) (h) (i) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle rear cover or the transaxle case. Apply FIPG to the rear cover. FIPG: Part No , THREE BOND 1281 or equivalent. Coat a needle roller bearing with ATF. Apply liquid sealer to the A bolt threads. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent. Install the 11 bolts. Torque: Bolt A: 18.6 N m (190 kgf cm, 14 in. lbf) Other bolt: 24.5 N m (250 kgf cm, 18 ft lbf) 19. INSPECT DISC AND FLANGE OF U/D BRAKE Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. D INSTALL U/D BRAKE (a) Install the 4 discs and 4 plates to the transaxle case. (b) Using a screwdriver, install the snap ring. D03582

44 AX42 COMPONENT PARTS (c) Using a dial indicator, measure the U/D brake piston stroke while applying and releasing compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi). Piston stroke: mm ( in.) HINT: Select an appropriate flange from the table below so that it will meet the specified value. Flange thickness: mm (in.) D03626 (d) Mark Thickness Mark Thickness (0.118) (0.134) (0.126) Temporarily remove the snap ring and attach the flange. Restore the snap ring. 21. INSTALL ONEWAY CLUTCH NO.2 (a) Install the outer race retainer to the oneway clutch No.2. D03907 Free (b) Install the U/D clutch assembly to the oneway clutch. Rotate the U/D clutch assembly to check the rotating direction for the lock or free operation. D INSTALL ONEWAY CLUTCH NO.2 (a) Install the oneway clutch No.2 to the transaxle case. Make sure that the mark on the oneway clutch outer race is visible. D03627

45 COMPONENT PARTS AX43 (b) Using a screwdriver, install the snap ring to the transaxle case. D INSTALL U/D CLUTCH ASSEMBLY (a) Coat the bearing and bearing race with petroleum jelly and install it onto the U/D clutch. Race diameter: mm (in.) D03580 (b) Inside Outside Bearing (1.4854) 58.0 (2.283) Race 29.9 (1.177) 55.5 (2.185) Install the U/D clutch assembly to the transaxle case. 24. INSTALL U/D PLANETARY GEAR ASSEMBLY AND DIFFERENTIAL ASSEMBLY (a) Install the pawl pin and spring to the parking lock pawl. D09691 (b) Temporarily install the parking lock pawl, shaft and spring to the transaxle case, as shown in the illustration. D09692 (c) Install the U/D planetary gear assembly to the transaxle case. Engage all the discs of U/D clutch and hub spline of the U/D planetary gear assembly firmly and assemble them securely. D03579

46 AX44 COMPONENT PARTS (d) Install the parking lock pawl shaft. D09693 (e) Install the pawl shaft with the bolt. Torque: 9.8 N m (100 kgf cm, 7 ft lbf) D03576 D (f) Using a straight edge and vernier calipers as shown in the illustration, measure the gap between the top of the differential drive pinion in the U/D planetary gear and contact surface of the transaxle case and housing (Dimension D). Note down the dimension D as it is necessary for the following process. D03875 Dimension (1) Dimension (2) (g) As shown in the illustration, measure the 2 places of the transaxle housing. Calculate the dimension E using the formula. Note down the dimension E as it is necessary for the following process. HINT: Dimension E = Dimension (1) Dimension (2) D INSTALL MULTIPLE DISC CLUTCH HUB (a) Install the bearing race to the transaxle while checking its direction. Bearing race diameter: mm (in.) Inside Outside Bearing race 34.5 (1.358) 48.5 (1.909) D03928

47 COMPONENT PARTS AX45 (b) Coat the thrust bearing and race with petroleum jelly and install them onto the multiple disc clutch hub. Thrust bearing and race diameter: mm (in.) Inside Outside Bearing 36.3 (1.429) 52.2 (2.055) D03628 (c) Install the bearing to the multiple clutch hub. Bearing diameter: mm (in.) Inside Outside Bearing 23.5 (0.925) 44.0 (1.732) (d) Install the forward clutch hub to the transaxle case. D03929 (e) Install the thrust bearing to the forward clutch. Bearing diameter: mm (in.) Inside Outside Bearing (1.3327) 52.2 (2.055) Install the thrust bearing properly so that the black race will be visible. D03820 (f) Install the forward clutch to the multiple clutch hub. Align the splines of all discs in the forward clutch with those of multiple clutch hub to assemble them securely. D INSTALL 2 NEW APPLY GASKET D03573

48 AX46 COMPONENT PARTS 27. INSTALL DIFFERENTIAL ASSEMBLY D03572 D INSTALL TRANSAXLE HOUSING (a) Calculate the end play value using the following formula and values of Dimension D and E that were measured when installing cylindrical roller bearing and U/D planetary gear. Select an appropriate U/D planetary gear thrust bearing race No.2 which satisfies the specified end play value, and install it. End play: mm ( in.) HINT: End play = Dimension E Dimension D thrust bearing thickness 3.28 mm ( in.) U/D gear thrust bearing race No.2 thickness Race thickness: mm (in.) E D Thickness Less than 7.64 (0.3008) 3.5 (0.138) 7.64 (0.3008) or more 3.8 (0.150) Bearing and bearing race diameter: mm (in.) Inside Outside Bearing 57.2 (2.252) (3.3449) Bearing race 56.4 (2.220) 83.0 (3.268) (b) Install the oil pump and 7 bolts to the transaxle case Torque: 22 N m (226 kgf cm, 16 ft lbf) D03569

49 COMPONENT PARTS AX47 (c) Coat on Oring of oil pump with ATF. D03629 (d) (e) Remove any packing material and be careful not to get oil on the contacting surfaces of the transaxle case or transaxle housing. Apply FIPG to the transaxle case. FIPG: Part No , THREE BOND 1281 or equivalent Seal Bend Width 1.2 mm (0.047 in.) D03630 C C C C A B A B A D03568 (f) Install the transaxle housing and 16 bolts to the transaxle case. Torque: Bolt A: 22 N m (226 kgf cm, 16 ft lbf) Bolt B and C: 29 N m (300 kgf cm, 22 ft lbf) HINT: Apply seal packing or equivalent to the bolt A. Seal packing: THREE BOND 2403 or equivalent Bolt length: Bolt A: 50 mm (1.969 in.) Bolt B: 50 mm (1.969 in.) Bolt C: 42 mm (1.654 in.) Because the bolt A is a seal bolt, apply the seal packing to new bolts and tighten them within 10 minutes after application. 29. INSPECT INPUT SHAFT END PLAY Using a dial indicator, measure the input shaft end play. End play: mm ( in.) 30. CHECK DIFFERENTIAL PRELOAD (See page AX108) D03567

50 AX48 COMPONENT PARTS 31. PLACE TRANSAXLE HOUSING D INSTALL MANUAL VALVE LEVER SHAFT (a) Coat a new oil seal with ATF. (b) Install the oil seal to the transaxle case. D03632 (c) Install the parking lock rod to the manual valve lever. D03905 (d) Install a new spacer and manual valve lever shaft to the transaxle case. D03565 (e) Using a pin punch and hammer, drive in a new pin. D03564

51 COMPONENT PARTS AX49 (f) (g) (h) Turn the spacer and the lever shaft to alight the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft. Using a pin punch, stake the spacer through the small hole. Check that the spacer does not turn. D03930 (i) Using needlenose pliers, install the return spring. D03559 (j) Install the parking lock pawl bracket with the 2 bolts. Torque: 20 N m (205 kgf cm, 15 ft lbf) Bolt length: 25 mm (0.984 in.) D03561 A B D03560 (k) Install the manual detent spring with the 2 bolts. Make sure to install the manual detent spring and cover in this order. Torque: Bolt A: 20 N m (205 kgf cm, 15 ft lbf) Bolt B: 12 N m (120 kgf cm, 9 ft lbf) Bolt length: Bolt A: 27 mm (1.063 in.) Bolt B: 16 mm (0.630 in.)

52 AX50 COMPONENT PARTS 33. INSTALL ACCUMULATOR PISTONS AND SPRINGS (a) Coat new 4 Orings with ATF and install them to the pistons. (b) Coat the 4 springs and 3 accumulator pistons with ATF, install them to the holes. Accumulator spring: C 1 C 3 B 3 Spring Free length Outer diameter mm (in.) B 3 Inner (2.3716) / 15.9 (0.626) Outer (2.8587) / 16.7 (0.657) C (3.4118) / 19.2 (0.756) C (3.5642) / 18.5 (0.728) Color Green Blue Yellow Red D INSTALL CHECK BALL BODY AND SPRING D INSTALL TRANSAXLE SOLENOID WIRE (a) Coat a new Oring with ATF, install it to the transaxle solenoid wire. D03636 (b) Install the solenoid wire retaining bolt Torque: 5.4 N m (55 kgf cm, 48 in. lbf) D03547

53 COMPONENT PARTS AX INSTALL APPLY GASKET (a) Coat 3 apply gaskets with ATF and install them to the transaxle case. D10705 C A C B A A B C B D INSTALL VALVE BODY ASSEMBLY (a) Align the groove of the manual valve with the pin of lever. (b) Install the 17 bolts. Torque: 11 N m (110 kgf cm, 8 ft lbf) Push the valve body against the accumulator piston spring and the check ball body to install it. Tighten those bolts marked by in the illustration first temporarily because they are positioning bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 25 mm (0.984 in.) Bolt B: 41 mm (1.614 in.) Bolt C: 45 mm (1.771 in.) 38. INSTALL OIL STRAINER (a) Coat new gasket with ATF, install it to the oil strainer. D09180 (b) Install the oil strainer and 3 bolts to the valve body. Torque: 11 N m (110 kgf cm, 8 ft lbf) D09179

54 AX52 COMPONENT PARTS (c) (d) Connect the 5 solenoid connectors. Install the ATF temperature sensor, clamp and bolt. Torque: 6.6 N m (67 kgf cm, 58 in. lbf) D INSTALL OIL PAN (a) Install the 3 magnets in the oil pan. (b) Apply seal packing or equivalent to the 18 bolts. Seal packing: THREE BOND 2430 or equivalent D10708 (c) Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.8 N m (80 kgf cm, 69 in. lbf) Because the bolts should be seal bolts, apply seal packing to new bolts and tighten them within 10 minutes after application. D INSTALL SPEED SENSOR (a) Coat 2 new Orings with ATF, install it to the 2 sensors. (b) Install the 2 sensors with the 2 bolts to the transaxle case. Torque: 11 N m (110 kgf cm, 8 in. lbf) D INSTALL UNION AND ELBOW (a) Coat 2 new Orings with ATF, install them to the union and elbow. (b) Install the union and elbow to the transaxle case. Torque: 27 N m (276 kgf cm, 20 ft lbf) D03805

55 COMPONENT PARTS AX INSTALL TRANSAXLE CASE PLUG NO.1 (a) Coat a new Oring with ATF, install it to the transaxle case plug No.1. (b) Install the transaxle case plug No.1 to the transaxle case. Torque: 7.4 N m (75 kgf cm, 65 in. lbf) D INSTALL NEUTRAL START SWITCH (a) Install the neutral start switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts. (b) Install a new nut stopper and nut. Torque: 6.9 N m (70 kgf cm, 61 in. lbf) D09639 (c) Temporarily install control shaft lever. D09640 (d) (e) Turn the lever counterclockwise until it stops, them turn it clockwise 2 notches. Remove the control shaft lever. D09641 (f) (g) Align the groove with neutral basic line. Tighten the 2 bolts. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) D09642

56 AX54 COMPONENT PARTS (h) Using a screwdriver, stake the nut with the nut stopper. D09643 (i) Install control shaft lever, washer and nut. Torque: 12.7 N m (130 kgf cm, 9 ft lbf) D09644 Seal Bend Width 1.2 mm (0.047 in.) D INSTALL TRANSFER ASSEMBLY (a) Remove any FIPG material and be careful not to get oil on the contacting surfaces of the transaxle case or transfer assembly. (b) Coat new gasket with petroleum jelly and install it to the transfer assembly. (c) Apply FIPG to the transfer assembly. FIPG: Part No , THREE BOND 1281 or equivalent (d) Install the intermediate shaft to the transfer assembly. D03540 D03082 (e) Install the transfer assembly, 2 bolts and 6 nuts to the transaxle case. Torque: 69 N m (700 kgf cm, 51 ft lbf) Push the transfer straight up and install it to the transaxle. Pull up the transfer case by inserting your fingers into the hole on both sides may cause damage to the oil seal lip. Be careful not to damage it.

57 OIL PUMP AX55 OIL PUMP COMPONENTS AX0AK05 Stator Shaft 9.8 (100, 7) Oil Pump Drive Gear x11 Oil Pump Body Oring Oil Seal Ring Oil Seal Oil Pump Driven Gear N m (kgf cm, ft lbf) : Specified torque Nonreusable part Apply petroleum jelly D09204

58 AX56 OIL PUMP AX0AL05 DISASSEMBLY 1. CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. Be careful not to damage the oil seal lip. D REMOVE 2 OIL SEAL RINGS D REMOVE STATOR SHAFT Using a torx socket T30, remove the 11 bolts and stator shaft. Keep the gears in assembling order. D REMOVE OIL PUMP DRIVE GEAR AND DRIVEN GEAR D REMOVE OIL SEAL (a) Mount oil pump in a soft jaw vise. (b) Using, remove oil seal from the oil pump body D03647

59 D03652 D09208 OIL PUMP AX57 AX0AM05 INSPECTION 1. CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: mm ( in.) Maximum body clearance: 0.17mm ( in.) If the body clearance is greater than the maximum, replace the oil pump body subassembly. 2. CHECK TIP CLEARANCE OF DRIVEN GEAR Measure the tip clearance between the driven gear teeth and the drive gear teeth. Standard tip clearance: mm ( in.) Maximum tip clearance: 0.30 mm ( in.) If the tip clearance is greater than the maximum, replace the oil pump body subassembly. 3. CHECK SIDE CLEARANCE OF BOTH GEAR Using a steel straight edge and feeler gauge, measure the side clearance of both gears. Standard side clearance: mm ( in.) Maximum side clearance: 0.05 mm ( in.) D03645 D CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing. Standard inside diameter: mm ( in.) Maximum inside diameter: mm ( in.) If the inside diameter is greater than the maximum, replace the oil pump body subassembly. D CHECK STATOR SHAFT BUSHING Using a dial indicator, measure the inside diameter of the stator shaft bushings. Standard inside diameter: mm ( in.) Maximum inside diameter: ( in.) If the inside diameter is greater than the maximum, replace the stator shaft.

60 AX58 D03654 OIL PUMP REASSEMBLY AX0AN05 1. INSTALL OIL SEAL (a) Using and a hammer, install a new oil seal from oil pump ( ) HINT: The seal end should be flat with the outer edge of the oil pump. (b) Coat the lip of oil seal with petroleum jelly. 2. INSTALL OIL PUMP DRIVE GEAR AND DRIVEN GEAR D INSTALL STATOR SHAFT (a) Align the stator shaft with each bolt hole. (b) Using a torx socket T30, install the 11 bolts. Torque: 9.8 N m (100 kgf cm, 7 in. lbf) D INSTALL 2 OIL SEAL RINGS Do not expand the ring ends excessively. D CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. Be careful not to damage the oil seal lip. D03649

61 DIRECT CLUTCH AX59 DIRECT CLUTCH COMPONENTS AX0AO05 Plate Flange Disc Direct Clutch Piston Snap Ring Clutch Balancer Direct Clutch Drum Snap Ring Piston Return Spring D03673

62 AX60 D03877 DIRECT CLUTCH DISASSEMBLY AX0AP03 1. CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch and needle roller bearing on the transaxle rear cover. (b) Using a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi). Piston stroke: mm ( in.) If the stroke is nonstandard, inspect the discs, plates and flange. 2. REMOVE SNAP RING Using a screwdriver, remove the snap ring from the direct clutch drum. D REMOVE FLANGE, DISC AND PLATE Remove the flange, 4 discs and 4 plates from the direct clutch drum. D03676

63 DIRECT CLUTCH AX61 D REMOVE PISTON RETURN SPRING (a) Place on the clutch balancer and compress the springs with a press (b) Using a snap ring expander, remove the snap ring from the direct clutch drum. Stop the press when the spring sheet is lowered to the place 1 2 mm ( in.) from the snap ring groove, preventing the spring sheet from the deforming. Do not expand the snap ring excessively. (c) Remove the clutch balancer and piston return spring from the direct clutch drum. D REMOVE DIRECT CLUTCH PISTON (a) Install direct clutch on the transaxle rear cover. (b) Holding the direct clutch piston with your hand, apply compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi) to the transaxle rear cover to remove the direct clutch piston. D03679

64 AX62 D04079 DIRECT CLUTCH AX0AQ04 INSPECTION 1. INSPECT DISC AND FLANGE Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs. Before assembling new discs, soak them in ATF for at least 15 minutes. 2. CHECK DIRECT CLUTCH RETURN SPRING Using a vernier calipers, measure the free length of the spring together with the spring seat. Standard free length: mm ( in.) D03830

65 DIRECT CLUTCH AX63 AX0AR03 REASSEMBLY 1. INSTALL DIRECT CLUTCH PISTON Coat the direct clutch piston with ATF, install it to the direct clutch drum. Be careful not to damage the lip seal of direct clutch piston. D INSTALL PISTON RETURN SPRING (a) Install the piston return spring and clutch balancer to the direct clutch drum. Be careful not to damage the lip seal of direct clutch balancer. D03678 D03677 (b) Place, on the clutch balancer and compress the piston return spring with a press (c) Using a snap ring expander, install the snap ring to the direct clutch drum. Be sure the end gap of the snap ring is not aligned with the clutch balancer claw. Stop the press when the spring sheet is lowered to the place 1 2 mm ( in.) from the snap ring groove, preventing the spring sheet from the deforming. Do not expand the snap ring excessively. 3. INSTALL PLATE, DISC AND FLANGE (a) Install the 4 plates, 4 discs and flange. Install in order: P=Plate, D=Disc, F=Flange P D P D P D P D F D03676

66 AX64 DIRECT CLUTCH (b) (c) Using a screwdriver, install the snap ring. Check that the end gap of the snap ring is not aligned with one of the cutouts. D03675 D CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the transaxle rear cover. (b) Using and a dial indicator, measure the direct clutch piston stroke while applying and releasing compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi). Piston stroke: mm ( in.) If the piston stroke is less than the limit of piston stroke, parts may have been assembled incorrectly, so check and reassemble again. If the stroke is nonstandard, select another flange. HINT: There are 6 flanges in different thickness. Flange Thickness: mm (in.) No. Thickness No. Thickness (0.118) (0.130) (0.122) (0.134) (0.126) (0.138) 5. CHECK DISK ROTATE Check that the disc rotates when rotating the disk after inserting the rear planetary sun gear. Do not place the rear planetary sun gear in a vise. D03682

67 FORWARD CLUTCH COMPONENTS FORWARD CLUTCH AX65 AX0AS05 Piston Return Spring Oring Forward Clutch Drum Forward Clutch Piston Snap Ring Thrust Bearing Flange Snap Ring Plate Disc Thrust Bearing Multiple Disc Clutch Hub Nonreusable part D03656

68 AX66 D03659 FORWARD CLUTCH DISASSEMBLY AX0AT03 1. CHECK PISTON STROKE OF FORWARD CLUTCH (a) Install the forward clutch on the oil pump. Be careful not to damage the oil seal ring of oil pump. (b) Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kpa, 4.0 kgf/cm 2, 57 psi). Piston stroke: mm ( in.) If the clearance is nonstandard, inspect the discs, plates flange. HINT: As the opening is big, cover it with a shop rug as well as an compressed air th prevent the air from discharging. 2. REMOVE FLANGE, PLATE AND DISC (a) Using a screwdriver, remove the snap ring from the forward clutch drum. D03660 (b) Remove the flange, 6 discs and 6 plates. D REMOVE PISTON RETURN SPRING (a) Place on the spring retainer and compress the return spring with a press ( ) (b) Using a snap ring expander, remove the snap ring. D03662

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