Check if the contact surfaces of the 4 front clutch discs, 4 forward multiple disc clutch plates and forward clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the front clutch discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the front clutch discs.

·

Before installing new front clutch discs, soak them in ATF for at least 15 minutes.

Using a vernier caliper, measure the free length of the forward clutch return spring sub-assembly together with the spring seat.

Standard Free Length:

21.69 mm (0.854 in.)

If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.

Using a vernier caliper, measure the free length of the overdrive brake return spring sub-assembly together with the spring seat.

Standard Free Length:

17.88 mm (0.704 in.)

If the free length is shorter than the standard free length, replace the overdrive brake return spring sub-assembly.

Check if the contact surfaces of the 2 reverse clutch discs, 2 No. 3 clutch plates and reverse clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the reverse clutch discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the reverse clutch discs.

·

Before installing new reverse clutch discs, soak them in ATF for at least 15 minutes.

Check if the contact surfaces of the 3 direct clutch discs, 3 rear clutch flanges and direct clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the direct clutch discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the direct clutch discs.

·

Before installing new direct clutch discs, soak them in ATF for at least 15 minutes.

Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly together with the spring seat.

Standard Free Length:

38.5 mm (1.516 in.)

If the free length is shorter than the standard free length, replace the direct clutch return spring sub-assembly.

Shake the direct clutch pin and confirm that the check ball is not stuck.

Shake the direct clutch pin and confirm that the check ball is not stuck.

Check if the contact surfaces of the 2 2nd coast and overdrive brake discs, 2 No. 2 2nd coast and overdrive brake flanges and 2nd coast and overdrive brake flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the 2nd coast and overdrive brake discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the 2nd coast and overdrive brake discs.

·

Before installing new 2nd coast and overdrive brake discs, soak them in ATF for at least 15 minutes.

Check if the contact surfaces of the 3 2nd brake discs, 2 2nd brake plates and 2 2nd brake flanges are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the 2nd brake discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the 2nd brake discs.

·

Before installing new 2nd brake discs, soak them in ATF for at least 15 minutes.

Using a vernier caliper, measure the free length of the 2nd brake piston return spring sub-assembly including the spring seat.

Standard Free Length:

14.65 mm (0.577 in.)

If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.

Check if the contact surfaces of the 4 1st and reverse brake discs, 4 1st and reverse brake plates and 1st and reverse brake flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any of the 1st and reverse brake discs is peeled off or discolored, or even if part of the printed mark is damaged, replace all the 1st and reverse brake discs.

·

Before installing new 1st and reverse brake discs, soak them in ATF for at least 15 minutes.

Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly together with the spring seat.

Standard Free Length:

13.96 mm (0.550 in.)

If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

Using a dial indicator, measure the input shaft assembly end play.

End Play:

0.374 to 1.292 mm (0.0147 to 0.0509 in.)

If the end play is not as specified, replace the stator shaft thrust needle roller bearing and forward clutch hub thrust needle roller bearing.

Using a dial indicator, measure the intermediate shaft assembly end play.

End Play:

0.204 to 0.966 mm (0.00803 to 0.03803 in.)

If the end play is not as specified, replace the rear clutch drum thrust needle roller bearing with one of a different thickness.

HINT:

There are 2 bearings of different thicknesses.

Rear Clutch Drum Thrust Needle Roller Bearing:

Color	Thickness (mm (in.))
Brown	3.551 mm (0.140 in.)
Black	3.866 mm (0.152 in.)

2.542,0.854 2.854,1.01 0.313,0.156 10 false *a 1.427,0.198 1.594,0.354 0.167,0.156 10 true *b 1.417,1.365 1.583,1.521 0.167,0.156 10 true *c

*a	Hold
*b	Free
*c	Locks

While holding the rear planetary sun gear assembly by hand, turn the one-way clutch assembly and check that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

If the one-way clutch assembly does not operate as specified, replace it.

0.896,1.875 1.229,1.875 1.229,1.875 1.531,1.208 true 1.302,0.552 1.51,0.729 0.208,0.177 10 true *b 1.958,0.542 2.229,0.729 0.271,0.188 10 true *a 0.708,1.802 0.969,1.99 0.26,0.188 10 false *1

*1	Rear Planetary Gear Assembly
*a	Locks
*b	Free

Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.

If the No. 2 one-way clutch does not operate as specified, replace it.

1.656,0.875 2.615,0.229 true 2.656,0.125 3.115,0.323 0.458,0.198 10 false SST

Using SST and a dial indicator, measure the 1st and reverse brake clearance while pressing the 1st and reverse brake discs and 1st and reverse brake plates from the rear side.

SST

09350-36010  (09350-06110)

Pack Clearance:

0.806 to 1.206 mm (0.0317 to 0.0475 in.)

NOTICE:

If the clearance is not as specified, select an appropriate new 1st and reverse brake flange so that the clearance will be within the specified range.

HINT:

There are 4 1st and reverse brake flanges of different thicknesses.

1st and Reverse Brake Flange Thickness:

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
-	3.4 (0.134)	2	3.8 (0.150)
1	3.6 (0.142)	3	4.0 (0.157)

Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm², 57 to 114 psi).

Pack Clearance:

0.847 to 1.247 mm (0.0333 to 0.0491 in.)

NOTICE:

If the clearance is not as specified, select an appropriate new 2nd brake flange so that the clearance will be within the specified range.

HINT:

There are 4 2nd brake flanges of different thicknesses.

2nd Brake Flange Thickness:

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)

Install the intermediate shaft assembly and rear clutch drum thrust needle roller bearing to the rear transaxle cover assembly.

Install the intermediate shaft assembly and thrust needle roller bearing to the rear transaxle cover assembly.

0.156,0.323 0.271,0.469 0.115,0.146 10 false B

As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using a vernier caliper. (Dimension B)

2.906,0.813 3.031,0.969 0.125,0.156 10 false C

As shown in the illustration, place a straightedge on the 2nd coast and overdrive brake piston and measure the distance between the rear transaxle cover assembly and straightedge using a vernier caliper. (Dimension C)

Calculate the piston stroke value using the following formula.

Formula:

Dimension B - Dimension C

Pack Clearance:

2.091 to 2.491 mm (0.0823 to 0.0981 in.)

NOTICE:

If the clearance is not as specified, select an appropriate new 2nd coast and overdrive brake flange so that the clearance will be within the specified range.

HINT:

There are 4 2nd coast and overdrive brake flanges of different thicknesses.

2nd Coast and Overdrive Brake Flange Thickness:

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
4	4.0 (0.1575)	6	4.4 (0.1732)
5	4.2 (0.1654)	7	4.6 (0.1811)

Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Pack Clearance:

1.406 to 1.806 mm (0.0554 to 0.0711 in.)

NOTICE:

If the clearance is not as specified, select an appropriate new forward clutch flange so that the clearance will be within the specified range.

HINT:

There are 4 forward clutch flanges of different thicknesses.

Forward Clutch Flange Thickness:

Mark	Thickness (mm (in.))	Mark	Thickness (mm (in.))
-	3.0 (0.118)	2	3.4 (0.134)
1	3.2 (0.126)	3	3.6 (0.142)