For 1990-2009 cars

#### Special Tools

• | DT 46451 (DW240-020) Brake Clutch Spring Compressor

• | DT 46454 (DW240-050) Overdrive Brake Adapter

• | DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut

• | DT 46456 (DW240-060-02) Brake Spring Compressor Plate

• | DT 46457 DW240-070) 1st/Reverse Brake Adapter

• | DT 46458 2nd Brake Adapter

• | DT 46460 (DW240-100) Counter Drive Gear Installation Adapter

• | DT 46461 (DW240-130) Differential Preload Adapter

• | DT 46462 (DW240-140) Transaxle Housing Side Bearing Outer Race Adapter

• | DT 46464 (DW240-160) Transaxle Case Outer Tapered Roller Bearing Race Adapter

• | DT 46465 Adapter Handle

• | DT 46471 (DW260-031-01) Transaxle Housing Oil Seal Installer

• | DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket

• | DT 47521 (DW 260-031-02) Transaxle Case Oil Seal Installer

### Assembly Procedure

1. Install 4 new O-rings to the 4 screw plugs.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the 4 screw plugs with the O-rings to the transaxle rear cover.

Tighten
Tighten the screw plugs to 7.4 N·m (65 lb in).

3. Install the 2 seal rings to the transaxle rear cover.
4. Using the vernier calipers, measure the free length of the overdrive (O/D) brake piston return spring together with the spring seat.

Specification
The standard free length is 18.99 mm (0.7476 in).

5. Coat 2 new O-rings (1) with automatic transaxle fluid (ATF), install them to the O/D brake piston.

Important: Be careful not to damage the O-rings of the O/D brake piston.

6. Coat the O/D brake piston with ATF, install it to the transaxle rear cover.

Notice: In order to prevent damage to the brake piston, do not depress the brake piston lower than 1-2 mm (0.039-0.078 in) beyond the snap ring groove.

7. Using the DT 46451 (1), DT 46454 (2) and a driver, install the O/D brake return spring and snap ring to the transaxle rear cover.
8. Using the DT 46462 (2), DT 46465 (1), install a new side bearing outer race into the transaxle housing.
9. Using the DT 46471 (1) and a hammer, drive in a new transaxle housing oil seal.

Specification
The oil seal in depth is 3.1 mm (0.122 in).

Important: Press-fit the outer tapered roller bearing race until it contacts the transaxle housing.

10. Install a new outer tapered roller bearing race into the transaxle housing.
11. Install the transaxle lube apply pipe and differential gear lube apply pipe to the transaxle housing.
12. Install the No. 1 transaxle apply pipe clamp to the transaxle housing with the bolt.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

13. Install the oil reservoir lock plate to the transaxle housing with the 3 bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

Important: First install a shim of the same thickness as before.

14. Install the shim to the transaxle case.
15. Install a new bearing outer race into the transaxle case.
16. Using the DT 47521 (1) and a hammer, drive in a new transaxle case oil seal.

Specifications
The oil seal in depth is 4.3 mm (0.169 in).

Important: First install a shim of the same thickness as before.

17. Install the shim to the transaxle case.

Important: Press-fit the shim until it contacts the transaxle case.

18. Using the DT 46464 (2) and DT 46465 (1), press in a new outer tapered roller bearing race into the transaxle case.
19. Install the No. 1 transaxle case plate to the transaxle case with the bolt.

Tighten
Tighten the bolt to 9.8 N·m (87 lb in).

20. Install the differential gear to the transaxle case.
21. Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily.
22. Tighten 8 or 9 bolts out of the 16 bolts of the transaxle housing completely.

Tighten
Tighten the bolt to 29 N·m (22 lb ft).

23. Using the DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.

Important: Note down the measured valve.

24. Using the DT 46461 and a small torque wrench, measure the preload of the differential gear.
25. Remove the transaxle housing and install the counter driven gear.
26. Install the transaxle housing and tighten the 16 bolts of the transaxle housing temporarily.
27. Tighten the bolts of the transaxle housing in the same manner as in step 22.

Tighten
Tighten the bolts to 29 N·m (22 lb in).

28. Using a DT 46461 , turn the differential gear assembly right and left 2 or 3 times to allow the bearing to settle.
29. Using a DT 46461 and a small torque wrench, measure the preload of the differential gear. From this valve deduct the valve measured in step 24. This is the preload of the counter driven gear.

Specification

• | The preload for a new bearing is 0.33-0.76 N·m (3.21-6.77 lb in).

• | The preload for a used bearing is 0.17-0.38 N·m (1.48-3.39 lb in).

Important: When the preload is larger than the specification, select a thinner adjuster shim. When the preload is smaller than specification, select a thicker adjuster shim.

If the preload of the counter driven gear does not satisfy the specification, select the adjuster shim from the table below and re-measure the valve. Until the valve is within the specification, repeat the procedure.
30. Using the vernier calipers, measure the free length of the 1st and reverse brake piston return spring together with the spring seat.

Specification
The standard free length is 18.053 mm (0.71075 in).

Important: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

Important: Before assembling the new discs, soak them in ATF for at least 15 minutes.

31. Check to see if the sliding surface of the disc, plate and the flange of the 1st and reverse brake are worn or burnt. Replace them, if necessary.
32. Coat 2 new O-rings (1) with ATF, install them to the 1st and reverse piston.

Important: Be careful not to damage the O-rings of the 1st and reverse brake piston.

33. Install the 1st and reverse brake piston to the transaxle case.
34. Install the return spring to the transaxle case.
35. Install the 4 plates, 4 discs and flange.
36. Install in order: 2-1-2-1-2-1-2-1-3, 3=Plate, 1=Disc, 2=Flange.

Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.

37. Using the DT 46457 (2) and DT 46455 (1) install the snap ring.

Important: If the piston stroke is non-standard, inspect the discs, plates and flange. The piston stroke is 0.6-1.3 mm (0.024-0.051 in).

38. Using a dial indicator, measure the 1st and reverse brake piston stroke while applying and releasing 392-785 kPa (57-114 psi) of compressed air through port (1).

Important: Be careful not to apply excessive force to the transaxle case.

39. Using the DT 46460 (3), DT 46455 (2) and DT 46456 (1), install the counter drive gear.
40. Coat a new oil seal with ATF.
41. Install the oil seal to the transaxle case.

Specification
The oil seal in depth (a) is 0.75-1.25 mm (0.3802-0.3998 in).

42. Install the parking lock rod to the manual valve lever.
43. Install a new spacer to the manual valve lever.
44. Install the manual valve lever shaft and manual valve lever.
45. Using a pin punch and hammer, drive in a new pin.
46. Turn the spacer and the lever shaft to align the small hole for locating the staking position in the spacer with the staking position mark on the lever shaft.
47. Using a pin punch, stake the spacer through the small hole.
48. Check that the spacer does not turn.
49. Install the manual detent spring with the bolt.

Tighten
Tighten the bolts to 9.8 N·m (87 lb in).

50. Install the parking lock shaft, torsion spring and parking lock pawl.
51. Check that the edge of the torsion spring fits into the groove securely.
52. Install the parking lock pawl bracket with the 2 bolts.

Tighten
Tighten the bolts to 7.4 N·m (65 lb in).

53. Using the DT 46460 (2) and the DT 46455 (1), install the planetary ring gear.
54. Before installing the planetary ring gear, be sure to replace the planetary ring flange of the planetary ring gear with a new one.
55. Fix the counter drive gear with the parking lock pawl.
56. Using the DT 46472 (1), install a new nut.

Tighten
Tighten the nut to 9.8 N·m (87 lb in).

57. Using a small torque wrench, while turning to counter drive gear 100 turn per minute and measure the preload.

Tighten
Tighten the nut to 29 N·m (22 lb ft) or less.

Specification
When the preload is smaller than the specification, tighten the nut more and adjust the preload to 0.05-0.35 N·m (0.43-3.12 lb in).

58. Stake the nut.
59. Install the planetary gear to the transaxle case.
60. Coat the planetary carrier thrust washer with petroleum jelly and install it onto the planetary gear.
61. Install the No. 2 one-way clutch to the transaxle case.
62. Check that the planetary gear turns freely counterclockwise and locks clockwise.
63. Install the anti-rattle clip in the place shown in the illustration (the space between the No. 2 one-way clutch outer race and transaxle case), push the anti-rattle clip in until you hear the click.
64. Using vernier calipers, measure the free length of the 2nd brake piston return spring together with the spring seat.

Specification
The standard free length is 15.85 mm (0.6240 in).

Important: If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

Important: Before assembling the new discs, soak them in ATF for at least 15 minutes.

65. Check to see if the sliding surface of the disc, plate and flange of 2nd brake are worn or burnt. Replace them, if necessary.

Important: Make sure the snap ring is installed in the groove of the transaxle case correctly.

66. Install the flange, 2 discs and 2 plates.
67. Install in this order 2-1-3-1-3, 1=Disc, 3=Plate, 2=Flange.
68. Install the 2nd brake return spring.
69. Coat 2 new O-rings (1) with ATF, install them to the 2nd brake piston.

Important: Be careful not to damage the O-rings.

70. Install the 2nd brake piston into the 2nd brake clutch cylinder.
71. Install the 2nd brake clutch cylinder to the transaxle case.
72. Using the DT 46455 (1) and DT 46458 (2), compress the 2nd brake piston return spring.

Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.

73. Using the screwdriver, install the snap ring.
74. Coat the thrust bearing race with petroleum jelly and install it onto the front planetary sun gear.

Specification

• | The race inner diameter is 19.3 mm (0.760 in).

• | The race outer diameter is 29.0 mm (1.142 in).

75. Install the front planetary sun gear to the transaxle case.
76. Install the thrust washer and one-way clutch assembly to the rear planetary sun gear.

Important: Check the direction of the bearing.

77. Coat the thrust bearing race with petroleum jelly and install it onto the rear planetary sun gear and one-way clutch assembly.

Specification

• | The bearing inner diameter 42.5 mm (1.673 in).

• | The bearing outer diameter 57.5 mm (2.264 in).

78. Install the rear planetary sun gear and one-way clutch assembly to the transaxle case.

Important: Check the direction of the race.

79. Coat the thrust bearing race with petroleum jelly and install it onto the transaxle case.

Specification

• | The race inner diameter is 34.95 mm (1.3760 in).

• | The race outer diameter is 45.50 mm (1.7913 in).

Important: Check the direction of the bearing.

80. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward clutch hub.

Specification

• | The bearing inner diameter is 33.3 mm (1.311 in).

• | The bearing outer diameter is 46.5 mm (1.831 in).

81. Install the forward clutch hub to the transaxle case.
82. Coat the thrust bearing race with petroleum jelly and install it onto the forward clutch hub.

Specification

• | The race inner diameter is 19.3 mm (1.760 in).

• | The race outer diameter is 30.6 mm (1.205 in).

83. Install the thrust bearing race and thrust needle roller bearing to the forward and reverse clutch assembly.

Specification

• | The race inner diameter is 18.1 mm (0.713 in).

• | The race outer diameter is 28.2 mm (1.110 in).

• | The bearing inner diameter is 18.1 mm (0.713 in).

• | The bearing outer diameter is 29.6 mm (1.165 in).

84. Install the forward and reverse clutch assembly to the transaxle case.

Important: If the lining of the disc is peeling off or discolored, or even if the part of the printed mark is defaced, replace all discs.

Important: Before assembling new discs, soak them in ATF for at least 15 minutes.

85. Check to see if the sliding surface of the disc, plate and flange of 2nd coast and O/D brake are worn or burnt. Replace them, if necessary.

Important: Make sure that the snap ring is installed in the groove of the transaxle case correctly.

86. Using a screwdriver, install the snap ring to the transaxle case.
87. Install the flange, 2 discs and 2 plates to the transaxle case.
88. Install in the following order: 3-2-3-2-1, 3=Plate, 2=-Disc, 1=Flange.
89. Clean the connected part the transaxle case and transaxle rear cover.
90. As shown in the illustration, place a straight edge on the transaxle case and measure the distance between the 2nd coast and O/D brake flange and straight edge using vernier calipers (a).
91. As shown in the illustration, place a straight edge on the O/D brake piston and measure the distance between the transaxle rear cover and the straight edge using vernier calipers (a).
92. Calculate the piston stroke value using the following formula. Select a flange which satisfies the piston stroke value and install it.
93. Install 4 new apply gaskets to the transaxle rear cover.
94. Coat the thrust needle roller bearing with petroleum jelly and install it onto the forward and reverse clutch assembly.

Specification

• | The bearing inner diameter is 43.2 mm (1.701 in).

• | The bearing outer diameter is 62.0 mm (2.441 in).

95. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle rear cover or transaxle case.
96. Apply formed in place gasket (FIPG) to the transaxle rear cover.

Specification
The FIPG three bond 1281, or equivalent, seal bend width is 1.2 mm (0.047 in).

97. Install the transaxle rear cover to the transaxle case with the 9 bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

98. Install the counter driven gear assembly to the transaxle case.
99. Install the differential gear assembly to the transaxle case.
100. Install the direct clutch hub to the transaxle case.
101. Install the thrust bearing race and thrust needle roller bearing to the transaxle case.

Specification

• | The race inner diameter is 20.5 mm (0.807 in).

• | The race outer diameter is 32.6 mm (1.283 in).

• | The bearing inner diameter is 17.8 mm (0.701 in).

• | The bearing outer diameter is 30.2 mm (1.189 in).

102. Install the clutch assembly to the transaxle case.
103. Install the new apply gasket.

Important: Check the direction of the bearing.

104. Install the thrust needle roller bearing to the transaxle case.
105. Place the oil pump through the input shaft, and align the bolt holes of the oil pump with the transaxle case.

Notice: Refer to Fastener Notice in the Preface section.

106. Install the 6 oil pump bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

Important: If the end play is not as specified, select and replace the thrust needle roller bearing.

107. Measure the end play in axial direction.

Specification

• | The end play is 0.3-0.9 mm (0.012-0.035 in).

• | The bearing inner diameter is 32.5 mm (1.280 in).

• | The bearing outer diameter is 48.5 mm (1.909 in).

• | The bearing thickness is 4.21 mm (0.1657 in).

• | The bearing inner diameter is 32.9 mm (1.295 in).

• | The bearing outer diameter is 48.5 mm (1.909 in).

• | The bearing thickness is 3.62 mm (0.1425 in).

108. Make sure that the input shaft rotates smoothly.
109. Remove any packing material. Do not get oil on the contacting surfaces of the transaxle housing or transaxle case.
110. Apply formed in place gasket (FIPG) to the transaxle housing.

Specification
FIPG: Three bond 1281 or equivalent, seal bend width is 1.2 mm (0.047 in).

111. Install the transaxle housing to the transaxle case with the 16 bolts.

Tighten
Tighten the bolts to 29 N·m (22 lb ft).

112. Apply seal packing or equivalent to the bolts.
113. Coat a new O-ring (1) with ATF, install it to the transaxle wire.
114. Install the transaxle wire to the transaxle case with the bolt.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

115. Coat new 6 O-rings with ATF and install them to the pistons (1, 2, 3).
116. Coat the 3 springs and 3 accumulator pistons with ATF, install them to the holes.
117. Coat a new apply gasket with ATF, install it to the transaxle case.
118. Coat a new brake drum gasket with ATF, install it to the transaxle case.
119. Install the spring and check valve.
120. Connect the manual valve control rod to the manual valve lever as shown in the illustration.

Important: When installing the valve body to the transaxle case, do not let each of the accumulator pistons incline. When installing the valve body to the transaxle case, do not hold the solenoids.

121. Install the valve body assembly to the transaxle case.

Tighten
Tighten the bolts to 11 N·m (97 lb in).

122. Connect the transaxle wire connector and harness to the valve body assembly.
123. Connect the 5 connectors.

123.1. | Lock-up control solenoid (5)

123.2. | Pressure control solenoid (1)

123.3. | No. 2 shift solenoid (2)

123.4. | No. 1 shift solenoid (3)

123.5. | Timing solenoid (4)

Important: Make sure that the transaxle wire does not come out from the oil pan installations surface.

124. Install the TFT sensor with clamp.
125. Install a new gasket to the oil strainer.
126. Install the oil strainer to the valve body with the 3 bolts.

Tighten
Tighten the bolts to 9.8 N·m (87 lb in).

127. Install the 2 magnets in the oil pan.
128. Install a new gasket to the oil pan and install them to the transaxle case with the 18 bolts.

Tighten
Tighten the bolts to 7 N·m (62 lb in).

129. Install the output shaft speed (OSS) sensor.

Tighten
Tighten the bolt to 7.4 N·m (65 lb in).

130. Install the No. 1 breather plug.
131. Install the input shaft speed (ISS) sensor with the bolt.

Tighten
Tighten the bolts to the 5.4 N·m (48 lb in).

132. Coat the new O-ring the ATF, install it to the screw plug.
133. Install the screw plug to the transaxle case.

Tighten
Tighten the bolts to 7.4 N·m (65 lb in).

134. Coat the 2 new O-rings with ATF, install them to the unions.
135. Install the 2 unions to the transaxle case.

Tighten
Tighten the unions to 25 N·m (18 lb ft).

136. Install the PNP switch to the manual valve lever shaft and temporarily install the 2 adjusting bolts.
137. Install a new lock washer and nuts.

Tighten
Tighten the nuts to 12 N·m (106 lb in).

138. Temporarily install the control lever.
139. Turn the lever counterclockwise until it stops, turn it clockwise 2 notches.
140. Remove the control lever.
141. Align the groove with the neutral basic line.
142. Tighten the 2 bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

143. Using a screwdriver, stake the nut with the lock washer.
144. Install the control lever, washer and nut.

Tighten
Tighten the nut to 12 N·m (106 lb in).

145. Install the torque converter (2) to the transaxle.
146. Measure the installation depth of the torque converter.

Specification
The standard value is 11.1 mm (0.44 in).

147. If the measured value is beyond the standard value, readjust the torque converter within the specified value.