Assembly Service Point

1. Install the O-ring to the plug.
   Fig 1: Plug O-ring

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2. Tighten the plug to the specified torque.

   Tightening torque: 

   23 ± 2 N.m (17 ± 1 ft-lb) 

   Fig 2: Transaxle Assembly Plug

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   CAUTION:

   • Do not re-use the O-ring.
   • Apply transmission fluid when installing the O-ring.
   Fig 3: Plug O-ring

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3. Install the O-ring to the plug.
4. Tighten the plug to the specified torque.

   Tightening torque: 

   7.5 ± 2.5 N.m (66 ± 22 in-lb) 

   Fig 4: Transaxle Assembly Plug

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   • Do not re-use the O-ring.
   • Apply transmission fluid when installing the O-ring.
5. Install the transmission fluid filter and the O-ring to the transaxle assembly.
   Fig 5: Installing Transmission Fluid Filter And O-Ring To Transaxle Assembly

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6. Install the fluid filter cover to the transaxle assembly, and then rotate it clockwise to secure it.
   Fig 6: Rotating Fluid Filter Cover To Transaxle Assembly

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7. Tighten the fluid filter cover mounting bolt to the specified torque.

   Tightening torque:

   7.0 ±0.4 N.m (62 ± 3 in-lb) 

   Fig 7: Installing Fluid Filter Cover Mounting Bolt

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   CAUTION:

   • Do not re-use the converter housing oil seal.
   • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
8. Apply the transmission fluid around the circumference of the converter housing oil seal. Then use the special tool MD998375 to install the converter housing oil seal so that the dimension (A) shown meets the standard value.

   Standard value (A): 1.3 ± 0.5 mm (0.05 ± 0.02 inch) 

   Fig 8: Converter Housing Oil Seal Dimension

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   CAUTION:

   • Do not re-use the O-ring.
   • Apply transmission fluid when installing the O-ring.
9. Install the O-ring to the input shaft.
   Fig 9: Input Shaft O-Ring

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   CAUTION:

   • Fit the torque converter fully into position by twisting it back and forth.
   • To install the torque converter, be careful not to scratch the bushing inside the sleeve.
10. Align (A) on the torque converter with the (B) on the drive sprocket at the transaxle assembly.
    Fig 10: Aligning Torque Converter With Drive Sprocket At Transaxle Assembly

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    CAUTION: Measure at two points or more to determine an average value.
11. The dimension (A) should meet the standard value.

    Standard value (A): approximately 12.2 mm (0.48 inch) 

    Fig 11: Checking Torque Converter Dimension

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12. Apply the transmission fluid to the terminal assembly mount on the transaxle assembly.
    Fig 12: Valve Body Assembly Hole

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    CAUTION: When the wire(s) on the valve body assembly are pinched, loose or twisted, correct them.
13. The wire (A) on the terminal assembly should not be trapped in the terminal assembly bracket (B).
    CAUTION:

    • To install the valve body assembly to the transaxle assembly, be careful not to scratch the O-ring seated in the connector on the valve body assembly.
    • Push in the valve body assembly so that it butts up tight to the case.
14. Install the valve body assembly to the transaxle assembly.
15. Tighten the two mounting bolts by hand.
    Fig 13: Terminal Assembly Wire

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    Length beneath the head mm (in)	87 (3.4)
    Quantity	2

16. Then tighten nine mounting bolts by hand.
    Fig 14: Valve Body Assembly Mounting Bolts (1 of 2)

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    Length beneath the head mm (in)	87 (3.4)
    Quantity	9

17. Tighten 11 bolts to the specified torque.

    Tightening torque: 

    7.9 ± 1.0 N.m (70 ± 8 in-lb) 

    Fig 15: Valve Body Assembly Mounting Bolts (2 of 2)

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    CAUTION:

    • To install the manual plate, use a flat-tipped screwdriver to counterhold the plate so that excessive torque is not applied to it.
    • Do not apply any fixture such as a screwdriver directly to the manual valve to protect it from deformation.
18. Install the manual plate and the spring washer, and tighten the mounting nuts to the specified torque.

    Tightening torque: 

    22 ± 0.4 N.m (16 ± 0.2 ft-lb) 

    Fig 16: Installing Manual Plate And Spring Washer

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    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
19. Install the O-ring to the fluid strainer.
    Fig 17: Fluid Strainer O-Ring

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    CAUTION: The fluid strainer should butt tight to the valve body.
20. Install the fluid strainer to the valve body assembly, and then tighten the mounting bolts to the specified torque.

    Length beneath the head mm (in)	12 (0.47)
    Quantity	3

    Tightening torque: 

    7.9 ± 1.0 N.m (70 ± 8 in-lb) 

    Fig 18: Fluid Strainer Mounting Bolts

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21. Install the magnet on the oil pan.
    Fig 19: Oil Pan Magnet

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    CAUTION: Do not re-use the oil pan gasket.
22. Install the oil pan and oil pan gasket on the transaxle assembly.
23. Tighten the front oil pan mounting bolts by hand.
    Fig 20: Installing Oil Pan And Oil Pan Gasket On Transaxle Assembly

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24. Tighten the oil pan mounting bolts to the specified torque in the order shown.

    Tightening torque: 

    5.9 ± 0.6 N.m (52 ± 5 in-lb) 

    Fig 21: Oil Pan Mounting Bolts Tightening Sequence

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    CAUTION:

    • Do not re-use the oil seal.
    • Apply transmission fluid to the outer circumference of the oil seal.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
25. Using the special tool MB990982, install the side oil seal on the transaxle assembly.

    Depth from the case edge: within - 1.8 ± 0.5 mm (0.07 ± 0.02 inch) (recessed). 

    Fig 22: Installing Side Oil Seal On Transaxle Assembly

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    CAUTION:

    • Do not re-use the oil seal.
    • Apply transmission fluid to the outer circumference of the oil seal.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
26. Using the special tool MB990982, install the side oil seal on the transaxle assembly.

    Depth from the case edge: within - 1.8 ± 0.5 mm (0.07 ± 0.02 inch) (recessed). 

    Fig 23: Installing Side Oil Seal On Transaxle Assembly

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    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • The O-ring should be seated fully into the groove on the transmission fluid cooler.
27. Install the O-ring on the transmission fluid cooler.
28. Install the transmission fluid cooler on the transaxle assembly, and tighten the mounting bolts to the specified torque.

    Tightening torque: 

    4.3 ± 0.5 N.m (38 ± 4 in-lb) 

    Fig 24: Installing O-Ring On Transmission Fluid Cooler

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    CAUTION: Do not re-use the transmission range switch.
29. Install the transmission range switch on the transaxle assembly as shown.
30. Install the transmission range switch on the transaxle assembly.
31. Tighten the transmission range switch mounting bolts by hand.
    Fig 25: Transmission Range Switch

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32. Install the manual control lever on the manual shaft.
33. Install the washer on the manual shaft, and tighten the mounting nut to the specified torque.

    Tightening torque: 

    17 ± 2 N.m (13 ± 1 ft-lb) 

34. Set the manual shaft at N position.
    Fig 26: Manual Control Lever

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35. Insert a 5 mm ( 0.2 inch) pin through the hole on the manual control lever down to the recess on the transmission range switch to align the transmission range switch.
    CAUTION: The pin should be engaged fully into the recess on the transmission range switch.
36. Tighten the transmission range switch mounting bolts to the specified torque.

    Tightening torque: 

    5.9 ± 1.0 N.m (52 ± 8 in-lb) 

    Fig 27: Inserting Pin Through Hole On Manual Control Lever

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37. Remove the pin.
    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
38. Install the O-ring on the output speed sensor.
    Fig 28: Output Speed Sensor O-Ring

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39. Install the output speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.

    Tightening torque: 

    5.9 ± 1.0 N.m (52 ± 8 in-lb) 

    Fig 29: Output Speed Sensor

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    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
40. Install the O-ring on the primary pulley speed sensor.
    Fig 30: Primary Pulley Speed Sensor O-Ring

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41. Install the primary pulley speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.

    Tightening torque: 

    5.9 ± 1.0 N.m (52 ± 8 in-lb) 

    Fig 31: Primary Pulley Speed Sensor

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    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
42. Install the O-ring on the secondary pulley speed sensor.
    Fig 32: Secondary Pulley Speed Sensor O-Ring

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43. Install the secondary pulley speed sensor on the transaxle assembly, and tighten the mounting bolt to the specified torque.

    Tightening torque: 

    5.9 ± 1.0 N.m (52 ± 8 in-lb) 

    Fig 33: Secondary Pulley Speed Sensor

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    CAUTION: Measure at two or more points to determine an average value.
44. The dimension (A) should meet the standard value.

    Standard value (A): approximately 12.2 mm (0.48 inch) 

45. Install the control cable bracket and breather hose on the transaxle assembly.
46. Install the harness bracket on the transaxle assembly.
    Fig 34: Checking Torque Converter Dimension

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    CAUTION:

    • Do not re-use the O-ring.
    • Apply transmission fluid when installing the O-ring.
    • Wipe off excessive fluid to avoid incorrect diagnosis of fluid leakage.
47. Install the oil filler tube and transmission fluid dipstick on the transaxle assembly.
    CAUTION: Do not re-use the drain plug gasket.
48. Install the drain plug and drain plug gasket on the transaxle assembly, and tighten to the specified torque.

Tightening torque: 

35 ± 4 N.m (26 ± 2 ft-lb) 

Fig 35: Installing Drain Plug And Drain Plug Gasket

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