1. Inspect pack clearance of reverse clutch

(A) install the intermediate shaft and needle roller bearing onto the transaxle rear cover.
(B) using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kpa, 4.0 Kgf/cm2, 57 psi).
Pack clearance: 0.60 To 0.82 Mm (0.02362 To 0.03228 In.)V
If the pack clearance is not as specified, inspect the discs, plates and flange.
2. Inspect pack clearance of direct clutch and overdrive clutch

(a) Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is not as specified, inspect the discs, plates and flange.
3. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC

(a) Check if the sliding surfaces of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
4. INSPECT OVERDRIVE DIRECT CLUTCH DISC

(a) Check if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
5. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft onto the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the clearance is not as specified, select another flange.
HINT: There are 7 flanges of different thickness.
Flange thickness: mm (in.)
7. INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
psi).
Clearance: 0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the clearance is not as specified, select another flange.
HINT: There are 7different thicknesses of flanges available
Flange thickness: mm (in.)

(b) Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.

NOTICE: Do not place the rear planetary sun gear in a vise.
Disassembly
ReassemblyTerminals of ECU
1. CHECK DRIVER SIDE J/B ASSEMBLY (MULTIPLEX NETWORK BODY ECU)
Disconnect the B6, 1C, 1K and 1L J/B connectors.
Measure the voltage and resistance according to
the value(s) in the table below.
HINT:
If the result is not as specified, there may be a
malfunction on the w ...
Installation
1. INSTALL TRANSFER ASSEMBLY
(a) Apply sealant 1281 to the transaxle assembly and
transfer assembly in continuous beaded from of 1.2
mm diameter as shown in the illustration.
NOTICE:
Wipe any grease off from the attaching
surfaces.
Install it within 10 minutes after applying the
se ...
Turn signal light switch
ON-VEHICLE INSPECTION
1. INSPECT TURN SIGNAL FLASHER CIRCUIT
Measure voltage between the terminals as shown in
the chart below.
Voltage
Connect the connector to turn the signal flasher and
turn the ignition switch ON, and inspect the wire
harness side connector from t ...