Step 11 - 20

ASSEMBLY

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed Testing and Inspection.




11. Install low/reverse spring compressor into position.




12. Compress low/reverse piston and install snap ring (1).




13. Install rear carrier bearing cone (3) using Installer 6053 (1).




14. Install rear carrier assembly (1) to transaxle case.




15. Install output gear bearing cone using Installer 5052 (3).




16. OUTPUT GEAR BEARING ADJUSTMENT:
a. With output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place.
b. Using Holder 6259, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.).
c. Measure bearing end play. Attach Gear Checking Plate L-4432 (1) to the gear.
d. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
e. Using a dial indicator mounted to the transaxle case, measure output gear end play.
f. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
g. Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller L4407A.
h. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.









17. Install the output gear (3) and bearing assembly using Installer 6261 (2).




18. Install NEW output gear retaining bolt (2) and washer (3).




19. Using Holder 6259 (4), torque output gear (1) retaining bolt to 271 Nm (200 ft. lbs.).




20. Using an inch pound torque wrench (1), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs. If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.