Part 2

ASSEMBLY - Continued

25. Install tapered snap ring (with tapered side up) (2).










26. Set up dial indicator (1) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.). Set up indicator and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.

LOW/REVERSE REACTION PLATE CHART















27. Install 2/4 clutch pack (1, 2).










NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

28. Orient 2/4 clutch return spring to retainer (3).










29. Install 2/4 clutch retainer to transaxle (1, 2).










30. Using Compressing Tool (1), compress 2/4 clutch return spring just enough to install snap ring (3).
31. Install snap ring.










32. Set up dial indicator (1) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.). Set up indicator and record measurement in four places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.










NOTE: The number seven needle (1) bearing has three anti-reversal tabs and is common with the number five position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2).











33. Install rear sun gear (2) and number seven needle bearing (1).










34. Install front carrier/rear annulus assembly (2) and number six needle bearing (1).










35. Install front sun gear assembly (1) and number four thrust washer (2).










36. Select the thinnest number four thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to retain (3).





37. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (3). If view through input speed sensor hole is not as shown in the view, the input clutch assembly (2) is not seated properly.










38. Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper number four thrust plate.
39. Install pump and gasket to transmission. Install and torque bolts.










40. Set up input shaft for measurement with Indicator Set (3) and End Play Set (1,2).
41. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.13-0.64 mm (0.005 to 0.025 in.) For example, if end play reading is 0.055 in. select number four Thrust Plate which is 0.071-0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. which is within specifications.
42. Refer to the number four thrust plate chart NO. 4 THRUST PLATE CHART to select the proper number four thrust plate.

NO. 4 THRUST PLATE CHART















43. Install input clutch assembly (1).










44. Install number one caged needle bearing (1) note: tanged side out (2).

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






45. Install cooler bypass valve (1) with O-ring end towards rear of case.





46. Install oil pump gasket (1).





47. Install oil pump (2).
48. Install oil pump-to-case bolts (1) and tighten 30 Nm (265 in. lbs.).