Part 1

ASSEMBLY

1. Install both output bearing cups using Installer 5050 (3) (Figure 1).

Figure 2 Install Piston Retainer Gasket

2. Install low/reverse piston retainer gasket (2) (Figure 2). Make sure gasket holes line up with case (1).

Figure 3 Install Piston Retainer

3. Install low/reverse piston retainer (1) (Figure 3).

Figure 4 Install Piston Retainer-to-Case Screws

4. Install low/reverse piston retainer-to-case screws (3) (Figure 4) and torque to 5 Nm (45 in. lbs.).

Figure 5 Install Low/Reverse Clutch Piston

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

5. Install low/reverse clutch piston (1) (Figure 5).

Figure 6 Guide Bracket Disassembled

6. Park guide bracket assembly - antiratchet spring (1) (Figure 6), guide bracket (2), split sleeve (3), spacer (4), pawl (5), and stepped spacer (6).

Figure 7 Guide Bracket

7. Assemble park guide bracket assembly (Figure 7).

Figure 8 Pivot Shaft and Guide Bracket

8. Install guide bracket (2) (Figure 8) into position and insert pivot shaft (3).

Figure 9 Install Anchor Shaft and Plug

9. Install anchor shaft and plug (3) (Figure 9). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.

Figure 10 Low/Reverse Piston Return Spring

10. Install low/reverse piston return spring (1) (Figure 10).

Figure 11 Compressor Tool in Use

11. Install low/reverse spring compressor Disc 6057 (3) (Figure 11), Compressor 5059 (4) and Bar 5058-3 (5) into position.

Figure 12 Install Snap Ring

12. Compress low/reverse piston and install snap ring. Snap ring opening must be between spring levers (1) (Figure 12).

Figure 13 Install Rear Carrier Bearing Cone

13. Install rear carrier bearing cone using Installer 6053 (2) using an arbor press (1) (Figure 13).

Figure 14 Install Rear Carrier Assembly

1 - REAR CARRIER ASSEMBLY

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

Figure 15 Install Output Gear Bearing Cone

15. Install output gear bearing cone using Installer 5052 (3) (Figure 15) handle C-4171 (2) and an arbor press (1).

Figure 16 Output Gear and (Select) Shim

16. OUTPUT GEAR BEARING ADJUSTMENT:

a. With output gear (3) (Figure 16) installed, install a 4.50 mm (0.177 in.) gauging shim (2) on the rear carrier assembly hub (1), using grease to hold the shim in place.
b. Using Tool 6259, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.).

Figure 17 Checking Output Gear Bearings End Play

17. OUTPUT GEAR BEARING ADJUSTMENT: cont.

a. Measure bearing end play. Attach Gear Checking Plate L-4432 (1) (Figure 17) to the gear (4).
b. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
c. Using a dial indicator (2) (Figure 17) mounted to the transaxle case, measure output gear (4) end play.
d. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
e. Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller L4407A.
f. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.

Output Gear Bearing Shim Chart (Part 1):

Output Gear Bearing Shim Chart (Part 2):

Figure 18 Install Output Gear

18. Install the output gear and bearing assembly using Installer 6261 (2) (Figure 18).

Figure 19 Output Gear Bolt and Washer

19. Install NEW output gear retaining bolt (2) (Figure 19) and washer (3).

Figure 20 Tighten Output Gear to 271 Nm (200 ft. lbs.)

20. Using Holder 6259 (4) (Figure 20), torque output gear retaining bolt to 271 Nm (200 ft. lbs.).

Figure 21 Check Output Gear Bearings Turning Torque

21. Using an inch pound torque wrench (1) (Figure 21), 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.