Part 1

ASSEMBLY

Figure 1 Install Both Output Bearing Cups

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.

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

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 Attaching 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. Use figure as a reference while assembling park guide bracket assembly (Figure 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 (1) (Figure 9) and plug (3). 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 into position (Figure 11).

Figure 12 Install Snap Ring

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

Figure 13 Install Rear Carrier Bearing Cone

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

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).

Figure 16 Checking Output Gear Bearings End Play

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) (Figure 16) 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.

Output Gear Bearing Shim Chart (Part 1):

Output Gear Bearing Shim Chart (Part 2):

Figure 17 Install Output Gear

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

Figure 18 Output Gear Bolt and Washer

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

Figure 19 Tighten Output Gear to 271 Nm (200 ft. lbs.)

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

Figure 20 Check Output Gear Bearings Turning Torque

20. Using an inch pound torque wrench (1) (Figure 20), 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.