Part 1 of 2
1. Position case in horizontal position.Drive Sprocket Bearing Installation:
2. If bearing was removed, install drive sprocket bearing using Stator and Driven Sprocket Bearing Replacer T86P-70043-B. If removed, install driven sprocket support. Install six (T-30) Torx(R) bolts and tighten to 7-9 Nm (5-7 ft-lb).
NOTE: Bolt holes are offset. Driven sprocket can only be aligned one way. Drain hole points downward.
Filter Assembly:
3. Clean filter with compressed air and install.
Converter Hub Seal Installation:
4. Install converter impeller hub seal using Converter Hub Seal Replacer T87L-77837-AH.
NOTE: After installation, verify presence of garter spring on seal.
Output Seal Installation:
5. Install RH differential seal using Output Seal Replacer T86P-1177-B, and Shaft Seal Replacer T94P-77001-JH.
End Play Tool:
6. Loosely install End Play Tool T87P-70014-AH and two bolts over RH output shaft opening. Tool will be used later to perform selective thrust washer checks.
No. 19 Needle Bearing Installation:
7. Place case in vertical position. Install No. 19 needle bearing over case boss with flat side facing up, outer lip facing down.
Final Drive Ring Gear:
8. Install final drive ring gear with external splines up. Using a hammer handle if necessary, tap gently to fully seat into case splines.
9. Assemble No. 18 thrust washer to differential assembly using petroleum jelly.
Differential Assembly:
10. Lower final drive assembly into case. Use hammer to gently tap into place.
11. Install snap ring and align opening of snap ring with rear lube fluid transfer tube passage.
12. Perform end clearance check for No. 18 selective thrust washer as follows:
a. Place screwdriver under differential case, pry up and release. This will seat retaining ring for planet support at the top of its groove in the case.
b. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent with stylus on end of output shaft.
c. Back out screw End Play Tool T87P-70014-AH installed in Step 6 until it no longer touches output shaft.
d. Zero dial indicator.
e. Tighten screw to 4-5 Nm (35-44 in-lb).
f. Observe reading on dial indicator.
No. 18 Selective Thrust Washer Snap Ring Selection Chart:
The clearance should be 0.10-0.40 mm (0.004-0.016 inch). If the clearance is not within specification, refer to the selection chart for correct thrust washer.
13. After installing the correct thrust washer, check the clearance.
NOTE: After completing end clearance check, back off screw on tool and leave tool in position for No. 5 and No. 8 selective thrust washer clearance check to be performed later.
14. Install low and intermediate band into case and align anchor pin pocket with anchor pin.
Rear Sun Gear And Drum:
15. Install rear sun gear and drum.
Reverse Clutch Assembly:
16. Install reverse clutch on planet assembly.
Front Carrier Hub:
Reverse Clutch Assembly And Planet Assembly:
17. Remover/Replacer Collets T94P-77001-FH and Tube T75L-7025-C over the front carrier hub. Slide Collet Sleeve T77F-7O25-C over tube onto collet to hold in place.
18. Use the reverse clutch and planetary removal and installation tool to install the reverse clutch assembly and planetary assembly as one unit. Remove installation tool.
NOTE: Align reverse clutch cylinder anchor bolt pocket with anchor bolt case hole.
NOTE: Make sure reverse clutch cylinder apply tube hole is aligned with case holes.
Reverse Anchor Pin Bolt And Nut:
19. Start reverse anchor pin bolt but do not tighten at this time.
Front Clutch Loading Tool:
20. Attach Front Clutch Loading Tool T86P-70389-A to forward/intermediate/direct clutch assembly.
NOTE: Modify clutch loading tool to fit lube holes by removing 0.50 mm (0.02 inch) of material off each side of tool.
21. Lower assembly into case, front sun shell gear splines into front planet.
CAUTION: Make sure the assembly is fully seated before removing the tool.
Installing Overdrive Band:
22. Install overdrive band into case.
Installing Plastic Retainer:
23. Install plastic retainer with crosshairs facing up.
NOTE: Perform the following steps to check the driven sprocket end-play clearance for No. 8 selective thickness thrust washers.
24. Tighten screw on End Play Tool T87P-70014-AH or equivalent previously installed to 4-5 Nm (35-44 in-lb).
No. 8 Thrust Washer And No. 9 Needle Bearing:
25. Remove No. 8 driven sprocket support thrust washer and No. 9 direct clutch hub needle bearing from the driven sprocket support.
Installing No. 9 Clutch Hub Needle Bearing:
26. Separate No. 8 thrust washer and No. 9 needle bearing. Install No. 9 needle bearing (only) into transaxle over the output shaft as shown with outer lip up.
Installing Gauge Tube:
27. Install Gauge Tube T94P-77001-MH or equivalent over output shaft until fully seated into No. 9 needle bearing (this is where the No. 8 thrust washer normally sits).
Installing Gauge Bar:
28. Place Gauge Bar T94P-77000-Q or equivalent across transaxle case with round legs of gauge bar resting on case cover gasket surface. Place Depth Micrometer D92P-4201-A or equivalent on gauge bar and measure down to gauge tube. Do this on both sides of output shaft (180 degrees apart). Add both readings, divide by two to obtain reading A.
No. 8 Thrust Washer Selection Chart:
29. Use reading A to select the correct No. 8 thrust washer from the selection chart.
NOTE: Reading A and Dimension C from this chart will be used in selection of No. 5 thrust washer.
Measuring Depth Of No.5 Thrust Washer Mating Surface:
30. Remove depth micrometer, gauge bar and gauge tube. Install gauge bar and depth micrometer as shown. Measure down to the No. 5 thrust washer mating surface of overdrive drum. Take another reading down to the No. 5 thrust washer mating surface of overdrive drum on the other side of the shaft (180 degrees apart). Add both readings, divide by two to obtain reading B. Remove gauge bar, depth micrometer and gauge tube from transaxle case.
NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on No. 8 thrust washer selection chart following the selected No. 8 thrust washer.
31. Subtract Reading A from Reading B, add difference between A and B to Dimension C. Record this as Reading D.
No.5 Thrust Washer Selection Chart:
32. Use Reading D to select the correct No. 5 thrust washer from the selection chart.
Installing No.5 Front Support Thrust Washer:
33. Install correct No. 5 thrust washer on driven sprocket support.
NOTE: Use petroleum jelly to hold washer in place for this step.
No. 8 Thrust Washer And No. 9 Needle Bearing:
34. Install the correct No. 8 thrust washer and No. 9 needle bearing on driven sprocket support. Use petroleum jelly to hold washer and bearing in place.
NOTE: No. 9 needle bearing may still be inside transaxle from No. 8 thrust washer selection procedure.
Driven Sprocket Support Assembly:
35. Lightly coat all seals with petroleum jelly before support installation. Install driven sprocket support assembly into case, making sure it is fully seated.
End Play Tool:
36. Remove End Play Tool T87P-70014-AH from bottom of case.
Parking Pawl Components:
37. Install parking pawl, parking pawl return spring, parking pawl shaft and locator pin.
NOTE: Make sure that the parking pawl engages the park gear and returns freely.
Parking Lever Actuating Rod:
38. Install parking lever actuating rod in case. Install park rod abutment and start abutment bolts. Push in parking pawl and locate rod between parking pawl and abutment.
Manual Control Shaft Removal:
39. Install manual control shaft seal by tapping into case.
Manual Control Shaft Components:
40. Start manual control shaft through manual control shaft seal and slide manual detent lever onto manual control shaft.
41. Slide manual control shaft through parking lever actuating rod and tap into case hole.
42. Install new manual control shaft lock pin through case hole, aligning with groove in manual control shaft.
43. Install new roll pins in manual detent lever and parking lever actuating rod.
No. 2 & No. 4 Thrust Washers:
44. Install No. 2 and No. 4 tabbed thrust washers onto drive and driven sprocket support. Align tabs on thrust washers with holes in sprocket supports. Apply grease to washers to help hold in position.
CAUTION: Be careful not to damage or bend tabs on exciter ring.
Drive Chain And Sprockets:
45. Install drive chain on drive sprocket and driven sprocket. Lower assembly into sprocket supports simultaneously with drive chain parallel to case surface, rotating sprockets to make sure that they are fully seated.
No. 1 & No. 3 Thrust Washers:
46. Install No. 1 and No. 3 thrust washers on chain cover. Use petroleum jelly to hold in place. Make sure tabs align with slots in chain cover.
CAUTION: Be careful not to damage or bend tabs on exciter ring.
47. Install new chain cover gasket on case.
Accumulator Springs:
48. Install accumulator springs in correct position in case.