Part 1

Transaxle

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tool(s) (Part 3):

Material:

Assembly (Steps 1-35)
1. If removed, using the special tools, install the transfer shaft fluid dam in the transaxle case.





2. If removed, using the special tool, press the transfer shaft bearing cup in the transaxle case.





3. If removed, using the special tools, press the differential bearing cup in the transaxle case.





4. Install the park pawl abutment and the pins.





5. Install the park pawl and the pin.





6. Install the park pawl spring.





7. Install the park pawl pin retainer and the 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs).





8. Slide the park pawl over and install the park pawl actuator rod.





9. Using the special tool, install a new manual lever shaft seal.





10. Install the transmission range (TR) sensor.
1 Position the park pawl actuating rod in the TR sensor.
2 Install the TR sensor in the transaxle case.





11. Using the special tool, install a new TR sensor locking pin.





12. Install a new O-ring seal on the reservoir. Lubricate the seal with clean automatic transmission fluid.





13. Install the fluid reservoir and the 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs).





14. Install a new pump-to-case seal.





15. Install the transfer shaft and gear assembly.





16. Install the differential and ring gear assembly.





17. Install the differential and transfer shaft bearing cups on the bearings.





18. Install the special tool on the differential and transfer shaft bearing cups.





19. Install the special tools (studs) in the transaxle case to align the torque converter housing.





20. NOTE: Make sure that the silicone has been cleaned off of the machined surface of the transaxle case and the torque converter housing before installing the special tools or the preload measurement can be inaccurate.

Install the special tools (4 spacers) on the studs to space the torque converter housing from the transaxle case.





21. Place the torque converter housing on the special tools.





22. Install the special tools (remaining 4 spacers and the 4 bolts).
^ Tighten to 24 Nm (18 ft. lbs).





23. Install the special tools (4 nuts) on the studs.
^ Tighten to 24 Nm (18 ft. lbs).





24. Rotate the transfer shaft and the differential several times to seat the bearings.





25. Using a feeler gauge, measure and record the smallest and largest preload gap on the special tool placed on the differential assembly. Add the 2 measurements and divide by 2. This is the thickness of the differential bearing preload shim.





26. Using a feeler gauge, measure and record the smallest and largest preload gap on the special tool placed on the transfer shaft assembly. Add the 2 measurements and divide by 2. This is the thickness of the transfer shaft bearing preload shim.





27. Remove the torque converter housing and the special tools from the transaxle case.





28. Remove the special tools from the transaxle case.





29. Remove the special tools from the transaxle case.





30. Remove the special tools from the transfer shaft and differential assemblies.





31. Remove the differential and transfer shaft bearing cups.





32. CAUTION: Support the torque converter housing using blocks of wood or damage to the torque converter housing can occur.

Using the special tool and a dead blow hammer, install the torque converter hub seal in the torque converter housing.





33. CAUTION: Support the torque converter housing using blocks of wood or damage to the torque converter housing can occur.

Using the special tools, install the halfshaft seal in the torque converter housing.





34. CAUTION: Support the torque converter housing using blocks of wood or damage to the torque converter housing can occur.

Using the special tools, install the fluid dam in the torque converter housing.





35. Install the transfer shaft preload shim in the torque converter housing.