Part 3
TransaxleAssembly (Steps 71-106)
71. Install the No. 5 center/rear planetary and the No. 6 center sun gear thrust bearings.
72. Install the rear planetary gear carrier assembly.
73. CAUTION: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low/one-way clutch snap ring can result in damage to the transaxle.
Install the low/reverse clutch pressure plate.
1 Make sure the tab on the bottom of the pressure plate fits in the gap of the low/one-way clutch snap ring.
2 Install the low/reverse clutch pressure plate.
74. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low/one-way clutch snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
75. Lubricate the low/reverse clutch pack in clean automatic transmission fluid.
76. Install the low/reverse clutch pack.
77. Using a suitable straight edge and a depth gauge, measure and record as measurement A, the distance from the transaxle case deck surface to the top low/reverse clutch plate.
78. Using the same straight edge and a suitable depth gauge, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.
79. Subtract measurement B from measurement A to get the low/reverse clutch clearance. The clearance should be between 1.01 mm (0.03 inch) and 2.47 mm (0.09 inch). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack.
80. Install the intermediate clutch pressure plate.
81. Lubricate the intermediate clutch pack assembly in clean automatic transmission fluid.
82. Install the intermediate clutch pack assembly.
83. Install the intermediate clutch pack wave spring
84. Using a suitable straight edge and a depth gauge, measure and record as measurement A, the distance from the transaxle case deck surface to a low point on the intermediate clutch wave spring.
85. Using the same straight edge and a suitable depth gauge, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.
86. Subtract measurement B from measurement A to get the intermediate clutch clearance. The clearance should be between 0.90 mm (0.03 inch) and 2.24 mm (0.08 inch). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
87. Install the intermediate clutch shell and gear assembly.
88. Install the No. 3 rear sun gear thrust bearing.
89. Install the overdrive/direct clutch hub and turbine shaft assembly.
90. Install the No. 1 cover assembly thrust bearing.
91. Install the cover assembly gasket.
92. Route the turbine shaft speed (TSS) sensor harness through the transaxle case to the valve body area and install the cover assembly. Tighten the bolts in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs).
93. Install the output shaft speed (OSS) sensor and the bolt.
^ Tighten to 12 Nm (9 ft. lbs).
94. NOTE: Make sure that the manual lever pin (part of the TR sensor) is correctly installed in the manual valve.
Position the TSS, OSS and TR sensor wiring harnesses aside and install the main control valve body.
95. Install the main control valve body and the 10 bolts. Tighten the bolts in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs).
96. CAUTION: Make sure not to pinch the TSS, OSS, or TR sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
NOTE: Install the different length bolts in the locations noted during disassembly.
Install the 11 solenoid body bolts hand tight.
1 42 mm (1.65 inch) bolt
2 63 mm (2.48 inch) bolts
3 80 mm (3.14 inch) bolts
4 95 mm (3.74 inch) bolts
97. Tighten the solenoid body bolts in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs).
98. Route the OSS sensor wiring harness and connect the electrical connector.
99. Connect the TR sensor electrical connector.
1 Connect the electrical connector.
2 Slide the locking tab over.
100. Connect the TSS sensor electrical connector.
101. Inspect the transaxle main control cover seal for damage and replace it if necessary.
102. NOTE: Install the stud bolts in the locations noted during disassembly.
Install the transaxle main control cover and install the 14 bolts.
1 Bolt location
2 Studbolt location
103. Tighten the main control cover bolts in the sequence shown.
^ Tighten to 12 Nm (9 ft. lbs).
104. Install the manual lever and the nut.
^ Tighten to 18 Nm (13 ft. lbs).
105. CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
Install two 10 mm x 1.50 bolts into the torque converter to assist in handling the torque converter and install the torque converter in the transaxle.
106. Remove the bolts from the torque converter.