Part 1
TransaxleAssembly (Steps 1-37)
Special Tools (Part 1):
Special Tools (Part 2):
Special Tool(s):
Material:
All vehicles
1. If the transfer shaft fluid dam and bearing race were removed during disassembly, assemble Adapter 205-153 and Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the special tool.
2. Using Adapter 205-153 and Oil Dam Seal Installer 307583, install the transfer shaft fluid dam in the transaxle case.
3. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the transaxle case.
4. Using Differential Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the transaxle case.
5. If removed, install a new differential bearing race on Differential Bearing Cup Installer 307-576.
6. Using Differential Bearing Cup Installer 307-576, Transfer Gear Roller Bearing Pilot 307-541 and Heavy Duty Threaded Drawbar 204-029, press the differential bearing cup in the transaxle case.
7. Install the park pawl abutment and the pins.
8. Install the park pawl and the pin.
9. Install the park pawl spring.
10. Install the park pawl pin retainer and the 2 bolts.
^ Tighten to 12 Nm (9 lb-ft).
11. Slide the park pawl over and install the park pawl actuator rod.
12. Lubricate a new manual shaft seal and Manual Lever Shaft Seal Installer 307-581 with petroleum jelly and install the seal on the special tool.
13. Using Manual Lever Shaft Seal Installer 307-581, install the manual lever shaft seal in the transaxle case.
14. Install the transmission range (TR) sensor.
1) Position the park pawl actuating rod in the TR sensor detent plate.
2) Install the TR sensor in the transaxle case.
15. Install a new TR sensor locking pin in the transaxle case.
16. Using Manual Lever Retaining Pin Installer 307-592, drive the TR sensor locking pin into the transaxle case.
17. Install a new O-ring seal on the reservoir. Lubricate the seal with clean automatic transmission fluid.
18. Install the fluid reservoir and the 2 bolts.
^ Tighten to 12 Nm (9 lb-ft).
19. Install a new pump-to-case seal.
20. Install the transfer shaft and gear assembly.
21. Tilt the transfer shaft and gear assembly over and install the differential assembly.
22. Install the differential and transfer shaft bearing cups on the bearings.
23. Install Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 and 307-591/2) on the differential and transfer shaft bearing cups.
24. Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (studs) in the transaxle case to align the torque converter housing.
25. NOTE: Make sure that the silicone has been cleaned off the machined surface of the transaxle case and the torque converter housing before installing the special tools or the preload measurement may be inaccurate.
Install Differential/Transfer Gear Bearing Shim Gauge 307591/3 (4 spacers) on the studs to space the torque converter housing from the transaxle case.
26. Place the torque converter housing on Differential/Transfer Gear Bearing Shim Gauge 307-591/3.
27. Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (remaining 4 spacers, bolts and washers).
^ Tighten to 24 Nm (18 lb-ft).
28. Install Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts and washers) on the studs.
^ Tighten to 24 Nm (18 lb-ft).
29. Rotate the transfer shaft and the differential several times to seat the bearings.
30. Using a feeler gauge, measure and record the smallest and largest preload gap on Differential/Transfer Gear Bearing Shim Gauge 307-591/1 placed on the differential assembly. Add the 2 measurements and divide by 2. This is the thickness of the differential bearing preload shim. For additional information, refer to Specifications for the differential bearing preload shim part number.
31. Using a feeler gauge, measure and record the smallest and largest preload gap on Differential/Transfer Gear Bearing Shim Gauge 307-591/2 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. For additional information, refer to Specifications for the transfer gear bearing preload shim part number.
32. Remove the torque converter housing and Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.
33. Remove Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) from the transaxle case.
34. Remove Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 studs) from the transaxle case.
35. Remove Differential/Transfer Gear Bearing Shim Gauge 307-591/1 and 307-591/2 from the differential and transfer shaft assemblies.
36. Remove the differential and transfer shaft bearing cups.
37. Install a new torque converter hub seal on Converter Seal Installer 307-575.
