Part 2

Assembly (Steps 38-82)

38. CAUTION: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

Using Converter Seal Installer 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.





Front wheel drive (FWD) vehicles
39. Install a new halfshaft seal on Halfshaft Seal Installer 307-582.





40. CAUTION: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

Assemble Adapter 205-153 and Halfshaft Seal Installer 307582. Using the special tools and a dead blow hammer, install the halfshaft seal in the torque converter housing.





All vehicles
41. Assemble Adapter 205-153 and Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the special tool.





42. CAUTION: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

Using Adapter 205-153 and Oil Dam Seal Installer 307-583, install the fluid dam in the torque converter housing.





43. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the torque converter housing.





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





45. Using Differential Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the torque converter housing.





46. Install the differential bearing preload shim in the torque converter housing.





47. Install a new differential bearing race on Differential Bearing Cup Installer 307-576.





48. 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 torque converter housing.





49. Install the fluid pump drive sprocket and driven sprocket thrust washers.





50. NOTE: The dot on the fluid pump sprocket is installed facing upward.

Install the fluid pump sprocket and chain assembly.





51. Position the fluid pump and filter assembly in place and install the 3 bolts.
^ Tighten to 12 Nm (9 lb-ft).





52. NOTE: Be sure that the oil pump drive chain is correctly engaged on both sprockets.

Position the stator support assembly in place on the torque converter housing.





53. Install the 10 stator support bolts. Tighten in the sequence shown.
^ Tighten to 41 Nm (30 lb-ft).





54. Position the differential carrier baffle in place and install the bolt.
^ Tighten to 12 Nm (9 lb-ft).





55. Lubricate the ends of the transaxle fluid tube with petroleum jelly and install it in the transaxle.





56. CAUTION: Make sure the sealing surface of both the transaxle case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transaxle case.

Apply a bead of silicone sealant to the machined surface of the transaxle case.





57. NOTE: Install the 2 studbolts in the correct location as noted during disassembly.

Install the torque converter housing on top of the transaxle case and install the 19 bolts.





58. NOTE: The studbolts are 1 and 16 in the tightening sequence.

Tighten the bolts in the sequence shown.
^ Tighten to 24 Nm (18 lb-ft).





59. Assemble Adapter 205-153 and Halfshaft Seal Installer 307-582 and install a new halfshaft seal on Halfshaft Seal Installer 307-582.





60. Using Adapter 205-153 and Halfshaft Seal Installer 307-582, install the halfshaft seal in the transaxle case.





61. Lubricate the forward clutch piston seals with petroleum jelly.





62. Position the forward clutch piston in place in the transaxle case.





63. NOTE: Install Forward/Overdrive Spring Compressor 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.

Using Forward/Overdrive Spring Compressor 307-584/1, push the forward clutch piston down into the bore.





64. Install the forward clutch piston return spring with the tabs facing downward.





65. NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.

Install Forward Clutch Spring Compressor 307-574 (307574/1 and 307-574/2), and Forward/Overdrive Spring Compressor 307-584 (307-584/1 and 307-584/2) and compress the forward clutch piston return spring.





66. NOTE: Special tools not shown for clarity.

Install the forward clutch piston return spring snap ring.
^ Install the snap ring.
^ The snap ring gap should be at the top of the transaxle case.





67. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and Forward/Overdrive Spring Compressor 307-584 (307-584/1 and 307-584/2).





68. Install the forward clutch wave spring.





69. Lubricate the forward clutch pack in clean automatic transmission fluid.





70. Install the forward clutch pack assembly.
1) Position the forward clutch pack assembly in the case.
2) Make sure the alignment tab on the clutch pack is positioned in the correct location.





71. Install the low one-way clutch.





72. NOTE: The low one-way clutch snap ring gap must be positioned as shown so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.

Install the low one-way clutch snap ring.





73. Compare the position of the low one-way clutch snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.





74. Using Dial Indicator Gauge With Holding Fixture 100002, install a dial indicator on the transaxle case and position the plunger on a top friction disc tab.





75. Install a new forward clutch feed seal.





76. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.85 mm (0.033 inch) and 2.41 mm (0.095 inch). If the clearance is out of range, check the forward clutch pack and low one-way clutch for correct installation. If the forward clutch pack and low one-way clutch is correctly installed, install a new forward clutch pack.





77. Remove the dial indicator from the transaxle case.
78. Install the No. 11 stator support thrust bearing.





79. Install the front planetary carrier hub.





80. Install the No. 10 front sun gear thrust bearing.





81. Install the front sun gear and shell assembly.





82. Install the front carrier and rear ring gear assembly.