Part 1

Transaxle


















Converter Housing with Converter Assembly and Pump Assembly











Forward Clutch











Differential Assembly and Final Drive Input











Clutches and Planet Gears











Clutches and Band











Main Control Assembly











Case Assembly











Snap Rings










Assembly

1. Using the Drive Pinion Bearing Cone Installer, install the final drive input gear bearing.

1. Install the final drive input gear bearing.

2. Install the Drive Pinion Bearing Cone Installer.





2. Using an arbor press, the Bearing/Oil Seal Plate and the Drive Pinion Bearing Cone Installer, seat the final drive input gear bearing.





3. Install a new collapsible spacer.





4. Using the Drive Pinion Bearing Cup Installer, position the final drive input gear.





5. NOTICE: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case or damage to the input gear can occur.

Rotate the transaxle 180 degrees.

6. Using the Drive Pinion Bearing Cup Installer and Differential Fluid Seal Installer, install the final drive input gear bearing.





7. Rotate the transaxle 180 degrees.

8. Using the Final Drive Input Gear Holding Tool, lock the final drive input gear.





9. Rotate the transaxle 180 degrees.

10. NOTE: A high tightening torque specification of 400 Nm (295 lb-ft) is necessary to crush the collapsible spacer for correct bearing preload.

NOTE: If the preload is too high, a new collapsible spacer must be installed.

Using the Wrench Guide Plate and Final Drive Input Nut Socket, tighten the nut to achieve the preload specification.

- Tighten to 400 Nm (295 lb-ft).





11. Rotate the transaxle 180 degrees.

12. NOTE: Make sure that the final drive rotates.

Unlock the Final Drive Input Gear Holding Tool.





13. Rotate the transaxle 180 degrees.

14. NOTICE: Make sure the bearing preload is between 0.4-0.7 Nm (3.5-6.2 lb-in) or bearing failure can occur.

NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.

Using the Wrench Guide Plate and Final Drive Input Nut Socket, measure the rotating torque.

- Rotational torque is 0.4-0.7 Nm (3.5-6.2 lb-in).





15. After achieving the correct rotating torque specification, remove the Wrench Guide Plate and Final Drive Input Nut Socket and stake the nut to prevent movement.





16. Rotate the transaxle 180 degrees.

17. Position the transfer shaft gears in the transaxle case.





18. Install the parking pawl return spring.





19. Connect the spring.

1. Install the parking pawl abutment.

2. Install the lever.

3. Install the pin.

4. Connect the spring.





20. Install the parking pawl assembly cover and bolts.
- Tighten to 13 Nm (115 lb-in).





21. Install the differential case assembly.





22. Position the bearing cups.





23. Install the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.





24. NOTICE: Do not use the bolts from Shim Selection Set 308-164, they will not work. Use only the bolts from Shim Selection Set 308-161 or damage to the transaxle case threads can occur.

NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.

Using the Shim Selection Set, assemble the transaxle for end play measurement.

1. Position the converter housing.

2. Install the Shim Selection bolts and seat the case cover flat.
- Tighten to 5 Nm (44 lb-in).





25. Remove the converter housing.

1. Remove bolts.

2. Remove the converter housing.





26. Remove the Differential/Transfer Gear Bearing Shim Gauge and Shim Selection Set.





27. Remove the bearing cups.





28. NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct transfer shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct transfer shaft shim. For additional information, refer to Specifications.





29. NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct differential shaft shim, measure the depth of the plunger on the Differential/Transfer Gear Bearing Shim Gauge and select the correct differential shaft shim. For additional information, refer to Specifications.





30. Using the Transfer Gear Bearing Cup Installer and Handle, install the correct transfer shaft shim and bearing cup into the converter housing.





31. Using the Differential Bearing Cup Installer and Handle, install the correct differential shaft shim and differential case bearing cup into the converter housing.





32. Apply a 1 mm (0.039 in) thick bead of silicone sealer to the case half.





33. NOTICE: Failure to apply threadlock and sealer to the bolts can result in a transmission fluid leak.

Position the converter housing on the transaxle case. Apply threadlock and sealer to the 5 bolts. Install and hand-tighten the bolts in the transaxle case.





34. Install the rest of the converter housing-to-transaxle case bolts and tighten all of the bolts.
- Tighten to 22 Nm (16 lb-ft).





35. Install the intermediate/overdrive band servo piston return spring.





36. Install the intermediate/overdrive servo piston.





37. Install the O-ring seal.





38. NOTE: The 3 bolts must be loosely installed, then tightened in a crisscross sequence to compress the intermediate/overdrive spring evenly.

Install the intermediate/overdrive band servo cover and bolts.

- Tighten to 13 Nm (115 lb-in).





39. Install the park pawl assembly and bolt.
- Tighten to 13 Nm (115 lb-in).





40. NOTE: Lubricate the O-ring with transmission fluid prior to assembly.

Install the new O-rings on the manual control lever shaft.





41. Install the manual control lever shaft.





42. NOTE: The roll pin does not need to sit flush with the park pawl assembly.

Install a new manual control lever shaft roll pin.





43. Loosely install the Transmission Range (TR) sensor.





44. NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.

Install the thinner and longer neutral drive accumulator springs.





45. Install the neutral drive accumulator piston.





46. Install the 1-2 accumulator springs.





47. Install the 1-2 accumulator piston.





48. Inspect the seals. Lubricate the seals in transmission fluid. Install the transaxle internal harness electrical connector.





49. NOTE: Make sure that the manual valve is in the manual control valve selector lever.

NOTE: Do not fully tighten the bolts at this stage.

Install the main control valve body.





50. Tighten the main control valve body bolts.
- Tighten the bolts in the sequence shown.
- Tighten to 9 Nm (80 lb-in).