Part 2

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










51. NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.

Install the main control wiring harness, connect the electrical connectors and install the main control ground wire bolt.

1. Shift Solenoid C (SSC), color N (White)

2. Shift Solenoid E (SSE), color G (Green)

3. Shift Solenoid D (SSD), color L (Blue)

4. Line Pressure Control (LPC), color B (Black)

5. Shift Solenoid A (SSA), color N (Natural)

6. Shift Solenoid B (SSB), color B (Black)

- Tighten the main control ground wire bolt to 10 Nm (89 lb-in).





52. Install the transmission fluid filter.





53. Connect the Transmission Fluid Temperature (TFT) sensor.





54. NOTE: Do not use more than the specified amount of sealer on the transmission fluid pan or internal transaxle damage could occur.

Apply a bead 1.5 mm (0.059 in) diameter of silicone sealer to the transmission fluid pan.





55. Install the transmission fluid pan.
- Tighten to 10 Nm (89 lb-in).





56. Rotate the transaxle 180 degrees.

57. Install the low/reverse clutch piston.





58. NOTE: Be sure the low/reverse clutch return spring is installed so that the tabs are facing up.

Install the low/reverse clutch return spring.





59. Install the wave spring.





60. Install the low One-Way Clutch (OWC) inner race.





61. NOTE: The opening of the retaining ring must be at the 10 o'clock position.

Install the low OWC retaining ring.





62. Install the low/reverse plates and pressure plate.





63. Install the low reverse clutch plate selective retaining ring.
- Using a feeler gauge, measure the clutch clearance.

- Compare the low reverse clutch pack clearance to the specification (2.2-2.5 mm [0.0866-0.0984 in]). If the clutch pack clearance is not within specification, select and install the correct size selective retaining ring to obtain the specified clearance.





64. NOTE: Make sure that the snap ring is installed before installing the planet assembly.

Install the planet assembly.





65. NOTICE: If the planet assembly is installed correctly, the edge of the planet assembly will fit flush with the transaxle case. If the planet assembly does not fit flush with the transaxle case, further assembly will cause damage to the transaxle.

Inspect the planet assembly installation.





66. NOTE: The planet assembly must only rotate counterclockwise. If the planet assembly rotates clockwise, then the OWC was not installed correctly.

Check to make sure that the OWC is correctly installed.
- Rotate the planet assembly clockwise and counterclockwise.





67. Install the intermediate/Overdrive (O/D) drum assembly.





68. Install the intermediate/O/D band.





69. Install the direct clutch cylinder thrust bearing with the rollers facing up.





70. Install new end cover-to-case seals.





71. Install new end cover seals.





72. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown or greater.





73. NOTICE: Failure to support the transaxle end cover in the center can result in inaccurate measurements causing damage to the transaxle.

Measure the gap between the transaxle end cover and the transaxle assembly.

1. Position the transaxle end cover on the transaxle assembly.

2. Support the transaxle end cover in the center.

3. Measure the gap between the transaxle end cover and the transaxle assembly.





74. Remove the transaxle end cover.





75. NOTE: The clearance for the direct clutch bearing shim is 0.25-0.50 mm (0.009-0.019 in).

NOTE: The correct shim thickness is between minimum and maximum.

Choose and install the correct direct clutch hub bearing shim:

- Line 1: total amount of shim thickness used during transaxle end cover mock up.

- Line 2: measure the gap between transaxle end cover and transaxle case.

- Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.

- Line 4: subtract 0.25 mm (0.009 in) from Line 3 for maximum shim thickness.

- Subtract 0.50 mm (0.019 in) from Line 3 for the minimum thickness shim.





76. NOTICE: Applying too much silicone sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.

Apply a 1 mm (0.039 in) bead of silicone sealer to the transaxle end cover.





77. Install the transaxle end cover.
- Tighten to 22 Nm (16 lb-ft).





78. Using the Transmission Band Select Gauge, collapse the intermediate/O/D band.
- Tighten to 5 Nm (44 lb-in), then back out three and a half turns.





79. Holding the Transmission Band Select Gauge, lightly seat the nut against the transaxle case, then remove the Transmission Band Select Gauge without changing the relationship of the nut on the bolt.





80. Using the Transmission Band Select Gauge, select an intermediate/O/D band bolt that measures from the end of the bolt to the face of the nut as shown.





81. NOTE: Apply thread sealer to the bolt.

Install the intermediate/O/D band anchor bolt.

- Tighten to 45 Nm (33 lb-ft).





82. Rotate the transaxle 180 degrees.

83. Install the forward clutch hub.





84. Install the forward clutch assembly.





85. Install the forward clutch thrust washer.





86. Install new pump seals and lubricate with clean transmission fluid.





87. Install the pump (do not force the pump down at this time).





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

Apply threadlock and sealer to the bolts and install the pump-to-case bolts.

- Use the bolts to seat the pump.

- Tighten the bolts in a crisscross pattern.

- Tighten to 30 Nm (22 lb-ft).





89. Install the Output Shaft Speed (OSS) sensor.
- Tighten to 10 Nm (89 lb-in).





90. NOTE: Apply thread sealer to the bolt.

Install the Turbine Shaft Speed (TSS) sensor.

- Tighten to 10 Nm (89 lb-in).





91. Using the Transmission Range Sensor Alignment Tool, align the TR sensor and tighten the bolts.
- Tighten to 10 Nm (89 lb-in).





92. NOTICE: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt. Damage to the manual control lever shaft will occur.

Install the manual control lever bolt.

- Tighten to 30 Nm (22 lb-ft).





93. Install the vent cap past the second detent notch. Be sure the vent moves up and down freely.





94. Using the Axle Oil Seal Installer and Handle, install the LH halfshaft seal.





95. Using the Output Shaft Seal Installer and Handle, install the RH halfshaft seal.





96. Install the differential opening cover.





97. Using the Torque Converter Handles, install the torque converter.





98. Using the Torque Converter Retainer, secure the torque converter.





99. Remove the Transmission Mounting Bracket from the transaxle.