Part 2

Transaxle














Disassembled Views










































26. Place the torque converter housing on the Differential/Transfer Gear Bearing Shim Gauge 307-591/3.





27. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (remaining 4 spacers, bolts and washers).
- Tighten to 24 Nm (18 lb-ft).






28. Install the 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 the 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 the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.





33. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) from the transaxle case.





34. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 studs) from the transaxle case.





35. Remove the 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 the Converter Seal Installer 307-575.





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

Using the 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. Assemble the Handle 205-153 on the Cover Axle Seal Installer 307-582A and install a new RH halfshaft seal on Cover Axle Seal Installer 307-582A.





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

Use the Handle 205-153 and the Cover Axle Seal Installer 307-582A. Install the RH halfshaft seal in the torque converter housing.






All vehicles

41. Assemble the Handle 205-153 and the Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the Oil Dam Seal Installer 307-583.





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

Using the Handle 205-153 and the 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 the 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 the Bearing Cup Installer 307-576.





48. Using the Bearing Cup Installer 307-576, Transfer Gear Bearing Installer 307-541 and the Drawbar 204-029, press the differential bearing cup in the torque converter housing.





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





50. NOTE: The dot on the pump sprocket is installed facing upward.
Install the pump sprocket and chain assembly.






51. Position the pump and filter assembly in place and install the 3 bolts.
- Tighten to 12 Nm (106 lb-in).






52. NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Position the stator support assembly in place on the torque converter housing.






53. Install the 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 (106 lb-in).






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





56. NOTICE: 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 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 the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install a new halfshaft seal on Cover Axle Seal Installer 307-582A.





60. Using the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install the halfshaft seal in the transaxle case.