Steps 53 - 105

53. Install the chain pan in the transaxle case.





54. Assemble and install the drive chain assembly.
1 Drive chain (copper colored link facing upward).
2 Driven sprocket assembly.
3 Reverse/overdrive ring gear assembly.
4 Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.





55. Install the chain pan cover by snapping it into place.





56. Install the No. 13 driven sprocket thrust bearing.





57. Install the final drive carrier and differential assembly.

Note: Plastic washers should be placed between bolt heads and special tool.





58. Install the special tools.
1 Install the special tool.
2 Install the special tool and bolts.





59. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
1 Repeat this measurement 180 degrees from the first measurement.
2 The average of these two dimensions is dimension B.
60. Use combined thickness of the special tool with long spacers 177.8 mm (7.11 inch) as dimension A.
61. Subtract dimension B from dimension A. This is dimension C.
62. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.





Differential End Play No.14 Shim





63. Install the differential bearing assembly
1 Install the No. 14 differential bearing shim (selective fit).
2 Install the No. 15 differential bearing.

Note: Check for correct alignment of the lube tube on the converter housing.





64. Install the torque converter housing onto the transaxle case.
1 Position and install the split flange gasket.

Note: Tighten the bolts in the indicated sequence.





65. Install the torque converter housing-to-transaxle case bolts.

Note: Note the number of grooves on the intermediate and overdrive servo apply rod.





66. Lubricate the assembly with clean MERCON (R) Automatic Transaxle Fluid (ATF).
1 Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
2 Install the intermediate and overdrive servo apply rod and piston assembly.
3 Install the overdrive servo apply rod spring.





67. Install the special tool.

Note: Struts on the special tool fit into the servo cover retaining ring groove.





68. Assemble the special tool.
1 Install struts.
2 Install bar.
3 Install bolts.
4 Install the center bolts





69. Using the special tool, measure the distance to the bar of special tool.
1 Record this as dimension A.





70. Back off the center bolt of special tool until the piston movement stops.





71. Using the special tool, measure the dimension to the bar of special tool record as dimension B.
1 Subtract dimension A from B to find the travel.
2 If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.





Intermediate/Overdrive Servo Apply Rod

Warning: Servo return spring force is very high. Failure to follow these instructions can result in personal injury.





72. Assemble the special tool.





73. Install the special tool.

Note: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.





74. Tighten the special tool bolt.
1 Install the servo cover retaining ring, using retaining ring pliers.





75. Loosen the special tool bolt.
1 When spring tension is released, remove the special tool.

Caution: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.

Note: If any leaks occur, make sure the special tool is correctly seated.





76. Using the special tool, inspect the hydraulic circuits. Use a rubber-tipped blow gun and 19 kPa (2.76 psi) of moisture-free regulated compressed air.
1 Reverse clutch test port.
2 Forward clutch test port.
3 Direct clutch test port.
4 Low/reverse clutch test port.
5 Servo release test port.
6 Servo apply test port.
7 Transaxle air test plate.
8 If air leakage is detected, disassemble the transaxle and locate source of leakage.





77. Install the thermostatic fluid level control valve.
1 Position the thermostatic fluid level control valve.
2 Install the bracket.
3 Install the thermostatic fluid level control valve bracket bolt.





78. Install forward clutch circuit filter (if equipped).

Caution: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.





79. Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.

Caution: Handle main control valve body with care to prevent manual valve damage.





80. Connect the manual valve.
1 Lift the main control away from the case.
2 Connect the Z-link to the manual valve.

Note: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.





81. Install the main control valve body mounting bolts.





82. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.





83. Move the manual control lever shaft to the "D" position.
1 Install pin to hold special tool in place.





84. Move the manual valve detent lever assembly to the "D" position.





85. Tighten the nut on the ball.
1 Remove the shifter pin from the special tool.





86. Tighten the detent nut. Rotate back to "D" position to recheck the adjustment.





87. Using the special tool, recheck the manual control lever assembly setting.





88. Install the manual control lever.





89. Rotate the manual valve detent lever assembly to the NEUTRAL position.
1 Low 1
2 Low 2
3 Drive
4 Neutral
5 Reverse
6 Park





90. Position the transaxle range (TR) sensor.





91. Using the special tool, align the TR sensor and tighten the bolts.
92. Install the main control cover gasket.

Note: Tighten the bolts in the indicated sequence.





93. Install the main control cover.





94. Install the vent tube.





95. Install a new transaxle filler tube grommet.





96. Install the transaxle filler tube assembly.
1 Install the tube.
2 Install the transaxle filler tube bolt.
1 Install the fluid level indicator.





97. Install the turbine shaft speed (TSS) sensor.
1 Use petroleum jelly on the O-ring seal and position the TSS sensor.
1 Install a new O-ring seal.
2 Install the TSS sensor bolt.





98. Using the special tool, install the LH differential seal.





99. Using the special tool, install the RH differential seal.

Note: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.





100. Using the special tool, install the torque converter fluid seal.
1 Coat the torque converter seal garter spring with petroleum jelly.





101. Install the drain plug.





102. Install the output shaft speed (OSS) sensor.

Note: Check for correct rotation of the pump drive shaft.





103. Install the pump drive shaft.





104. Using the special tool, install the torque converter.





105. Remove the transaxle from the special tool.