Part 2

Assembly Continued








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.
^ 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 transaxle fluid.
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 bolt.





69. Using the special tool, measure the distance to the bar of special tool.
^ Record this as dimension A.
70. Back off the center bolt of special tool until the piston movement stops.





Vehicles with narrow groove case

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








Intermediate/Overdrive Servo Apply Rod





Vehicles with wide groove case

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





Intermediate/Overdrive Servo Apply Rod

All applications

73. Wipe the servo piston and the servo cover cap with a lint-free cloth.

Caution: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.

74. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attached to the servo rod.
75. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston.





76. Inspect the servo retainer spring for cracks, breaks or deformation.





77. Install the special tool.

Caution: If the case is stamped WG, install a wide-groove snap ring, or damage to the servo will result.

Caution: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.

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.





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





79. Loosen the special tool bolt.
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.





80. 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. Transmission air test plate.
If air leakage is detected, disassemble the transaxle and locate source of leakage.





81. 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.

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





82. 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.





83. 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.





84. Install the main control valve body mounting bolts.





85. Install the manual control lever.





86. 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.





87. Position the transaxle range (TR) sensor.
88. Using the special too[, align the TR sensor and tighten the bolts.

Note: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary.





89. Install the main control cover gasket.

Note: Tighten the bolts in the indicated sequence.





90. Install the main control cover.





91. Install the vent tube.





92. Install a new transaxle filler tube grommet.





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





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





95. Using the special too], install the LH differential seal.





96. 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.





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





98. Install the drain plug.

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





99. Install the pump drive shaft.





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

Note: The torque converter hub must be fully seated into the transaxle pump drive gear.





101. Check the installation depth of the torque converter.
^ Lay a straightedge on the transaxle converter housing.
^ Check the clearance between the straight edge and the pilot hub.





102. Remove the transaxle from the special tool.