Part 1

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TRANSAXLE - ASSEMBLY





































1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.






2. Assemble the Handle and Seal Installer. Install a new LH seal on the Seal Installer.






3. Using the Seal Installer 307-626 and Handle 205-153, install the halfshaft seal in the transaxle case.






4. Install a new manual control shaft seal on Manual Lever Seal Installer.






5. Using the Manual Lever Seal Installer, install the manual control shaft seal in the transaxle case.






6. If not previously installed, install the clutch support tower and the 3 bolts.

- Tighten to 12 Nm {1.2 kgf-m, 106 in-lbf}.






7. Remove Input Shaft Support Seal Installer.






8. Install Clutch Piston Seal Protector.






9. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transaxle fluid.






10. Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.

CAUTION:Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.






11. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
a. Outer tabs.

b. Open area at the bottom of the transaxle case.

c. Bleed hole.

d. Inner double tabs.






12. Remove the intermediate (2, 6) clutch piston return spring.






13. Install 2-6 Spring Compressor on the intermediate (2, 6) clutch piston.






14. Using 2-6 Spring Compressor, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.






15. Remove 2-6 Spring Compressor and Clutch Piston Seal Protector.






16. Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
a. Outer tabs.

b. Outer tabs.

c. Inner double tabs.

CAUTION:Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.






17. Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
a. Snap ring

b. Snap ring gap

c. low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)

CAUTION:Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.






18. Install Snap Ring Installer on the transaxle case to center the intermediate (2, 6) clutch return spring.






19. Install Snap Ring Installer on the snap ring.






20. Install Forward Clutch Spring Compressor on the transaxle case.






21. Using Forward Clutch Spring Compressor and Snap Ring Installer, install the intermediate (2, 6) clutch snap ring in the groove

CAUTION:Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.






22. Remove Forward Clutch Spring Compressor and Snap Ring Installer.






23. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.






24. Install the No. 1 thrust bearing with the flat side facing up.

CAUTION:Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.






25. Install the overdrive/direct clutch assembly.






26. Install the No. 3 thrust bearing with the flat side facing down.

CAUTION:Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.






27. Install the direct/intermediate clutch hub and rear sun gear assembly.






28. Install the intermediate (2, 6) wave spring assembly.






29. Soak the intermediate (2, 6) clutch assembly in clean transaxle fluid.






30. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement






31. Install Shim Selection Gauge on the transaxle case.






32. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge to the top of the intermediate (2, 6) clutch pack at 3 different points. Average the 3 distances.






33. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the top of the transaxle case step above the intermediate (2, 6) clutch.

34. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.0094 in) and 2.60 mm (0.1024 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.





Subtract measurement A from measurement B and check to see if it is within range of 0.240 mm (0.0094 in) and 2.60 mm (0.1024 in).






35. Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.

NOTE:When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.






36. Install the OWC assembly.






37. Install the rear planetary carrier/center ring gear assembly.






38. Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.

NOTE:Note the position of the low/reverse pressure plate. When installing the center support, the long support legs must fit through the low/reverse pressure plate and rest on the OWC.






39. Soak the low/reverse clutch in clean automatic transaxle fluid.






40. Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.






41. Install Shim Selection Gauge on the side of the center support with the long support legs.






42. Using a suitable depth gauge, measure and record as measurement A, the distance from the top of Shim Selection Gauge to the top contact surface of the low/reverse clutch piston.






43. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the leg surface of the center support.

44. Subtract measurement B from measurement A and record as measurement C.









45. Install Shim Selection Gauge on the transaxle case.






46. Using a suitable depth micrometer, measure and record as measurement D, the distance from the Shim Selection Gauge to the top of the OWC.






47. Using a suitable depth gauge, measure and record as measurement E, the distance from the top of Shim Selection Gauge to the top of the low/reverse clutch at 3 different points and average the 3 distances.

48. Subtract measurement E from measurement D and record as measurement F.





49. Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.0165 in) and 2.000 mm (0.0787 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.





Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.0165 in) and 2.000 mm (0.0787 in).






50. Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case

NOTE:When the low/reverse clutch is correctly installed, the wave spring is on top.






51. Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
a. Long center support legs face down.

b. Feed holes face the front of the transaxle case.

NOTE:Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.






52. Install the No. 5 and No. 6 thrust bearings.
a. No. 5 thrust bearing.

b. No. 6 thrust bearing.






53. Install the center sun gear.






54. Install the center carrier/front ring gear assembly.






55. Install the No. 7 and No. 8 thrust bearings.
a. No. 7 thrust bearing.

b. No. 8 thrust bearing.

112. Clean the main control cover sealing surface.






113. Apply silicone to the main control sealing surface of the transaxle case.






114. Position the main control cover in place.






115. Install the main control cover bolts.

- Tighten to 12 Nm {1.2 kgf-m, 106 in-lbf}.

a. Bolt location.

b. Stud bolt location.

NOTE:Install the main control cover stud bolts in the correct location as noted during disassembly.





Continued in Part 2 Part 2