Part 2
-
TRANSAXLE - ASSEMBLY
Part 2
Continued From Part 1 Part 1
116. Using the Torque Converter Handle, install the torque converter.
NOTE:The torque converter is heavy. Be careful not to drop it or damage will result.
117. Remove the Torque Converter Handle.
118. Install the Torque Converter Retainer.
119. Remove the transaxle from the bench-mounted holding fixture.
120. Remove the Holding Fixture.
56. Install the front planetary/rear ring gear assembly.
57. Install the forward (1, 2, 3, 4) clutch wave spring.
58. Soak the forward (1, 2, 3, 4) clutch pack in clean automatic transaxle fluid.
59. Install the forward (1, 2, 3, 4) clutch pack.
60. Install the forward (1, 2, 3, 4) clutch pressure plate.
61. Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
a. Forward (1, 2, 3, 4) clutch snap ring.
b. Forward (1, 2, 3, 4) clutch snap ring gap.
CAUTION:Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
62. Using a suitable tool, seat the snap ring in the snap ring groove.
63. Install Dial Indicator Gauge With Holding Fixture 100-002 or a suitable dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
64. Install the low/reverse and forward (1, 2, 3, 4) clutch feed seals in the transaxle case.
65. Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.0039 in) and 1.840 mm (0.0724 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
66. Install the front planetary sun gear and shell assembly.
67. Install the No. 10 thrust bearing.
68. Install the park pawl.
69. Install the park pawl pin and spring.
70. Install the park pawl actuator rod in the TR sensor.
71. Position the park pawl aside and position the park pawl actuator rod and the TR sensor in the transaxle case.
72. Install the manual control shaft and align the roll pin holes.
73. Install the manual control shaft roll pin.
74. Install the manual control lever and the nut.
- Tighten to 24 Nm {2.4 kgf-m, 18 ft-lbf}.
CAUTION:Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
75. Install the 5 clutch feed seals.
76. Position the transmission fluid baffle in place.
77. Install the lube funnel and position the alignment pin in the alignment hole.
78. Position the lube funnel hold-down bracket in place and install the 2 bolts.
- Tighten to 12 Nm {1.2 kgf-m, 106 in-lbf}.
79. Install the No. 12 thrust bearing.
80. Simultaneously install the drive/driven sprocket and chain assembly. Lightly tap on the driven sprocket to be sure it is fully seated in the case.
81. Install the No. 11 thrust bearing.
82. Install the No. 13 thrust washer.
83. Install the final drive sun gear.
84. Install the differential assembly
85. Install the No. 15 thrust bearing.
86. Install the Turbine Shaft Seal Protector on the input shaft.
87. Clean the torque converter housing sealing surface.
88. Assemble the Handle and Seal Installer. Install a new RH seal on the Seal Installer.
89. Using the Handle and Seal Installer, install the RH halfshaft seal.
90. Install the differential ring gear in the torque converter housing.
91. Install the beveled differential ring gear snap ring with the flat side facing down.
CAUTION:Be sure the flat side of the beveled snap ring is facing down or the ring can come loose, causing damage to the transaxle.
92. Seat the snap ring using a suitable tool.
93. Install the pump and filter assembly in the torque converter housing and install the pump bolts.
a. Tighten to 35 Nm {3.5 kgf-m, 26 ft-lbf}.
b. Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
94. Install the transmission fluid baffle and the 2 bolts.
- Tighten to 12 Nm {1.2 kgf-m, 106 in-lbf}.
95. Apply silicone to the sealing surface of the transaxle case.
NOTE:Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
96. Install the torque converter housing on the transaxle case and install the 17 bolts.
a. Tighten to 24 Nm {2.4 kgf-m, 18 ft-lbf}.
b. Stud bolt location.
NOTE:Be sure the stud bolt is in the correct location as noted during disassembly.
97. Remove the Turbine Shaft Seal Protector.
98. Install the TSS sensor and the bolt.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
99. Install the OSS sensor and the bolt.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
100. Assemble the bypass valve in the sleeve and install the assembly in the case.
a. Bypass valve
b. Bypass valve sleeve
101. Install the bypass valve spring.
102. Install the separator plate and align it on the stud and the guide pin.
103. Position the main control assembly in place and align the manual valve on the TR sensor.
NOTE:Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
104. Install the nut hand-tight.
105. Install the short bolts hand-tight.
106. Install the long bolts hand-tight.
107. Tighten the main control bolts and the nut.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
108. Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the bolt.
- Tighten to 13 Nm {1.3 kgf-m, 115 in-lbf}.
109. Install the solenoid body-to-main control cover seal.
NOTE:Be sure the solenoid body-to-main control cover seal is installed with the holes facing up.
110. Connect the TR sensor electrical connector.
111. Connect the OSS sensor electrical connector.
