Assemble Part 2
part 2
82. Install input piston into housing then the O-ring onto input shaft.
83. Install spring retainer into piston, then the 3rd clutch piston housing into input housing
84. Compress third clutch housing using tool No. J-23327, then install snap ring.
85. Install 3rd clutch inner seal, then the 3rd clutch piston into housing.
86. Install 3rd clutch spring retainer by compressing with tool No. J-23327, then installing snap ring.
87. Install 3rd clutch plates alternate, beginning with steel plate.
88. Install 3rd clutch backing plate with stepped side facing up, then secure with snap ring.
89. Install input clutch plates alternately, starting with composition plate.
90. Install input clutch backing plate with identification mark facing
upward, then insert snap ring.
91. Ensure proper operation of input clutch assembly by applying approximately 90 psi of air pressure to air passages marked C and D and check for proper clutch apply.
92. Remove 2nd clutch support from 2nd clutch assembly, then the 2nd clutch backing snap ring.
93. Remove clutch plates, then the waved plate.
94. Remove 2nd clutch hub snap ring, then the apply ring and spring return.
95. Remove 2nd clutch apply piston.
96. Inspect backing plate for damage, then the steel and composition plates for wear, lining separation, pitting and/or damage. The 2nd clutch composition plates are presoaked in a friction type solution and cleaning in solvent should be avoided.
97. Inspect apply ring and spring return for damaged or distorted springs or apply ring damage.
98. Inspect piston for damage, then the seal for rolled edges or damage.
99. If necessary to replace piston seal, remove old seal from piston, then apply a suitable lubricant to new seal and install with seal lip facing 2nd clutch housing.
100. Inspect 2nd clutch housing for inner piston seal damage, and replace as necessary.
101. Check for damaged bushings, and spline teeth.
102. Inspect bands for scored surfaces, then the retainer and ball assembly for damage.
103. Check 2nd clutch housing for warpage.
104. If necessary to replace 2nd clutch retainer and ball assembly, remove old assembly using a suitable 3/8 inch drift, then tap new assembly into place.
105. Install 2nd clutch piston and the apply ring and spring return assembly, then secure with snap ring.
106. Install wave plate, alternately install clutch plates starting with a steel plate, then secure assembly with snap ring.
107. Apply approximately 90 psi air pressure to passage 2, check for proper application of 2nd clutch.
108. Inspect selective 2nd clutch thrust bearing and washer for damage and replace as needed.
109. Build up the following assemblies on bench:
a. Install input shaft/sun gear thrust washer on input shaft
b. Install sprag, roller clutch and input sun gear assembly into in ut clutch assembly, ensuring tat clutch hubs engage clutch plate.
110. Install input clutch, roller clutch and sprag assembly into case using J-33381 or equivalent. Do not install 2nd clutch, and clutch thrust bearing or thrust washer at this time.
111. Measure and adjust input shaft endplay as follows:
a. Tighten loading tool against arbor J-26958-B.
b. Install gauging tool J-33386 or equivalent.
c. Insert selective thrust washer into opening "B," check fit using feeler gauges, and select proper thrust washer by referring to the chart.
127. Inspect output shaft, for snap ring groove, spline, journal or bearing damage and replace as necessary.
128. Install output shaft into case, then the C-ring onto output shaft through bottom of case, using tool No. J-28583.
129. Inspect drive and driven sprockets for damaged or chipped teeth, damaged bearing surfaces, then for spline damage.
130. Inspect thrust washers for damage, then the drive link for excessive wear and damaged links.
131. Inspect 4th clutch shaft for damaged bushings and splines, then the turbine shaft for damaged journals, splines and oil seals.
132. If necessary to replace oil seals, proceed as follows.
a. Remove old seals using a suitable cutting tool.
b. Place tool No. J-29569-1 over turbine shaft and coat with petrolatum.
c. Slide new seals into position.
d. Properly seat seals using sizing tool No. J-29569 or J-29829-2.
133. Install thrust washer onto drive sprocket and retain with petrolatum, then assemble sprockets and drive link onto case, ensuring colored link is facing upward.
134. Install thrust washer onto driven sprocket and retain with petrolatum, then insert 4th clutch shaft through driven sprocket.
135. Install 4th clutch apply plate with identification mark facing down, then install 4th clutch plates.
136. Inspect manual valve link and spring retainer or clip for damage or distortion, and inspect manual valve for wear, nicks and scoring. Replace any component found damaged.
137. Inspect input clutch accumulator piston for damage, then the piston seal and replace as necessary.
138. Inspect accumulator pin for scoring, then the spring for bent or collapsed coils.
139. Inspect converter clutch, spring and ball for damage, then the converter clutch piston and seal.
140. Inspect converter clutch pin for damage, then the converter clutch spring for damaged coils.
141. Inspect 3-2 downshift valve and spring for damage, then the axle oil seal.
142. If necessary to replace axle oil seal, remove old oil using a suitable tool, then install new oil seal using tool No. J-34115.
143. Install accumulator pistons, pins and springs into respective bores in case.
144. Install channel plate and modulator port gaskets.
145. Position driven sprocket thrust washer on channel plate, then mount channel plate on case and install control body alignment sleeve in channel plate. Ensure that 4th clutch plate and apply plate tangs are properly aligned with channel plate lugs.
146. Install channel plate retaining bolts as shown in Figure, then torque to specifications.
147. Install manual valve and link, and secure with spring or clip, then position oil weir between channel plate and case.
148. Position check balls in proper positions in channel plate, then install detent spring and roller as assembly
149. Inspect converter clutch solenoid screen and seal for damage and contamination, and replace as needed.
150. Install spacer plate to channel plate gasket, spacer plate and spacer plate to valve body gasket, using alignment pins J-25025-A or equivalent
151. Insert converter clutch solenoid screen along with O-ring through opening in spacer plate. On early design transaxles, the converter clutch solenoid screen is located in valve body and does not use an O-ring seal.
152. Inspect oil pump drive shaft for journal damage, spline damage and/or seal damage and replace as necessary.
153. Install oil pump drive shaft, then the converter clutch solenoid screen.
154. Clean control valve assembly in a suitable solvent, ensuring to actuate valves to insure any dirt and debris is dislodged, then air dry.
155. Position control valve assembly on a clean surface as shown in figures.
156. Remove valve trains, beginning at upper left hand corner of control valve assembly. Some valves are under spring pressure and bore should be covered with a clean shop cloth when removing roll pin.
157. Remove blind hole roll pins using a suitable tool, then place valves, springs and bushings on clean surface exactly the way they were removed.
158. Remove servo pipe lip seals, then clean all integral components in a suitable solvent and dry with compressed air.
159. Inspect all valves and bushings for scoring, nicks and scratches, then the springs for damaged or distorted coils.
160. Inspect valve body casting for porosity, interconnected oil passages, damaged machine surfaces and damaged oil shaft pump bearing.
161. If necessary to replace oil pump shaft bearing, remove old bearing using tool No. J-28698 and a suitable too, then install new bearing until properly seated using same tool.
162. Assemble control valve assembly in exactly the reverse order of disassembly. Ensure proper positioning of valve lands and bushing passages, then install new servo pipe lip seals.
163. Install check balls into control valve assembly, and retain with petrolatum, then place control valve assembly onto channel plate and position on alignment ins.
164. Install control valve attaching bolts, then torque to specifications.
165. Install servo pipes into valve body, then the retainer and attaching bolt
166. Remove oil pump cover attaching bolts, then the pump cover.
167. Remove vane ring, then the vanes.
168. Remove rotor, then the vane ring.
169. Remove seal, then the springs.
170. Remove slide, then the slide seal support and slide seal.
171. Remove pivot pin, roll pin, then the 3-2 coast down valve, spring and bore plug.
172. Clean all pump components in a suitable solvent, then air dry.
173. Inspect pump body for porosity, interconnected oil passages, pump pocket damage and damaged machined surfaces.
174. Inspect slide, springs, rotors and vanes for damage, then the seals and support.
175. If rotor, vane or slide require replacement, select new components as follows:
a. Measure an undamaged portion of component to be replaced as shown in Figure.
b. Select properly sized replacement as shown in chart. Failure to select properly sized replacements for the rotor, vane or slider will cause damage to transaxle.
176. Inspect cover, bearings and vane rings for damage and distortion.
177. Inspect pressure switches and connectors, and the VCC thermistor if equipped, and replace if damaged or deformed.
178. Install 3-2 coast down valve train into pump body, then the vane ring onto pump pocket.
179. Install pump slide into pump body, then the seal and support into slide.
180. Insert inner priming spring into outer priming spring, then press springs into pump.
181. Install seal onto slide, then the seal ring.
182. Install rotor into pump body, then insert vanes into rotor, ensuring vanes are flush with top of rotor. Install vane ring.
183. Install pump cover onto pump body, then insert attaching bolts.
184. Install pump pressure screen into pump, then place pump onto control valve assembly and torque attaching bolts to 10 ft. lbs.
185. Install case connector and O-ring, converter clutch solenoid and the wiring harness in positions noted during disassembly.
186. Install gaskets onto case and channel plate, then install side cover and insert attaching bolts. Torque attaching bolts to 10 ft. lbs.
187. Remove oil pipes from accumulator cover and governor retainer, then the governor screen from pipe.
188. Inspect governor oil pipes, orifice cup plug and lube oil pipes for damage, then the accumulator cover for damage or porosity.
189. Inspect accumulator pistons and seals for damage and replace seals as necessary, then check springs for collapsed or damaged coils.
190. Inspect lube pipe for damage, then the thermo element
191. If necessary to replace thermo element, proceed as follows:
a. Remove washers and pins, then the thermo element.
b. Remove element plate.
c. Set thermo pin height using tool No. J-34094, then install element plate.
d. Install washer and pin assemblies, then set pin height using tool No. J-34094.
e. Install new thermo element.
192. Install accumulator pins into case, then the accumulator springs. The 3-4 accumulator springs are larger than the 1-2 accumulator
springs.
193. Place accumulator pistons onto pins, then place spring into pocket.
194. Install lube oil pipe retainer onto lube pipe, then place O-ring seal onto retainer.
195. Install lube oil pipe into case, ensuring pipe is installed into driven sprocket support lube hole, then place spacer plate with new gasket onto case.
196. Place oil pipes into accumulator cover, then install governor screen into governor feed pipe, closed end first.
197. Insert governor pipes into governor retainer, then install oil scavenging scoop and attaching bolts.
198. Place accumulator cover, pipes and governor retainer as an assembly, onto case, ensuring lube pipe is installed into final drive internal gear, then insert attaching bolts and torque to 20ft lbs.
199. Install new filter lip seal into case, then a new filter.
200. Install new case gasket, then position case magnet as shown.
201. Install bottom pan, then insert attaching bolts and torque to 10 ft lbs.
202. Inspect servo pistons for cracks and/or damage, then the servo seals, and replace as necessary. Do not remove seals unless replacement is required.
203. Measure apply pin length as described under Transaxle Disassembly, step 19.
204. Assemble 1-2 and reverse servo as follows:
a. Place spring retainer onto pin, noting reverse servo pin is larger than 1-2 servo pin, the 1-2 servo spring retainer has a step that faces spring and the reverse servo has a wave spring and two retainers with the wave spring installed between the retainers.
b. Place cushion spring onto pin, then the servo piston.
c. Insert snap ring.
205. Install servo return spring into servo bore, then insert servos into case.
206. Install new servo cover oil seal ring, then the cover into case and insert snap ring into groove.
Governor & Modulator-Less Internal Speed Sensor:
Governor With Internal Speed Sensor:
207. Thoroughly clean governor assembly in a suitable solvent, then inspect governor assembly for blocked oil passages, damaged springs, seals or binding weights.
208. Inspect gear for worn or damaged teeth, then the bearing for damage.
209. Inspect cover for porosity or cracks, then the speedometer gear for wear.
210. Inspect governor sleeve for damage.
211. Install governor assembly into case, then the gear onto governor.
212. Install new governor cover O-ring seal, then the governor cover onto case, ensuring shaft is correctly positioned in case cover.
213. Insert governor cover attaching bolts, then torque to 8 ft lbs.
214. Inspect transmission modulator as follows:
a. Obtain known good modulator, then place both in tool J-24466.
b. Apply pressure to both modulators.
c. If indicator lines on tool move out of view, replace modulator.
d. Inspect exterior for nicks or damage.
215. Install modulator valve into case, then lace new O-ring seal onto modulator.
216. Install modulator into case, then insert retainer and bolt
217. Remove transaxle support fixture, then place transaxle assembly onto a suitable jackstand.
218. Install converter assembly, then the converter holding strap.