Part 2
Part 2102. 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.
103. Install 2nd clutch piston and the apply ring and spring return assembly, then secure with snap ring.
104. Install wave plate, alternately install clutch plates starting with a steel plate, then secure assembly with snap ring.
105. Apply approximately 90 psi air pressure to passage 2 to check for proper application of 2nd clutch.
106. Inspect selective 2nd clutch thrust bearing and washer for damage and replace as needed.
107. 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 input clutch assembly, ensuring clutch hubs engage clutch plate.
108. Install input clutch, roller clutch and sprag assembly into case using J-33381 or equivalent. Do not install 2nd clutch, 2nd clutch thrust bearing or thrust washer at this time.
109. Measure and adjust input shaft end play as follows:
a. Tighten loading tool against arbor J-26958.
b. Install gauging tool J-3386 or equivalent.
c. Insert selective thrust washer into opening "B," check fit using feeler gauges, and select proper thrust washer by referring to chart.
d. Remove gauging tool.
110. Install selected 2nd clutch thrust washer, then the thrust bearing, with large race on bearing facing down.
111. Install reverse reaction drum plate onto input housing.
112. Install 2nd clutch assembly onto input clutch assembly, ensuring clutch plates engage input clutch hub and that clutch housing engages reverse reaction drum splines.
113. Inspect reverse band for cracks, damage or lining separation, then position band on anchor pins and install into case.
114. Remove snap ring from driven sprocket support by compressing return spring, using a suitable press.
115. Remove retainer and piston from sprocket support.
116. Inspect driven sprocket support for worn or damaged oil seal rings, then the bushings for damage or scoring.
117. Check for blocked or interconnected oil passages, then the cup plug for blockage.
118. Inspect chain scavenging scoop and weir for cracks or damage, then the piston and seals for wear or damage, and replace as necessary.
119. Inspect thrust washer for damage, then the spring retainer for damaged or distorted springs.
120. Inspect driven sprocket bearing for damage, and if necessary to replace, tap out bearing using tool No. J-34129, then install new bearing using tool No. J-34126 or equivalents, and a suitable press. Ensure bearing is properly seated.
121. Install piston into driven sprocket support using tool No. J-34093 or equivalent, then the spring retainer onto piston.
122. Compress spring retainer using a suitable press, then insert snap ring.
123. Install thrust washer onto driven sprocket support and retain with petrolatum, then insert driven sprocket support into case. Lubrication hole in support must align with hole in bottom of case.
124. Install chain scavenging scoop into case.
125. Inspect output shaft for snap ring groove, spline, journal or bearing damage and replace as necessary.
126. Install output shaft into case, then the C-ring onto output shaft through bottom of case, using tool No. J-28583 or equivalent.
127. Inspect drive and driven sprockets for damaged or chipped teeth, damaged bearing surfaces, then for spline damage.
128. Inspect thrust washers for damage, then the drive link for excessive wear and damaged links.
129. Inspect 4th clutch shaft for damaged bushings and splines, then the turbine shaft for damaged journals, splines and oil seals.
130. 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 or equivalent, 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 or equivalent.
131. Install thrust washer onto drive sprocket and retain with petrolatum, then assemble sprockets and drive link onto case, ensuring colored link is facing upward.
132. Install thrust washer onto driven sprocket and retain with petrolatum, then insert 4th clutch shaft through driven sprocket.
133. Install 4th clutch apply plate with identification mark facing down, then install 4th clutch plates.
134. 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.
135. Inspect input clutch accumulator piston for damage, then the piston seal and replace as necessary.
136. Inspect accumulator pin for scoring, then the spring for bent or collapsed coils.
137. Inspect converter clutch, spring and ball for damage, then the converter clutch piston and seal.
138. Inspect converter clutch pin for damage, then the converter clutch spring for damaged coils.
139. Inspect 3-2 downshift valve and spring for damage, then the axle oil seal.
140. If necessary to replace axle oil seal, remove old oil using a suitable tool, then install new oil seal using tool No. J-34115.
141. Install accumulator pistons, pins and springs into respective bores in case.
142. Install channel plate and modulator port gaskets.
143. Position driven sprocket thrust washer on channel plate, then mount channel plate on case and install control body alignment sleeve in channel plate. Ensure 4th clutch plate and apply plate tangs are properly aligned with channel plate lugs.
144. Install channel plate retaining bolts as shown, then torque to specifications.
145. Install manual valve and link, and secure with spring or clip, then position oil weir between channel plate and case.
146. Position check balls in proper positions in channel plate, then install detent spring and roller as assembly.
147. Inspect converter clutch solenoid screen and seal for damage and contamination, and replace as needed.
148. Install spacer plate to channel plate gasket, spacer plate and spacer plate to valve body gasket, using alignment pins J-25025-A or equivalent.
149. 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.
150. Inspect oil pump driveshaft for journal damage, spline damage and/or seal damage and replace as necessary.
151. Install oil pump driveshaft, then the converter clutch solenoid screen.
152. Clean control valve assembly in a suitable solvent, ensuring to actuate valves to insure any dirt and debris is dislodged, then air dry.
153. Position control valve assembly on a clean surface as shown.
154. 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.
155. Remove blind hole roll pins using a suitable tool, then place valves, springs and bushings on clean surface exactly the way they were removed.
156. Remove servo pipe lip seals, then clean all integral components in a suitable solvent and dry with compressed air.
157. Inspect all valves and bushings for scoring, nicks and scratches, then the springs for damaged or distorted coils.
158. Inspect valve body casting for porosity, interconnected oil passages, damaged machine surfaces and damaged oil shaft pump bearing.
159. If necessary to replace oil pump shaft bearing, remove old bearing using tool No. J-28698 or equivalent, then install new bearing until properly seated using same tool.
160. Assemble control valve assembly in exactly the reverse order of disassembly as shown. Ensure proper positioning of valve lands and bushing passages, then install new servo pipe lip seals.
161. Install check balls into control valve assembly and retain with petrolatum, then place control valve assembly onto channel plate and position on alignment pins.
162. Install control valve attaching bolts, then torque to specifications.
163. Install servo pipes into valve body, then the retainer and attaching bolt. Remove oil pump cover attaching bolts, then the pump cover.
164. Remove vane ring, then the vanes.
165. Remove rotor, then the vane ring.
166. Remove seal, then the springs.
167. Remove slide, then the slide seal support and slide seal.
168. Remove pivot pin, roll pin, then the 3-2 coast down valve, spring and bore plug.
169. Clean all pump components in a suitable solvent, then air dry.
170. Inspect pump body for porosity, interconnected oil passages, pump pocket damage and damaged machined surfaces.
171. Inspect slide, springs, rotors and vanes for damage, then the seals and support.
172. If rotor, vane or slide require replacement, select new components as follows:
a. Measure an undamaged portion of component to be replaced as shown.
b. Select properly sized replacement as shown in charts. Failure to select properly sized replacements for the rotor, vane or slider will cause damage to transaxle.
173. Inspect cover, bearings and vane rings for damage and distortion.
174. Inspect pressure switches and connectors, and the VCC thermister if equipped, and replace if damaged or deformed.
175. Install 3-2 coast down valve train into pump body, then the vane ring onto pump pocket.
176. Install pump slide into pump body, then the seal and support into slide.
177. Insert inner priming spring into outer priming spring, then press springs into pump.
178. Install seal onto slide, then the seal ring.
179. Install rotor into pump body, then insert vanes into rotor, ensuring vanes are flush with top of rotor. Install vane ring.
180. Install pump cover onto pump body, then insert attaching bolts.
181. Install pump pressure screen into pump, then place pump onto control valve assembly and torque to specifications.
182. Install case connector and O-ring, converter clutch solenoid and the wiring harness in positions noted during disassembly.
183. Install gaskets onto case and channel plate, then install side cover and insert attaching bolts. Torque to specifications.
184. Inspect governor oil pipes, orifice cup plug and lube oil pipes for damage, then the accumulator cover for damage or porosity.
185. Inspect accumulator pistons and seals for damage and replace seals as necessary, then check springs for collapsed or damaged coils.
186. Inspect accumulator and servo pistons and seals for damage and replace seals as necessary, then check springs for collapsed or damaged coils.
187. Inspect lube pipe for damage, then the thermo element.
188. If thermo element requires replacement, 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 or equivalent, then install element plate
d. Install washer and pin assemblies, then set pin height using tool No. J-34094 or equivalent.
e. Install new thermo element.
189. Place accumulator pistons onto pins, then place spring into pocket.
190. Install lube oil pipe retainer onto lube pipe, then place O-ring seal onto retainer.
191. 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.
192. Place oil pipes into accumulator cover, then install governor screen into governor feed pipe, closed end first.
193. Insert governor pipes into governor retainer, then install oil scavenging scoop and attaching bolts.
194. 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 specifications.
195. Install servo and accumulator assembly as shown.
196. On all models, install new filter lip seal into case, then a new filter.
197. Install new case gasket, then position case magnet, if equipped, as shown.
198. Install bottom pan, then insert attaching bolts and torque to specifications.
199. On all models, measure apply pin length as described under "Transaxle Disassembly."
200. 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.
201. Install servo return spring into servo bore, then insert servos into case.
202. Install new servo cover oil seal ring, then the cover into case and insert snap ring into groove.
203. Inspect gear for worn or damaged teeth, then the bearing for damage.
204. Inspect cover for porosity or cracks, then the speedometer gear for wear.
205. Inspect governor sleeve for damage.
206. Install governor assembly into case, then the gear onto governor.
207. Install new governor cover O-ring seal, then the governor cover onto case, ensuring shaft is correctly positioned in case cover.
208. Insert governor cover attaching bolts, then torque to specification.
209. Inspect forward and reverse servo pistons and seals for cracks and/or damage, and replace as necessary.
210. Install forward and reverse servo assemblies as shown.
211. Inspect transaxle 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.
212. Install modulator valve into case, then place new O-ring seal onto modulator.
213. Install modulator into case, then insert retainer and bolt.
214. Remove transaxle support fixture, then place transaxle assembly onto a suitable jackstand.
215. Install converter assembly, then the converter holding strap.