Assemble

1. Install rear bearing snap ring to case.

2. Using suitable snap ring pliers, expand snap ring, then install rear bearing to bearing bore. Snap grooves on bearing should be up on output and down on input.

3. Install O-ring to reverse idler shaft end.

4. Using Dexron II or Dexron IIE lube and install reverse idler gear bearing.

5. Install O-ring to opposite end of shaft.

6. Install reverse idler gear to case with chamfer side of gear towards rear of case.

7. Lube O-ring, then twist shaft through gear into case, ensuring O-ring stays in position.

8. Install reverse idler shaft cap using twisting motion, then tighten two attaching bolts to specifications.

9. Install rear cover dowel pins as required.

10. Using suitable bolt and washers, with minimum shank of 1.75 inch, arc diameter of 1.0 inch and washer minimum thickness of 0.44 inch, install manual detent shaft oil seal, ensuring seal seat in bore.

11. Using sealant part No. 518 P/N 21005993, or equivalent, apply to both sides of gasket or case using small roller, then install case to converter housing gasket.

12. Install transaxle case, lower case over shafts and work down onto differential bearing, turning reverse idler gear as required.




13. Install case to converter housing attaching bolts, then tighten in sequence to specifications. Two bolts are on torque converter side of housing, do not turn transaxle until 1st gears are installed.

14. Ensure both shafts rotate freely.





15. Using differential endplay tool No. SA9112T, or equivalent, select largest gauge tool the will fit between case bearing pocket and outer differential race.

16. Select proper snap ring using tool No. SA9112T, or equivalent, then install snap ring.

17. Apply sealant part No. 518 P/N 21005993, or equivalent, case side axle seal mating surface, then install seal using tool No. SA9113T, or equivalent.

18. Install retaining ring.

19. Install forward/reverse servo piston seal ring, as required, as follows:




a. Position servo piston on seal installation support base tool No. SA9137T-2, or equivalent.

b. Install expander cone tool No. SA9137T-1, or equivalent, to servo piston.

c. Lube seal ring using Dexron II, then position seal on expander cone.

d. Using seal pusher tool No. SA9143T, or equivalent, install seal ring.

e. Position servo piston on seal sizer support base tool No. SA9137T-4, or equivalent.

f. Using sizer tool No. SA9137T-3, or equivalent, over piston with large internal diameter facing downward, size seal rings until tool bottoms out.

20. Slide forward/reverse fork onto second reverse gear.




21. Install forward/reverse servo piston to bore and align fork and servo shaft as servo is pushed inward, prior to pushing servo all the way in, align servo bolt hole with fork hole. Servo shaft flat should face differential side of transaxle.

22. Clean 2nd/reverse servo bolt threads, then apply thread lock sealant 242 P/N 21485277 or equivalent to bolt threads.

23. Install servo bolts and tighten to specifications.

24. Install servo spring.

25. Install servo cover O-ring, then install cover and tighten attaching bolts to specifications.

26. Install 1st driven gear and sprag assembly.

27. Install 1st driven gear thrust washer.

28. Move park pawl actuator rod to engage parking pawl.

29. Install new input shaft clamp nut and tighten quickly to specifications. The thread locking material used on the new nut will cure in a short time and an incorrect torque will occur if not tightened fast enough.

30. Install 1st drive gear hub assembly.

31. Hold first gear and clutch assembly together, then install to input shaft.

32. Install input shaft holding tool No. SA9119T, or equivalent.

33. Install input shaft clamp nut and tighten to specifications.

34. Connect manual valve link to manual detent lever.

35. Install manual detent and link to transaxle, then connect park lock actuator rod to detent lever.

36. Hold detent lever, slide manual detent lever shaft through case and detent lever, rotate shaft until shaft and lever dowel holes align, then install new roll pin.

37. Install selector switch attaching bolts, but do not tighten bolts.

38. Install new case gasket.

39. Install rear cover, insert input and output shaft tube shaft ends and lower cover. If cover does not seat, turn input and output shafts to align shaft bushings.




40. Lubricate and install rear cover attaching bolts in sequence and tighten to specifications.

42. Turn transaxle valve body side up.

43. Apply sealant part No. 515 P/N 21005993, or equivalent, to axle seal to case mating surface, then install converter housing axle seal using tool No. SA9113T, or equivalent.

44. Install converter housing to case attaching bolts and tighten to specifications.

45. Install valve body assembly with valve body flat facing upward, valve body has two should bolts to assist upper and lower valve body alignment.

46. Lower valve body, then install manual link to manual valve.




47. Clean and lubricate valve body to case bolts using Dexron II, or equivalent, then install valve body to case bolts and tighten to specifications in sequence shown.

48. Adjust selector switch as follows:

a. Place in position; check for continuity across selector switch terminals, if continuity is not indicated, rotate switch until continuity is present.

b. Tighten switch to case attaching bolts, then recheck for continuity.

49. Install valve body cover gasket and cover.




50. Clean and lubricate valve body cover bolts using Dexron II, or equivalent, then install valve body cover bolts and tighten to specifications in sequence shown.

51. Install input shaft to converter O-ring, ensuring O-ring is between split washer and converter case and not next to input shaft splines.




52. Using spiral ring expander and installer tool No. SA9135T, or equivalent, install spiral ring.




53. Using converter endplay tool No. SA9163T, or equivalent, check converter endplay. Endplay should be less than 0.026 inch.

54. Install converter O-ring and torque converter. Rotate and support converter to align input shaft spline and pump drive slots to converter.

55. Rotate converter ensuring paint dot is downward.

56. Install transaxle pressure filter, tighten until gasket makes contact, then tighten an additional turn.

57. Install transaxle temperature sensor and tighten to specifications.

58. Install cooler line connectors and tighten to specifications.

59. Install turbine speed sensor and tighten to specifications.

60. Install vehicle speed sensor and tighten to specifications.

61. Install oil indicator tube attaching bolt and tighten to specifications.

62. Install transaxle drain plug and tighten to specifications.