General Repair Notes and Instructions
GENERAL REPAIR INSTRUCTIONS1. Use fender, seat and floor covers to keep the Vehicle clean and prevent damage.
2. During disassembly, keep parts in the appropriate order to facilitate reassembly.
3. Observe the following:
a. Before performing electrical work, disconnect the negative (-) terminal cable from the battery.
b. If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (-) terminal which is grounded to the vehicle body.
c. To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it.
d. Clean the battery terminal posts and cable terminals with a clean shop rag. Do not scrape them with a file or other abrasive objects.
e. Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post.
f. Be sure the cover for the positive (+) terminal is properly in place.
4. Check hose and wiring connectors to make sure that they are secure and correct.
5. Non -reusable parts
a. Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones.
b. Non-reusable parts are indicated in the component illustrations by a "DIAMOND" symbol.
6. Precoated parts
Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory.
a. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.
b. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.
c. Precoated parts are indicated in the component illustrations by a "STAR" symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure.
10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.
11. To pull apart electrical connectors, pull on the connector itself, not the wires.
12. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
a. If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety.
b. After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly.
GENERAL NOTES
The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: DEXRON(R) II
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least 15 minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.