Transaxle Reassembly
- Handle all parts carefully to avoid damaging bearing and mating surfaces. Lubricate all parts with Dexron-II ATF before reassembly. Gaskets and thrust washers may be held in place with petroleum jelly.
- Place transaxle on bench with oil pan mounting surface up. Install annulus gear and output flange assembly with bearings and transfer drive gear attached. Install snap ring on output flange rear bearing.
- Install bearing outer races, inner races and spacer (in proper direction) to transfer idle gear. See Fig 1 . Coat spacer with petroleum jelly, and attach spacer to transaxle case. Install NEW "O" ring in groove of transfer idler gear shaft.
- Install transfer idler gear assembly in transaxle case. Insert idler shaft from outside of case. Install and tighten idler shaft to transaxle case using Wrench Adapter (09454-21100).
- Using torque wrench and Torque Wrench Adapter (09458-33001), measure output flange preload. See Fig 2 . Preload should be 7 INCH lbs. (0.8 N.m).
- If preload is incorrect, tighten or loosen transfer idler shaft until correct reading is obtained. Install idler shaft lock plate, and tighten bolt to 35-43 ft. lbs. (48-60 N.m).
- Install NEW "O" ring in groove around output flange and install bearing retainer. Apply sealant to top of bearing retainer screws. Ensure sealant does not ooze out of screw heads. Tighten screws to 11-15 ft. lbs. (15-20 N.m). Use hammer and punch to lock screw head in position to prevent rotation. Install transfer shaft and tapered bearing into case. Install Transfer Shaft Retainer (09455-21301) on converter housing. See Fig 3 .
- Install transfer shaft bearing inner race, outer race and snap ring to transfer shaft (end opposite retainer plate). Install transfer driven gear onto transfer shaft. Install snap ring on end of transfer shaft. Turn transaxle case so engine mating side is up.
- Install thrust race No. 11 and thrust bearing No. 12. See Fig 4 . Install planetary gear carrier on internal gear. Attach thrust race No. 10 and bearing No. 9 to forward sun gear. Assemble forward sun gear with reverse sun gear, and install assembly into planetary gear carrier. Install lined plates and steel plates. Install pressure plate and return spring. Attach wave spring to center support.
- Install 2 NEW "O" rings into center support assembly. Attach Center Support Remover (09453-21310) to center support. Lubricate overrunning clutch of low-reverse brake in center support with Dexron-II ATF. Insert center support and low-reverse brake assembly into case. Install snap ring.
- Insert manual control shaft into case, pushing it fully toward manual control lever. With shaft fully seated against inner part of case, install a NEW "O" ring.
- With "O" ring installed, pull manual control shaft back until set screw groove is aligned with set screw hole. Install set screw with gasket, detent ball and spring as shaft is pulled back into place. Tighten set screw to 71-89 INCH lbs. (8-10 N.m).
- Install parking sprag rod to detent plate of manual control shaft. Install parking sprag rod support, and tighten bolts to 15-19 ft. lbs. (20-26 N.m).
- Install "O" ring at top center of valve body (brake oil pressure passage). Install valve body in transaxle, fitting detent plate pin (for manual control shaft) in slot of manual valve. Install and tighten valve body bolts to 89-102 INCH lbs. (10-11.5 N.m).
- Install solenoid valve connector it case, with cutout facing oil pan side. Install oil filter, oil pan gasket and oil pan. Tighten bolts to 89-102 INCH lbs. (10-11.5 N.m).
- Turn transaxle over so oil pump mounting surface is facing upward. Install anchor rod for kickdown band. Install kickdown servo spring, piston and servo switch. Install snap ring.
- Install kickdown band, and attach band ends to anchor rod and servo piston rod. Install kick down drum, meshing splines with reverse sun gear. Place kickdown band on kickdown drum, and tighten kickdown servo adjusting screw (if equipped) to hold band in place.
- Install thrust bearing No. 8 and thrust race No. 7 on kickdown drum. See Fig 4 . Install clutch hub to forward sun gear splines. Install thrust race No. 5 and thrust bearing No. 6 on clutch hub.
- Install fiber thrust washer No. 2 on rear clutch retainer. Install thrust bearing No. 4 and metal thrust race on rear clutch retainer. Combine front and rear clutch assemblies and install assemblies. Install differential assembly.
- Attach thrust race No. 3 to rear of oil pump assembly. If end play (measured during disassembly) is not .012-.040" (.30-1.00 mm), replace thrust washer No. 1 to correct end play. See Fig 4 . When selecting thrust washer No. 1, select appropriate thrust race No. 3 to be used with thrust washer No. 1. See THRUST WASHER & THRUST RACE SELECTION table.
- Install original or selected thrust washer No. 1 on front clutch. Install Oil Pump Guide Pin (09452-21401) in transaxle case. Install oil pump gasket and oil pump assembly, and remove guide pin. Install "O" ring in groove of oil pump housing, and lubricate "O" ring with Dexron-II. Install oil pump, and tighten bolts to 11-16 ft. lbs. (15-22 N.m). Ensure thrust washer does not drop out of place.
- Ensure transfer shaft end play (measured during disassembly) is .0010" (.025 mm). If end play is incorrect, remove bearing outer race, and replace old spacer with NEW spacer. See TRANSFER SHAFT END PLAY SPACERS table. Reinstall bearing outer race.
- Apply silicone sealant to top parting surface of transaxle case. Place spacer on differential bearing outer race. Install gasket on transaxle case. Install converter housing, and tighten bolts to 14-16 ft. lbs. (19-22 N.m).
- Check differential case end play. End play should be 0-.006" (0-0.15 mm). Install transfer shaft cover and holder. Install drive shaft oil seals. Install inhibitor switch and manual lever. Tighten inhibitor switch bolt to 89-106 INCH lbs. (10-12 N.m). Adjust inhibitor switch (if necessary). Install pulse generators. Tighten pulse generator bolts to 89-106 INCH lbs. (10-12 N.m).
- Insert end clutch shaft with longest spline inward. Install thrust washer with grooved side outward. Install end clutch hub to end clutch. Fit thrust bearing No. 13 on return spring end of end clutch hub. Install end clutch and cover.
- Lubricate torque converter surface (where converter slides into oil pump) with Dexron-II fluid, and carefully install converter. Ensure converter meshes with oil pump drive gear.
- After installing torque converter, measure distance from mating surface of converter housing to torque converter machined surface mounting tabs. Torque converter is properly installed when measurement is approximately .47" (12 mm). If not, remove converter and check alignment of converter with oil pump drive.
NOTE:
It may be necessary to use Spring Compressor (09222-28000) to install kickdown servo piston snap ring.
NOTE:
If thrust race No. 3 is replaced with one of different thickness, also replace thrust washer No. 1 between oil pump and front clutch.
THRUST WASHER & THRUST RACE SELECTION
| Washer No. 1 Thickness In. (mm) | Race No. 3 Thickness In. (mm) |
|---|---|
| .055 (1.40) | .039 (1.00) |
| .055 (1.40) | .047 (1.20) |
| .071 (1.80) | .055 (1.40) |
| .071 (1.80) | .063 (1.60) |
| .087 (2.20) | .071 (1.80) |
| .087 (2.20) | .079 (2.00) |
| .102 (2.60) | .087 (2.20) |
| .102 (2.60) | .095 (2.40) |
TRANSFER SHAFT END PLAY SPACERS
| Part No. | Thickness In. (mm) |
|---|---|
| 45851-37120 | .0472 (1.200) |
| 45851-37123 | .0484 (1.230) |
| 45851-37126 | .0496 (1.260) |
| 45851-37129 | .0508 (1.290) |
| 45851-37132 | .0520 (1.320) |
| 45851-37135 | .0531 (1.350) |
| 45851-37138 | .0543 (1.380) |
| 45851-37141 | .0555 (1.410) |
| 45851-37144 | .0567 (1.440) |
| 45851-37147 | .0579 (1.470) |
| 45851-37150 | .0591 (1.500) |
| 45851-37153 | .0602 (1.530) |
| 45851-37156 | .0614 (1.560) |
| 45851-37159 | .0626 (1.590) |
| 45851-37162 | .0638 (1.620) |
| 45851-37165 | .0650 (1.650) |
| 45851-37168 | .0661 (1.680) |
| 45851-37171 | .0673 (1.710) |
| 45851-37174 | .0685 (1.740) |
| 45851-37177 | .0697 (1.770) |
| 45851-37180 | .0709 (1.800) |