Transaxle Component Initial Assembly: Reassembly

Coat 1st/reverse brake piston with ATF and install on oil pump housing. Insert brake piston/oil pump assembly into transaxle case. Ensure brake piston ball valve lines up with drilling in transaxle housing and anti-rotation lug for thrust washer of oil pump is facing toward top of case.
Install 1st/reverse gear brake shell into case so that tab of shell engages upper groove in transaxle case. See Fig 1 . Position 1st/Reverse brake piston return springs on spring plate, insert plate into case with springs downward, then install attaching bolts and tighten to specified torque in a diagonal pattern.

Fig 1: Installing 1st/Reverse Gear Brake Shell

NOTE: After spring late installation, insert pump shaft into oil pump and ensure that pump gears rotate freely; if not, remove oil pump and ensure that it is assembled correctly.

Lubricate servo cover "O" rings, then install servo assembly into case and install retaining snap ring. Rotate transaxle on work stand so that servo cover points down.
Position 2nd gear brake band in case and ensure that it engages servo piston. Loosely install push rod for adjusting screw, then install adjusting screw and lock nut.
Lubricate Direct/Reverse clutch assembly, then install it into case, sliding it onto oil pump neck and into 2nd gear brake band.
Tighten brake band adjusting screw just enough to prevent band from shifting its position on Direct/Reverse clutch drum. Rotate transaxle case so that open end is facing up.
Place thrust washer in position on forward clutch and use, petrolatum to hold it in place. Install forward clutch assembly into Direct/Reverse clutch, making sure splines on forward clutch drum fully engage splines on Direct/Reverse clutch lined clutch plates.
Install forward planetary-to-forward clutch thrust washer into forward clutch. Install planetary gear set into forward annulus gear in forward clutch. Install sure gear (short end first) into gear set, then install driving shell and thrust washer over sun gear.

NOTE: Ensure lugs of driving shell engage tabs of Direct/Reverse clutch drum.

Install thrust washer on underside of reverse planetary gear set and use petroleum to hold in place. Install gear set into case and onto sun gear.

NOTE: Lined brake plates must be soaked in automatic transaxle fluid for at least 1 minutes prior to installation.

Install 1st/Reverse brake waved washer into case. Install 1st/Reverse brake plates into case starting with a steel (external splines) plate and alternating lined (internal splines) plates and steel plates until all brake plates are installed. See FIRST/REVERSE BRAKE PLATE APPLICATION table.

FIRST/REVERSE BRAKE PLATE APPLICATION

Application	Steel Plates	Lined Plates
All Models	5	5

Install 1st gear one-way clutch assembly into transaxle case, then push clutch downward while rotating reverse planetary gear set to fully engage parts.

NOTE: With one-way clutch installed, it should not be possible to rotate reverse planetary gear set counterclockwise due to the locking action of the one-way clutch.

Install one-way clutch-to-case snap ring. If all parts are correctly installed, the one-way clutch snap ring groove will be exposed. Do not attempt to force snap ring into groove of an incorrectly assembled transaxle. See Fig 2
Position both thrust washers on rear side of reverse planetary gear set annulus gear, then install gear into transaxle case so that it fully engages planetary gear set.
Install separation plate gasket over case studs, place separation plate on top of gasket, then install and tighten attaching screws.

NOTE: At this time 2nd gear brake band must be adjusted. To adjust band, the transaxle case must be horizontal to prevent band from jamming. Adjust band as follows:

Loosen lock nut and tighten brake band adjusting screw to 87 INCH lbs. (10 N.m). Loosen screw. Retighten again to 43 INCH lbs. (5.0 N.m). Back off adjusting screw 2 1/2 turns and tighten adjusting screw lock nut.
If case linkage was disassembled, reassemble in case using Figure as an assembly guide.
Install a new seal on accumulator piston (lip pointing toward case), and install piston and spring into case. Install valve body assembly into case, making sure manual valve engages manual lever, and that kickdown valve engages kickdown lever. Install valve body-to-case attaching bolts and tighten from center outward.

NOTE: Do not use sealer on oil pan gasket, as any, surplus sealer may find its way into transaxle fluid and cause control valves to stick.

Position a new oil pan gasket on transaxle case. Install oil pan and tighten attaching bolts.

Fig 2: Installing 1st Gear One-Way Clutch Circlip