Part 1

ASSEMBLY

CAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contaminate and/or fail a new or rebuilt unit.

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM Quick Learn procedure must be performed.





1. Install both output bearing cups using Tool 6060 (Fig. 79).





2. Install low/reverse piston retainer gasket (Fig. 80). Make sure gasket holes line up with case.





3. Install low/reverse piston retainer (Fig. 81).





4. Install low/reverse piston retainer-to-case bolts (Fig. 82) and torque to 5 Nm (46 in. lbs.).





5. Install low/reverse clutch piston (Fig. 83).








6. Assemble park guide bracket assembly (Fig. 85) (Fig. 84).





7. Install guide bracket into position and insert pivot shaft (Fig. 86).





8. Install anchor shaft and plug (Fig. 87). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.





9. Install low/reverse piston return spring (Fig. 88).








10. Install low/reverse spring compressor into position (Fig. 89). Compress low/reverse piston and install snap ring as shown in (Fig. 90).





11. Install rear carrier bearing cone using Tool 6063 (Fig. 91).





12. Install rear carrier assembly to transaxle case (Fig. 92).





13. Install output gear bearing cone using Tool 5062 (Fig. 93).
14. OUTPUT GEAR BEARING ADJUSTMENT:





a. With output gear removed, install a 4.60 mm (0.177 inch) gauging shim (Fig. 95) on the rear carrier assembly hub, using grease to hold the shim in place.
b. Using Tool 6259, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.).





c. Measure bearing end play. Attach Tool L-4432 to the gear (Fig. 94).
d. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
e. Using a dial indicator mounted to the transaxle case, measure output gear end play as shown in (Fig. 94).
f. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
g. Use Tool 6269 to remove the output gear retaining bolt and washer. To remove the output gear, use Tool L4407A.
h. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.





OUTPUT GEAR BEARING SHIM CHART





15. Install the output gear and bearing assembly using Tool 6261 (Fig. 96).








16. Install NEW output gear retaining bolt and washer (Fig. 97). Using Tool 6269, torque output gear retaining bolt to 271 Nm (200 ft. lbs.) (Fig. 98).





17. Using an inch pound torque wrench (Fig. 99), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs. If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque of 3 - 8 in. lbs. is obtained.





18. Install output gear stirrup with serrated side out (Fig. 100).
19. Install retaining strap.





20. Install strap bolts but do not tighten at this time (Fig. 101).





21. Rotate stirrup clockwise against flats of retaining bolt (Fig. 102).





22. Torque stirrup strap bolts to 23 Nm (200 in. lbs.) (Fig. 103).





23. Bend tabs on strap up against flats of bolts (Fig. 104).





24. Install transfer shaft bearing cone using Tool 6062 (Fig. 105).





25. Install bearing cup and oil baffle to transfer shaft (Fig. 106).





26. Using Tool 6049A, install transfer shaft (Fig. 107).





27. Using Tool 6061, install transfer shaft bearing snap ring (Fig. 108).





28. Install transfer shaft bearing cup into retainer using Tool 6061 (Fig. 109).





29. Install bearing cup retainer to transaxle (Fig. 110).





30. Install transfer gear bearing cone to transfer gear using Tool 6062 (Fig. 111).
31. TRANSFER GEAR BEARING ADJUSTMENT.





a. Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft (Fig. 112).
b. Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
c. Measure end play. Attach Tool L4432 to the transfer gear.
d. Mount a steel ball with grease into the end of the transfer shaft.
e. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
f. Using a dial indicator, measure transfer shaft end play.
g. Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
h. Use Tool 6269 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
i. Remove the gauging shim (Fig. 112) and install the proper shim indicated by the chart.





TRANSFER SHAFT BEARING SHIM CHART





32. Install the transfer shaft gear using Tool 6261 (Fig. 113).