Assembly Part 2

NOTE: Screw Tool 5049-A onto transfer shaft. Install transfer shaft.

Fig. 238:

Fig. 239:

Fig. 240:

Fig. 241:

Fig. 242:

TRANSFER SHAFT BEARING
1. Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft.
2. Install transfer shaft gear and bearing assembly and torque the nut to 271 Nm (200 ft. lbs.). To measure bearing end play:
- Attach Tool L-4432 to the transfer gear.
- Mount a steel ball with grease into the end of the transfer shaft.
- Push and pull the gear while rotating back and forth to insure seating of the bearing rollers.
- Using a dial indicator, measure transfer shaft end play.





TRANSFER SHAFT BEARING SHIM CHART

4. Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting.
5. Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L-4407.

Fig. 243:

Fig. 244:

6. Remove the gauging shim and install the correct shim (Fig. 243). Install the transfer gear and bearing assembly (Fig. 244).

CAUTION: Original retaining nut may not be reused. Always use a new retaining nut when reassembling.

Fig. 245:

7. Install the new retaining nut and washer and torque to 271 Nm (200 ft. lbs.) (Fig. 245). Measure transfer shaft end play, end play should be 0.05 to 0.10 mm (0.002 to 0.004 inch).
8. Measure bearing end play as outlined in Step 3. End play should be between 0.05 mm and 0.10 mm (0.002 to 0.004 inch).

NOTE: If end play is too high, install a 0.04 mm (0.0016 inch) thinner shim. If end play is too low, install a 0.04 mm (0.0016 inch) thicker shim combination. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 inch) end play is obtained.

Fig. 246:

Fig. 247:

Fig. 248:

Fig. 249:

Fig. 250:

NOTE: Install the low/reverse reaction plate stepped side up.

Fig. 251:

Fig. 252:

Fig. 253:

Press down clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 to 1.04 (0.035 to 0.042 inch).
Select the proper low/reverse reaction plate to achieve specifications:





LOW/REVERSE REACTION PLATE CHART

Fig. 254:

Fig. 255:

NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align.

Fig. 256:

Fig. 257:

Fig. 258:

NOTE: Verify that Miller Tool 5058 is centered properly to the V4 clutch retainer before depressing the tool.

Fig. 259:

Fig. 260:

Press down clutch pack with finger and zero dial indicator. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance.

Fig. 261:

Fig. 262:

Fig. 263:

DETERMINING No. 4 THRUST PLATE THICKNESS-INPUT SHAFT END PLAY

Fig. 264:

Fig. 265:

To determine the proper thickness of the No. 4 thrust plate, select the thinnest No. 4 thrust plate. Using petrolatum (Fig 264) to hold thrust plate in position, install input clutch assembly. Be sure the input clutch assembly is completely seated (Fig. 265).

CAUTION: If view through input speed sensor hole is not as shown above, the input clutches assembly is not seated properly.

Fig. 266:

Remove the oil pump O-ring (Fig. 266). You will be able to install and remove the oil pump and gasket very easily to select the proper No. 4 thrust plate.

NOTE: Use screw-in dowels or phillips-head screwdrivers to align pump to case.

CAUTION: Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.

Fig. 267:

Measure the input shaft end play with the transaxle in the vertical position. This will ensure that the measurement will be accurate.

NOTE: Input shaft end play must be 0.005 to 0.025 inch.

For example, if end play reading is 0.065 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is within specifications.
See chart to select the proper No. 4 thrust plate.





NO.4 THRUST PLATE CHART

Reinstall the input clutches assembly with the selected thrust plate.

Fig. 268:

Fig. 269:

CAUTION: The cooler bypass valve must be replaced if a transaxle failure has occurred. Do not reuse old valve or attempt to clean old valve. When installing bypass valve, insert with O-ring end towards rear of case.

Fig. 270:

Fig. 271:

Fig. 272:

Fig. 273:

Fig. 274:

Fig. 275:

Fig. 276:

NOTE: Dependent on engine application, some accumulators will have two springs and others will have one spring. The springs are color coded for application and year.

Fig. 277:

Fig. 278:

Fig. 279:

NOTE: To ease installation of the valve body, turn the manual valve fully clockwise.

CAUTION: Do not handle the valve body from the manual valve. Damage could result.

Fig. 280:

Fig. 281:

Fig. 282:

Fig. 283:

Fig. 284:

Fig. 285:

1. Install transaxle solenoid pack (Fig. 285).
2. Install input and output speed sensors. This concludes the assembly of the transaxle centerline.