Attachment III - Technical Information
OVERVIEWIn some of the affected vehicles, the transmission intermediate clutch piston may have been install incorrectly. The piston seal may tear during vehicle operation and possibly result in poor shifting, transmission slipping, warning lamp illumination, and eventual loss of 2nd and 6th gear function.
Dealers are to remove and partially disassemble the transaxle to install a new Intermediate Clutch Clutch Piston.
SERVICE PROCEDURE
1. Remove the transaxle from the vehicle For additional information, refer to the appropriate WSM Section 307
DISASSEMBLY TRANSAXLE
NOTE:
Special tools that are needed for this portion of the service procedure are as follows:
^ Transaxle Holding Fixture # 307-580 or equivalent
^ Input Shaft Support Seal Installer # 307-578/1.
^ Forward/Intermediate Spring Compressor # 307-584/1 and /2
^ Depth Micrometer # 303-D075 or equivalent
^ Straight Edge (used with the Depth Micrometer # 303-D075)
2. Using the Holding Fixture # 307-580, install the transaxle onto the bench See Figure 1.
3. NOTICE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.
Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter. See Figure 2.
4. NOTICE: The torque converter is heavy. Be careful not to drop the converter or damage will result.
Remove the torque converter from the transaxle. See Figure 3.
5. NOTE: Record the location of the studbolts for assembly. Remove the 14 bolts and the main control cover. See Figure 4.
6. Disconnect the Turbine Shaft Speed (ISS) sensor electrical connector. See Figure 5.
7. NOTE: Position the transaxle so that the cover assembly is facing upward. Remove the 10 cover assembly bolts. See Figure 6.
8. NOTE: The 155 harness is part of the cover assembly. Care must be taken when removing the cover not to damage the harness or the connector.
Remove the cover assembly and carefully route the 155 sensor wiring harness and electrical connector out of the transaxle case. See Figure 7.
9. Remove the cover assembly gasket and set aside.
10. Install the Input Shaft Support Seal installer # 307578/1 on the cover to protect and prevent the 4 Teflon� seals from expanding See Figure 8.
11. Remove the No.1 cover assembly thrust bearing. See Figure 9.
12. Remove the overdrive/direct clutch hub and turbine shaft assembly. See Figure 10.
13. Remove No. 3 rear sun gear thrust bearing (the bearing may be stuck to the overdrive direct clutch hub/turbine shaft assembly) See Figure 11.
14. Remove the intermediate clutch shell and sun gear assembly See Figure 12.
15. Remove the intermediate clutch assembly consisting of a wave spring 3 steel and 3 friction plates and the pressure plate Do not remove the low/reverse clutch assembly See Figure 13.
DISASSEMBLY - INTERMEDIATE PISTON
16. NOTICE: Center the Special Tool # 307-584 with the beveled edge downward over the intermediate clutch return spring Failure to center the tool may damage the spring.
NOTE:
Make sure that the Special Tool # 307-584 is positioned correctly to gain access to the intermediate clutch return spring snap ring.
Position the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2 over the intermediate clutch return spring Using a press compress the spring enough to remove the snap ring See Figure 14.
17. Remove the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2.
18. Remove the intermediate clutch return spring See Figure 15.
19. Remove and discard the intermediate clutch piston Check the cover assembly for any seal debris See Figure 16.
ASSEMBLY - INTERMEDIATE PISTON
20. Lubricate the sealing surfaces on the new intermediate clutch piston with petroleum jelly See Figure 17.
21. Install the new intermediate clutch piston See Figure 18.
22. Install the intermediate clutch piston return spring See Figure 19.
23. NOTE: Make sure the snap ring is fully seated in the groove before releasing the pressure on the return spring.
Install the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2. Using a press, compress the intermediate clutch piston return spring enough to install the snap ring. Remove the Forward/Intermediate Spring Compressor 307-584/1 and 307-584/2. See Figure 20.
ASSEMBLY - TRANSAXLE
24. Install the new intermediate clutch pressure plate See Figure 21.
25. Lubricate the new intermediate clutch pack assembly in clean transmission fluid See Figure 22.
26. Install the new intermediate clutch pack assembly See Figure 23.
27. Install the intermediate clutch pack wave spring See Figure 24.
28. Using a suitable straight edge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to a low point on the intermediate clutch wave spring. See Figure 25.
29. Using the straight edge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface. See Figure 26.
30. Subtract measurement B from measurement A and add 1.6 mm (0.062 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.90 mm (0.035 in) and 2.24 mm (0.088 in). If the clearance is out of range, the intermediate clutch pack has been incorrectly installed.
31. Install the rear sun gear and shell assembly. See Figure 27.
32. Install the No.3 rear sun gear thrust bearing. See Figure 28.
33. Install the overdrive/direct clutch hub and turbine shaft assembly See Figure 29.
34. NOTE: Add petroleum jelly to the bearing to hold the bearing in place while assembling Install the No 1 cover assembly thrust bearing See Figure 30.
35. Install the cover assembly gasket onto the transaxle assembly.
36. Route the Turbine Shaft Speed (TSS) sensor harness through the transaxle case to the valve body area See Figure 31.
37. Before installing the cover assembly. inspect the cover assembly gasket for any damage. If necessary, install a new gasket. Then install the cover assembly, cover assembly bolts and tighten the bolts in the sequence shown See Figure 32.
^ Tighten to 12 Nm (106 lb-in).
38. Connect the ISS sensor electrical connector See Figure 33.
39. Position the body assembly solenoid seal upward 1/4 in (64 mm) to make sure that the pan seals correctly See Figure 34.
40. Inspect the transaxle main control cover seal for damage and install new if necessary. See Figure 35.
41. NOTE: Install the studbolts in the locations noted during disassembly.
Install the transaxle main control cover and install the bolts
42. Tighten the main control cover bolts in the sequence shown. See Figure 36.
^ Tighten to 12 Nm (106 lb-in).
43. NOTICE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
NOTE: Position the transaxle in the holding fixture so that the torque converter housing is facing upward.
Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transaxle. See Figure 37.
44. Remove the bolts from the torque converter. See Figure 38.
45. Install the transaxle. For additional information, refer to the appropriate WSM, Section 307.