Part 3
Transaxle
Disassembled Views
70. Install the forward clutch pack assembly.
1. Position the forward clutch pack assembly in the case.
2. Make sure the alignment tab on the clutch pack is positioned in the correct location.
71. Install the low OWC.
72. NOTE: The low OWC snap ring gap must be positioned as shown so that the low/reverse clutch pressure plate tab fits into the gap when it is installed later in this procedure.
Install the low OWC snap ring.
73. Compare the position of the low OWC snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
74. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transaxle case and position the plunger on a top friction disc tab.
75. Install a new forward clutch feed seal.
76. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator Gauge. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.094 in). If the clearance is out of range, check the forward clutch pack and low OWC for correct installation. If the forward clutch pack and low OWC is correctly installed, install a new forward clutch pack.
77. Remove the Dial Indicator Gauge with Holding Fixture 100-002 from the transaxle case.
78. Install the No. 11 stator support thrust bearing.
79. Install the front planetary carrier hub.
80. Install the No. 10 front sun gear thrust bearing.
81. Install the front sun gear and shell assembly.
82. Install the front carrier and rear ring gear assembly.
83. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
84. Install the center planetary carrier and front ring gear assembly.
85. NOTE: The groove on the center sun gear is installed facing up.
Install the center planetary sun gear.
86. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
87. Install the rear planetary gear carrier assembly.
88. NOTICE: Failure to align the tab on the bottom of the low/reverse pressure plate with the gap in the low One-Way Clutch (OWC) snap ring may result in damage to the transaxle.
Install the low/reverse clutch pressure plate.
1. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC snap ring.
2. Install the low/reverse clutch pressure plate.
89. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
90. Lubricate the low/reverse clutch pack with clean transmission fluid.
91. Install the low/reverse clutch pack.
92. Install the low/reverse pressure plate.
93. Using a suitable straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to the low/reverse pressure plate.
94. Using the same straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.
95. 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 low/reverse clutch clearance. The clearance should be between 1.01 mm (0.039 in) and 2.47 mm (0.097 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack.
96. Install the intermediate clutch pressure plate.
97. Lubricate the intermediate clutch pack assembly in clean transmission fluid.
98. Install the intermediate clutch pack assembly.
99. Install the intermediate clutch pack wave spring.
100. Using a suitable straightedge 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.
101. Using the straightedge 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.
102. 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, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
103. Install the rear sun gear and shell assembly.
104. Install the No. 3 rear sun gear thrust bearing.
105. Install the overdrive/direct clutch hub and turbine shaft assembly.
106. Install the No. 1 cover assembly thrust bearing.
107. Install the cover assembly gasket.
108. Route the Turbine Shaft Speed (TSS) sensor harness through the transaxle case to the valve body area and install the cover assembly.
109. Install the cover assembly bolts and tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
110. Install the Output Shaft Speed (OSS) sensor and the bolt.
- Tighten to 12 Nm (106 lb-in).
111. NOTICE: Be careful not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.
NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.
1. Manual pin
2. Manual valve
112. Install the main control valve body bolts. Tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
113. NOTICE: Make sure not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
NOTE: Install the different length bolts in the locations noted during disassembly.
Install the solenoid body bolts hand-tight.
1. 42 mm (1.653 in) bolt
2. 63 mm (2.48 in) bolts
3. 80 mm (3.149 in) bolts
4. 95 mm (3.74 in) bolts
114. Tighten the solenoid body bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
115. Route the OSS sensor wiring harness into the retainer.
116. Connect the TSS and OSS sensor electrical connectors.
117. Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
118. Inspect the transaxle main control cover seal for damage and install new if necessary.
119. NOTE: Install the studbolts in the locations noted during disassembly.
Install the transaxle main control cover and install the bolts.
1. Bolt location
2. Studbolt location
120. Tighten the main control cover bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
121. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
NOTICE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the nut.
- Tighten to 18 Nm (159 lb-in).
122. 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.
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.
123. Remove the bolts from the torque converter.
