Part 6

Transaxle - Overhaul


















Disassembled Views









































All vehicles

191. NOTICE: Do not handle the solenoid body in the leadframe area or by the screens of the solenoid body filter or damage to the solenoid body may occur.

NOTICE: Use care not to break the alignment tabs when installing the solenoid body filter. Damage to the transaxle will occur if the solenoid body is not correctly aligned.

NOTICE: Make sure that the filter passage areas are clean of foreign material before installing the filter. Damage to the transaxle will occur if the filter passages are not clean.

Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.






192. Slide the park pawl over and install the park pawl actuator rod.





193. Lubricate a new manual shaft seal and the Manual Lever Seal Installer 307-581 with petroleum jelly and install the seal on the Manual Lever Seal Installer 307-581.





194. Using the Manual Lever Seal Installer 307-581, install the manual lever shaft seal in the transaxle case.





195. Install the TR (Transmission Range) sensor.
1. Position the park pawl actuating rod in the TR (Transmission Range) sensor detent plate.

2. Install the TR (Transmission Range) sensor in the transaxle case.






196. Install a new TR (Transmission Range) sensor locking pin in the transaxle case.





197. Using the Manual Lever Retaining Pin Installer 307-592, drive the TR (Transmission Range) sensor locking pin into the transaxle case.





198. Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.





199. Install the transmission fluid reservoir and the 2 bolts.
- Tighten to 12 Nm (106 lb-in).






200. Install a new pump-to-case seal.





201. Install the transfer shaft and gear assembly.





202. Tilt the transfer shaft and gear assembly over and install the differential assembly.





203. Install a new torque converter hub seal on the Converter Seal Installer 307-575.





204. NOTICE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

Using the Converter Seal Installer 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.






Front Wheel Drive (FWD) vehicles

205. Assemble the Handle 205-153 on the Cover Axle Seal Installer 307-582A and install a new RH halfshaft seal on Cover Axle Seal Installer 307-582A.





206. NOTICE: Support the torque converter housing using blocks of wood or damage to the torque converter housing may occur.

Use the Handle 205-153 and the Cover Axle Seal Installer 307-582A. Install the RH halfshaft seal in the torque converter housing.






All vehicles

207. Install the pump drive sprocket and driven sprocket thrust washers.





208. NOTE: The dot on the pump sprocket is installed facing upward.
Install the pump sprocket and chain assembly.






209. Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.

210. NOTE: Lubricate the seal with clean transmission fluid.
Install the fluid filter seal in the fluid pump.






211. NOTE: Install the filter in the correct orientation as noted in removal.
Install the fluid filter in the fluid pump.






212. Position the pump and filter assembly in place and install the 3 bolts.
- Tighten to 12 Nm (106 lb-in).






213. NOTE: Be sure that the pump drive chain is correctly engaged on both sprockets.
Position the stator support assembly in place on the torque converter housing.






214. Install the stator support bolts. Tighten in the sequence shown.
- Tighten to 41 Nm (30 lb-ft).






215. Position the differential carrier baffle in place and install the bolt.
- Tighten to 12 Nm (106 lb-in).






216. Lubricate the ends of the transaxle fluid tube with petroleum jelly and install it in the transaxle.





217. NOTICE: Make sure the sealing surface of both the transaxle case and the torque converter housing are clean, dry and free of oil or the silicone will not seal the transaxle case.

Apply a bead of silicone sealant to the machined surface of the transaxle case.






218. NOTE: Install the 2 studbolts in the correct location as noted during disassembly.
Install the torque converter housing on top of the transaxle case and install the bolts.






219. NOTE: The studbolts are 1 and 16 in the tightening sequence.

Tighten the bolts in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).






220. Assemble the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install a new halfshaft seal on Cover Axle Seal Installer 307-582A.





221. Using the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install the halfshaft seal in the transaxle case.





222. Lubricate the forward clutch piston seals with petroleum jelly.





223. Position the forward clutch piston in place in the transaxle case.





224. NOTE: Install the Forward/Intermediate Spring Compressor 307-584/1 with the stepped end of the cylinder facing downward when pushing the forward clutch piston into the bore.
Using the Forward/Intermediate Spring Compressor 307-584/1, push the forward clutch piston down into the bore.






225. Install the forward clutch piston return spring with the tabs facing downward.





226. NOTE: Install the Forward/Overdrive Spring Compressor with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

NOTE: Before compressing the forward clutch piston return spring, make sure the spring is centered.
Install the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and compress the forward clutch piston return spring.






227. NOTE: Forward Clutch Spring Compressor and the Forward/Overdrive Spring Compressor not shown for clarity.
Install the forward clutch piston return spring snap ring.

- Install the snap ring.

- The snap ring gap should be at the top of the transaxle case.






228. Remove the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).





229. Install the forward clutch wave spring.





230. Lubricate the forward clutch pack in clean transmission fluid.





231. 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.






232. Install the low OWC (One-Way Clutch).





233. NOTE: The low OWC (One-Way Clutch) 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.
Install the low OWC (One-Way Clutch) snap ring.






234. Compare the position of the low OWC (One-Way Clutch) snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.





235. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transaxle case and position the plunger on a top friction disc tab.





236. Install a new forward clutch feed seal.





237. 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 (One-Way Clutch) for correct installation. If the forward clutch pack and low OWC (One-Way Clutch) is correctly installed, install a new forward clutch pack.





238. Remove the Dial Indicator Gauge with Holding Fixture 100-002 from the transaxle case.

239. Install the No. 11 stator support thrust bearing.





240. Install the front planetary carrier hub.