Part 1

Transaxle


















Disassembled Views

































All vehicles

1. Clean and inspect the transaxle case for damage. Clean the silicone from the transaxle case-to-torque converter housing sealing surface and the main control cover sealing surface.





2. Assemble the Handle 205-153 and the Bushing Installer 307-664 and install a new bushing on the Bushing Installer.





3. Using the Handle 205-153 and the Bushing Installer 307-664, install the new bushing in the transaxle case.





4. Assemble the Handle 205-153 and Seal Installer 307-626. Install a new LH halfshaft seal on the Differential Seal Installer 307-626.





5. Using the Differential Seal Installer 307-626 and Handle 205-153, install the new LH halfshaft seal in the transaxle case.





6. Install a new manual control shaft seal on Manual Lever Seal Installer 307-581.





7. Using the Manual Lever Seal Installer 307-581, install the new manual control shaft seal in the transaxle case.





8. If not previously installed, install the clutch support tower and the 3 bolts.
- Tighten to 12 Nm (106 lb-in).






9. Remove Input Shaft Support Seal Installer 307-578/1.





10. Install 2-6 Piston Seal Protector 307-632.





11. Lubricate the seals on the intermediate (2, 6) clutch piston with clean transmission fluid.





12. NOTICE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.

Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.






13. Position the intermediate (2, 6) clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
1. Outer tabs

2. Open area at the bottom of the transaxle case

3. Bleed hole

4. Inner double tabs






14. Remove the intermediate (2, 6) clutch piston return spring.





15. Install Forward/Intermediate Spring Compressor 307-584/1 on the intermediate (2, 6) clutch piston.





16. Using Forward/Intermediate Spring Compressor 307-584/1, push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.





17. Remove Forward/Intermediate Spring Compressor 307-584/1 and Clutch Piston Seal Protector 307-632.





18. NOTICE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.

Install the intermediate (2, 6) clutch piston return spring. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
1. Outer tabs

2. Bleed hole

3. Inner double tabs






19. NOTICE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.

Position the snap ring in place. Align the gap of the snap ring to face the front of the transaxle.
1. Snap ring

2. Snap ring gap

3. Low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports (located at the front of the transaxle case)






20. Install the 2-6 Piston Return Spring Compressor 307-633/2 on the transaxle case to center the intermediate (2, 6) clutch return spring.





21. Install the 2-6 Piston Return Spring Compressor 307-633/1 on the snap ring.





22. Install Forward Clutch Spring Compressor 307-574/1 on the transaxle case.





23. NOTICE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.

Using the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633, install the intermediate (2, 6) clutch snap ring in the groove.






24. Remove the Forward Clutch Spring Compressor 307-574/1 and the 2-6 Piston Return Spring Compressor 307-633.





25. Install the intermediate (2, 6) clutch apply ring. Tap the ring in place using a suitable tool.





26. NOTICE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.

Install the No. 1 thrust bearing with the flat side facing up.






27. Install the overdrive/direct clutch assembly.





28. NOTICE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.

Install the No. 3 thrust bearing with the flat side facing down.






29. Install the direct/intermediate clutch hub and rear sun gear assembly.





30. Install the intermediate (2, 6) wave spring assembly.





31. Soak the intermediate (2, 6) clutch assembly in clean transmission fluid.





32. Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.





33. Install the Shim Selection Gauge 307-300 on the transaxle case.





34. Using a suitable depth gauge, measure and record as measurement A, the distance from the Shim Selection Gauge 307-300 to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.





35. Using a suitable depth gauge, measure and record as measurement B, the distance from the top of Shim Selection Gauge 307-300 to the transaxle case step above the intermediate (2, 6) clutch.





36. Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.





37. NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.






38. Install the One-Way Clutch (OWC) assembly.





39. Install the rear planetary carrier/center ring gear assembly.