Part 1
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PRECAUTION
1. If the drive plates or 2/4 band are replaced with new ones, soak the new part in ATF for at least 15 minutes before installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
3. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
4. Use petroleum jelly, not grease, during reassembly.
5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
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PROCEDURE
1. If necessary, use the Special Service Tools (SSTs) or equivalent to install the #18 driven sprocket bearing in the transaxle case.
2. Apply thread sealant to the fitting. Install the fluid cooler line fitting on the transaxle case. Tighten to 40 Nm (30 ft. lbs.).
3. Apply thread sealant to the port plug. Install the line pressure port plug on the transaxle case. Tighten to 8 Nm (72 inch lbs.).
4. Use a small rubber mallet to install the manual valve detent lever shaft seal in the case.
5. Install the manual valve detent lever and shaft into the case.
6. Use a hammer and a punch to install a new manual valve detent lever shaft roll pin.
CAUTION: Do not allow the manual valve detent lever roll pin to make contact with the case.
7. Use a hammer and a punch to install a new manual valve detent lever roll pin.
8. Verify that the manual valve detent lever rotates freely. Install the manual valve actuator rod (Z-link).
9. Use the SST or equivalent to install the manual control shaft seal.
10. Install the parking pawl and return spring.
11. Install the parking pawl shaft.
12. Install the parking pawl shaft retainer and bolt to 8 Nm (72 inch lbs.).
13. Assemble the parking lock cam, cam actuator, spring, and spacer on the manual lever control shaft.
NOTE: Verify that the manual lever control shaft assembly can move freely.
14. Install the manual lever control shaft assembly into the case.
15. Install the manual control shaft nut and tighten to 74 Nm (55 ft. lbs.).
16. Install the parking pawl spring.
NOTE: Bolt will be torqued after linkage adjustment.
17. Install the manual control outer lever and bolt by hand.
18. Use the SST or equivalent to install a new final drive lube tube seal into the case.
19. Lubricate the end of a new final drive lube tube and push it into the seal.
20. Push the final drive lube tube into the bearing of the case and seat it with the SST.
21. Push a new drive chain/differential lube tube into the housing.
22. Seat the end of the drive chain/differential lube tube with the SST.
23. Install the mounting bolt and tighten to 15 Nm (11 ft. lbs.).
NOTE: The gear is installed with the lug end up away from the housing.
24. Lower the final drive ring gear into the housing.
25. Install the final drive gear retaining ring.
26. Install the fitting to the converter housing and tighten to 40 Nm (30 ft. lbs.).
27. Slide the 2/4 band into the case.
28. Lubricate the seal and bore in the case.
29. Lower the pump into the transaxle case.
30. Install the nine oil pump assembly-to-transaxle case bolts and tighten to 12 - 14 Nm (104 - 127 inch lbs.).
31. Install a new outer seal on the low/reverse piston.
32. Install a new inner seal on the piston.
33. Install the low/reverse clutch piston into SST (49 UN01 093) and SST (49 UN01 097). Install the low/reverse clutch piston into the case. Remove the SSTs.
34. Install the return spring assembly.
35. Use a screwdriver to install the retaining ring. Verify that the ring is seated all around.
CAUTION: The wave spring is installed in this position for measurement purposes only.
36. Install the low/reverse wave spring.
37. Install the low/reverse steel and friction plates, and the pressure plate.
NOTE: The thrust plate is installed in this position for measurement purposes only.
38. Install the low one-way clutch thrust plate.
39. Use a feeler gauge to measure the clearance between the pressure plate and the thrust plate. Make a second measurement on the opposite side. Average the two measurements to obtain the clearance.
40. The standard clearance is 0.54 - 1.17 mm (0.02 - 0.05 inch). If the clearance is not within the specification, select the proper thickness pressure plate to obtain the standard clearance.
41. Remove the thrust plate, pressure plate, steel and friction plates, and the wave spring for installation later.
42. Install the #1 pump support thrust bearing.
43. Remove the SST (seal sizer) from the forward/coasting/ direct clutch cylinder.
44. Install the assembly of the forward/coasting/direct clutch cylinder and reverse drum assembly.
45. Install the turbine shaft.
46. Install the #4 turbine shaft thrust bearing.