Part 3

109. Install a depth micrometer on the head of the SST. Measure and record the distance from the depth micrometer to the bar of the SST. (distance A).
110. Unscrew until the servo piston movement stops. Measure and record the distance to the bar of the SST, (distance B).





111. Subtract A from B to obtain travel C.





112. If the depth micrometer reading is not within the travel specification, replace the 2/4 servo piston rod and recheck.
113. Remove the SST.
114. Install a nut with an integral washer onto the forcing bolt of the servo cover remover/replacer tool with a permanent thread sealer. This nut and washer will aid in the installation of the cover.





115. Lubricate the 2/4 servo piston, servo cover, servo cover seal and servo case bore, using ATF or petroleum jelly to aid in the installation and prevent cutting of the seal.
116. Install the servo cover in the case.
117. Install the SST.

WARNING: Servo return spring force is very high.

118. Compress the servo cover and install the retaining ring.
119. Remove the SST.





NOTE: If the cover will not seat deep enough in the bore to install the servo cover retaining ring, a blunt punch may be used with a small hammer. Gently tap the cover around the outer edge with the punch until the snap ring groove is fully exposed.





120. Install the servo cover cap by using the SST, if equipped originally.

WARNING: Use safety glasses when using compressed air.

CAUTION: The coasting clutch circuit should not be applied. Failure to do so may result in the coasting clutch piston coming out of the forward clutch piston.

121. Install the SST by using six mounting bolts. Use a rubber tipped blow gun and compressed air 275 kPa (40 psi) to check the following clutch hydraulic circuits for function and leakage.
^ Reverse Clutch
^ Forward Clutch
^ Direct Clutch
^ Low/reverse Clutch
^ Servo Release
^ Servo Apply

WARNING: Wear eye protection when using compressed air.

122. If leakage is heard in any circuit, the transaxle must be disassembled and the source of leakage corrected. Remove the SST.





123. Install the filter in the forward clutch circuit. Place the thermostatic oil level control valve in the transaxle case.
124. Install the bracket and the bolt. Tighten to 11 - 13 Nm (96 - 117 inch lbs.).
125. If necessary, install the O-ring on the solenoid body connector.

CAUTION: Do not pull on the wires or damage the connector body.

126. Place the control valve body slightly away from the transaxle case and push the solenoid body connector into its bore.
127. Align the Z-link in the manual valve.





128. Install the 12 mounting bolts. Tighten the mounting bolts in the sequence shown to 9 - 11 Nm (80 - 97 inch lbs.).





129. Loosen the nut on the ball stud for the manual valve detent actuating rod.
130. Remove the manual lever control shaft outer lever.





131. Use the SST to move the shaft to the D range position and install the pin to hold the tool in position.





132. Move the manual valve detent lever to the D range position.





133. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
134. Initially tighten the nut on the ball. Remove the shifter pin.





135. Rotate the SST until the socket can be installed on the nut. Tighten the manual valve detent lever ball stud nut to 11 - 13 Nm (96 - 117 inch lbs.).
136. Remove the pin and SST.
137. Install the manual control lever assembly and bolt. Tighten to 24 - 30 Nm (18 - 22 ft. lbs.).





138. Install the transaxle range switch on the manual lever shaft. Hand-tighten the two mounting bolts.

NOTE: The outer lever must be in the N position.





139. Use the SST to align the switch on the shaft and case.





140. Tighten the transaxle range switch bolts to 11 - 13 Nm (96 - 117 inch lbs.). Remove the SST.





141. Install the control valve body cover gasket on the case. Attach the cover to the case.
142. Install the fourteen mounting bolts in the sequence shown.





143. Install and tighten the control valve body cover-to-transaxle case bolts. Tighten to 12 Nm (108 inch lbs.) for a galvanized cover and 20 Nm (15 ft. lbs.) for a black cover.





144. Install the O-ring seal on the vehicle speedometer sensor.
145. Push the vehicle speedometer sensor into the bore.
146. Install the bolt.
147. Tighten the bolt to 5 - 6 Nm (44 - 53 inch lbs.).





148. Install the oil tube seal grommet into the case.





149. Install the oil filler tube.
150. Install the mounting bolt. Tighten the mounting bolt to 7 - 9 Nm (62 - 80 inch lbs.).
151. Install the oil level indicator in the tube.
152. Install the turbine shaft speed sensor O-ring seal.
153. Push the turbine shaft speed sensor into the bore.
154. Install the mounting bolt.
155. Tighten the bolt to 12 - 14 Nm (104 - 127 inch lbs.).





156. Use the SST or equivalent and a hammer to install the RH and LH differential seals.





157. Use the SST or equivalent and a hammer to install the torque converter impeller hub seal spring, then verify that the seal spring has not been dislodged.





158. Apply sealant to the drain plug. Install the drain plug. Tighten the drain plug to 15 - 35 Nm (11 - 26 ft. lbs.).





159. Install the oil pump drive shaft into the end of the turbine shaft.





160. Install the torque converter in the transaxle.





161. Remove the transaxle from the SST.
162. Dry the transaxle exterior and prepare it for installation.