Part 1 of 3
AUTOMATIC TRANSAXLE ASSEMBLYPRECAUTION
GENERAL NOTES
1. Select the adjustment shim(s), referring to Bearing Preload.
2. If the driver plates or 2/4 brake band are replaced with new ones, soak the new part in ATF for at least two hours before installation.
3. Before assembly, apply Automatic Transmission Fluid (ATF) to all seal rings, rotating parts, O-rings, and sliding parts.
4. ALL O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
5. Use petroleum jelly, not grease, during reassembly.
6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
7. Assembly the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling the transaxle with ATF.
WARNING
- Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.
ASSEMBLY
Outer Diameter Of Bearing Component
Bearing And Race Locations
Components
TRANSAXLE ASSEMBLY PROCEDURE
1. If necessary, use the 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.
Tightening torque: 40 Nm (4.1 kgf-m, 30 ft. lbs.)
3. Apply thread sealant to the port plug. Install the line pressure port plug on the transaxle case.
Tightening torque: 8 Nm (O.8 kgf-m, 6 ft. 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.
Tightening torque: 8 Nm (0.8 kgf-m, 6 ft. lbs.)
13. Install the manual control lever shaft component into the case.
14. Install the parking pawl spring.
NOTE
- Bolt will be torqued after linkage adjustment.
15. Install the manual control outer lever and bolt by hand.
16. Use the SST or equivalent to install a new final drive lube tube seal into the case.
17. Lubricate the end of a new final drive lube tube and push it into the seal.
18. Push the final drive lube tube into the bearing of the case and seat it with the SST
19. Push a new drive chain/differential lube tube into the housing.
20. Seat the end of the drive chain/differential lube tube with the SST
21. Install the mounting bolt.
Tightening torque 15 Nm (1.5 kgf-m, 11 ft. lbs.)
NOTE
- The gear is installed with the lug end up away from the housing.
22. Lower the final drive ring gear into the housing.
23. Install the final drive gear retaining ring.
24. Install the fitting to the converter housing.
Tightening torque: 40 Nm (4.1 kgf-m, 30 ft. lbs.)
25. Slide the 2/4 band into the case.
26. Lubricate the seal and bore in the case.
27. Lower the pump into the transaxle case.
28. Install the nine oil pump component-to-transaxle case bolts.
Tightening torque: 12 - 14 Nm (122 - 146 kgf-cm, 104 - 127 inch lbs.)
29. Install a new outer seal on the low/reverse piston.
30. Install a new inner seal on the piston.
31. 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.
32. Install the return spring component.
33. 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.
34. Install the low/reverse wave spring.
35. 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.
36. Install the low one-way clutch thrust plate.
37. 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.
Pressure plate sizes
38. The standard clearance is 0.18 - 1.13 mm (0.007 - 0.044 inch). If the clearance is not within the specification, select the proper thickness pressure plate to obtain the standard clearance.
39. Remove the thrust plate, pressure plate, steel and friction plates, and the wave spring for installation later.
40. Install the # 1 pump support thrust bearing.
41. Remove the SST (seal sizer) from the forward/coasting/direct clutch cylinder.
42. Install the assembly of the forward/coasting/direct clutch cylinder and reverse drum component.
43. Install the turbine shaft.
44. Install the # 4 turbine shaft thrust bearing.
45. Install the forward one-way clutch/low-intermediate sun gear.
46. Be sure that the assembly is fully installed in all clutch plates and is resting on the # 4 turbine shaft thrust bearing.
47. Install the # 5 low-intermediate sun gear thrust bearing.
48. Install the low-intermediate carrier.
49. Install the # 6 low-intermediate carrier thrust bearing.
50. Install the low-intermediate ring gear.
Part 2 of 3