Assembly
ASSEMBLE1. Use differential bearing cup replacer tool No. T88C-7025-BH or equivalent and driver handle tool No. T80T-4000-W or equivalent to install differential bearing outer race into torque converter housing.
Torque Converter Housing Spacers:
2. Install differential in torque converter housing. Place six spacers (from shim selection set T87C-77000-JF on torque converter housing at positions shown in the Torque Converter Housing Spacers image.
3. Place rear bearing cup over differential bearing.
4. Place shim selection gauge onto output gear. Turn two halves of gauge to eliminate any gap between them.
5. Place differential bearing outer race on top of shim selection gauge.
6. Place transaxle case onto spacers and install shim selection tool bolt set tool No. T92P-77000-DH or equivalent and tighten bolts.
7. Use pins (part of shim selection set) to open gauge halves until all freeplay is gone and the differential bearing race is seated.
8. Turn gauge halves in opposite direction to eliminate any gap between gauge halves.
9. Engage differential rotator tool No. T92P-77000-BH or equivalent, and an in lbs torque wrench to the differential.
10. Turn differential while measuring turning torque.
11. Use pins to separate gauge halves until turning torque of 6.9-12.2 in lbs is achieved.
12. Use feeler gauge to measure gap between gauge halves.
Differential Bearing Shim Specifications:
13. Refer to the Differential Bearing Shim Specifications to determine proper thickness required for differential shim, based on gap measured between two gauge halves.
14. Remove bolts and separate transaxle case from torque converter housing.
15. Remove spacers, gauge halves, differential, and bearing.
16. Install appropriate differential bearing shim.
17. Use differential bearing cup replacer tool No. T88C-7025-BH or equivalent, and driver handle tool No. T80T-4000-W or equivalent to install differential bearing outer race into transaxle case.
18. Use shifter shaft seal replacer tool No. T92P-77000-EH or equivalent, to install manual control lever oil seal.
19. Install manual shift linkage rod, manual detent lever, and park actuator support into transaxle case.
20. Align groove of manual shift linkage rod with hole in transaxle.
21. Install new manual shift linkage rod roll pin into transaxle.
22. Install new park actuator support roll pin into park actuator support.
23. Install parking lever actuating rod onto park actuator support.
24. Install new manual detent lever inner pin into manual detent lever.
25. Install manual detent spring and manual detent spring bolt. Tighten detent spring bolt.
26. Use differential seal replacer tool No. T87C-77000-H or equivalent to install differential oil seal on transaxle.
27. Use differential seal replacer to install differential oil seal on torque converter housing.
28. Install reduction gear bearing outer race. Tighten outer race bolts.
29. Install parking actuator support and tighten bolts.
30. Install parking pawl shaft into transaxle.
31. Install parking pawl over parking shaft, then install parking pawl return spring.
32. Place reduction gear onto transaxle case as shown in the Reduction Gear Installation image.
33. Place idler gear bearing into transaxle case to measure to measure dimensions B, C, and D to calculate A (distance between surface of idler gear bearing inner race and reduction gear adjusting shim mating surface of reduction gear).
34. Use depth micrometer and straightedge to measure dimension D in at least two places.
35. Calculate dimension A. Use equation A=D-(B+C).
Dimension "E" Measurement:
36. Measure dimension E (distance between end of idler gear and idler gear bearing inner race mating surface) in at least two places.
37. Select proper thickness of reduction gear bearing adjusting shim. Use equation, A-E-0.0020 inch, for shim thickness.
NOTE: Idler gear bearing preload is 0.0020 inch.
38. Select appropriate shim from reduction gear bearing adjusting shim kits as follows:
a. F3XY-7N112-A for shims 0.1969-0.2173 inch.
b. F3XY-7N112-B for shims 0.2181-0.2386 inch.
c. F3XY-7N112-C for shims 0.2394-0.2646 inch.
39. Install reduction gear and reduction gear bearing adjusting shim into transaxle case.
40. Use step plate adapter tool No. D80L-630-10 or equivalent and bearing cone replacer tool No. T88T-7025-B or equivalent to press idler gear bearing inner race onto idler gear.
41. Use differential bearing cup replacer tool No. T88C-77000-FH and driver handle tool No. T80T-4000-W to install idler gear bearing outer race into transaxle case.
42. Use new locknut to press idler gear onto reduction gear.
NOTE: Use parking pawl to lock idler gear while tightening locknut.
43. Tighten locknut. Spin reduction gear several times in each direction to seat bearing rollers properly.
44. Use locknut socket and preload gauge to measure reduction gear turning torque. Turning torque should measure 0.4-1.4 in lbs.
45. If turning torque is too low, increase thickness of reduction gear bearing adjusting shim. If turning torque is too high, reduce reduction gear bearing adjusting shim thickness.
46. After turning torque has been set within specifications, use mainshaft locknut staking tool No. T77J-7025-F, or equivalent, to stake locknut.
47. Pack output shaft and shaft bearing retainer lubrication circuit seal ring grooves with petroleum jelly.
48. Install new lubrication circuit seal rings onto output shaft and output shaft bearing retainer.
49. Install output shaft bearing retainer and tighten retainer bolts.
50. Install output shaft hub thrust washer.
51. Install output shaft assembly, then use the following procedure to select adjusting shim:
a. Use equation, T=A-B to select output shaft bearing selective shim.
Output Shaft Bearing "A" Measurement:
b. Place straightedge across side cover mating surface and measure from straightedge to output shaft hub thrust washer surface (A1).
c. Subtract thickness of straightedge (A2) from A1. The result is measurement A.
d. To determine dimension B, subtract A2 from B1.
e. Place straightedge across output shaft hub thrust washer and measure down to transaxle case. This measurement is B1.
f. Use equation, A-B=Output shaft bearing selective shim which results in output shaft endplay of 0.0059 inch (T). Refer to the Output Shaft Bearing Selective Shim Specifications chart for output shaft bearing shim specifications.
52. Install output shaft bearing selective shim onto output shaft.
53. Apply suitable liquid gasket to transaxle case mating surface.
54. Place side cover onto transaxle case and tighten the attaching bolts.
Low/Reverse Clutch Plate Installation:
55. Install seven low/reverse internal spline clutch plates, eight low/reverse external clutch plates, low/reverse dish plate, and low/reverse clutch pressure plate.
56. Install low/reverse clutch pressure plate retainer snap ring.
External Spline Clutch Plate Clearance:
57. Measure clearance between external spline clutch plate and transaxle case. If clearance is not between 0.067-0.138 inch, select and insert proper clutch pressure plate from the Clutch Pressure Plate Specifications chart.
58. Place forward clutch hub assembly lower thrust washer in transaxle case with black side facing up. Coat forward clutch hub lower thrust washer with petroleum jelly.
59. Place forward clutch hub assembly lower thrust washer into transaxle case. Align teeth of internal spline clutch plates for low and reverse clutch before installing forward clutch assembly. Ensure bearing retainer seal rings are not spread.
60. Install forward clutch assembly.
61. Install forward clutch hub upper thrust washer into transaxle case.
62. Install coasting clutch upper thrust washer on coasting clutch hub. Ensure tabs on washer are facing coasting clutch hub.
63. Install coasting clutch hub, aligning internal spline clutch plate teeth with coasting clutch.
64. Hold forward clutch hub and turn ring gear. If ring gear turns counterclockwise and is installed properly, replace forward one-way clutch.
65. Install forward clutch hub and ring gear assembly, aligning teeth of forward clutch internal spline drive plates.
66. Install rear planetary gear lower thrust washers onto rear planetary gear.
67. Install rear sun gear into rear planetary gear.
68. Install rear planetary gear assembly into transaxle case.
69. Set and align low/reverse clutch piston.
70. Set and align return springs to transaxle case gutters.
71. Install low/reverse clutch piston and retainer assembly into transaxle case.
72. Push low/reverse clutch piston and low/reverse clutch piston retainer evenly to ensure they move smoothly. If they do not move smoothly, align return spring.
Low/Reverse Clutch Piston Pressure Plate Installation:
73. Place low/reverse clutch piston pressure plate retainer snap ring over turbine shaft, and install intermediate clutch spring compressor, shim selection tool bolt set, shifter shaft seal replacer, clutch spring compressor bar, and bolts.
74. Turn center bolt on clutch spring compressor until snap ring groove is exposed.
75. Position low/reverse clutch piston pressure plate retainer snap ring into snap ring groove, then remove clutch spring compressor bolts, transaxle shift seal installer, and clutch spring compressor bar.
76. Install low one-way clutch into front planetary gear by turning front planetary gear clockwise.
77. Use screwdriver to install low one-way clutch pressure plate retainer snap ring.
78. Coat primary sun gear lower thrust washer with petroleum jelly, then install onto front planetary gear.
79. Install primary sun gear bearing race, primary sun gear upper thrust washer, and 3-4 clutch hub onto primary sun gear.
80. Install 3-4 clutch hub and primary sun gear into transaxle case.
81. Coat 3-4 clutch drum and input shaft upper and lower thrust washers with petroleum jelly, then install 3-4 clutch drum, washers, and 3-4 clutch hub bearing onto 3-4 clutch hub.
82. Align reverse clutch drive plates.
83. Install input shaft and 3-4 clutch assembly into reverse clutch assembly.
84. Align teeth of 3-4 clutch internal spline clutch plates.
85. Install 3-4 clutch/reverse clutch assembly into transaxle case.
86. Adjust total endplay and reverse clutch drum endplay using the following procedure:
a. Place straightedge across output shaft rear bearing surface.
b. Measure top of straightedge to mating surface of oil pump assembly. This is measurement A.
c. With straightedge in same position, measure from straightedge to oil pump adjustment shim. This is measurement B.
d. Subtract measurement B from measurement A to get C (A-B=C).
e. Place straightedge across oil pump mating surface gasket.
f. Measure from top of straightedge to reverse clutch bearing roller. This is measurement D.
g. Subtract thickness of straightedge from measurement D to get measurement E.
h. Subtract measurement C from measurement E to get total endplay.
Bearing Race Specifications:
i. Select bearing race to bring endplay within 0.0098-0.0217 inch.
j. Place straightedge across top of output shaft rear bearing.
k. Use depth micrometer to measure from straightedge to oil pump mating surface. This is measurement A.
l. With straightedge across top of output shaft rear bearing, measure to drum endplay shim surface. This is measurement B.
m. Measurement B subtracted from measurement A equals C (A-B=C).
n. Place straightedge across oil pump mating surface and measure to reverse drum mating surface.
o. Use micrometer to measure thickness of straightedge.
p. Subtract thickness of straightedge from measurement D to get measurement E.
q. Subtract measurement C from measurement E to get reverse clutch drum endplay.
Reverse Clutch Drum Endplay Thrust Washer Specifications:
r. Select thrust washer to bring reverse clutch drum endplay 0.0217- 0.0354.
s. Install 2-4 band adjusting stop, washer, and band adjusting stop locknut into transaxle case.
87. Place 2-4 band and band strut around reverse clutch drum.
88. Install 2-4 servo assembly into transaxle case.
89. Position new gasket and 2-4 servo piston retainer bolts. Tighten bolts.
90. Tighten band adjusting stop until 2-4 band fits evenly around reverse clutch drum.
91. Install selected 3-4 clutch drum bearing race into oil pump assembly.
92. Place reverse clutch drum thrust washer into reverse clutch drum.
93. Install oil pump assembly and baffle plate into transaxle case. Tighten oil pump bolts.
94. Install new input shaft 0-ring onto input shaft.
95. Tighten band adjusting stop.
96. Back band adjusting stop off 2.5 turns, then tighten band adjusting stop locknut.
97. Apply compressed air to transaxle case and ensure 2-4 band operates properly. Check through both passages.
98. Install differential into transaxle case.
99. Install differential lubricant tube into torque converter housing. Tighten lubricant tube bolts.
100. Install new differential oil port 0-ring.
101. Apply suitable liquid gasket to torque converter housing mating surfaces.
102. Install transaxle case onto torque converter housing. Tighten bolts.
103. Install rear lube oil transfer tube seal, low/reverse clutch apply oil transfer tube, and three low/reverse clutch apply oil transfer tube bolts and tighten bolts.
104. Check contact surfaces of accumulator pistons for damage. Replace if necessary.
105. Install D-R accumulator piston in its bore. Apply transaxle fluid to seals.
106. Install D-R accumulator return spring on the D-R accumulator piston.
107. Install N-D accumulator piston in its bore. Apply transaxle fluid to seals.
108. Use compressed air to check operation clutches, accumulators, and 2-4 band.
CAUTION: Do not apply over 57 psi of air pressure.
109. Install four new 0-rings onto transaxle case.
110. Apply transaxle fluid to manual valve, then route valve body wiring harness through transaxle case and clip spring in place.
111. Set manual shift linkage rod to Neutral position.
112. Install main control valve body into transaxle case while aligning manual valve with manual detent lever.
113. Tighten valve body bolts a, b, and c to specifications.
114. Install transaxle oil filter and tighten bolts.
115. Ensure transaxle and transaxle oil pan mating surfaces are smooth and clean.
116. Install two oil pan magnets into transaxle oil pan.
117. Install new oil pan to case gasket and transaxle oil pan to transaxle.
118. Install transaxle oil pan bolts in a criss-cross pattern and tighten.
119. Install transaxle drain plug with new gasket. Tighten drain plug.
120. Place manual shift linkage rod in Park position.
121. Temporarily install Manual Lever Position (MLP) switch onto manual shift linkage rod.
122. Move manual shift linkage rod to Neutral position.
123. Insert gear position sensor adjuster tool No. T92P-70010-CH or equivalent, into MLP switch and manual shaft adjustment holes as vertically as possible.
124. Tighten MLP switch bolts.
125. Remove pin from MLP switch.
126. Install transaxle oil cooler tube onto transaxle. Tighten bolts.
127. Install oil filler tube onto transaxle. Tighten upper and lower filler tube bolts.
128. If new torque converter is used, add about 1 1/8 qt transaxle fluid to torque converter.
129. If old torque converter is used, add same amount of transaxle fluid as the amount drained from torque convertor during removal.
130. Install torque converter while aligning torque converter and front pump support and gear notches.
Torque Converter Installation:
131. Measure distance A to ensure torque converter is in proper position. Distance should be 0.55 inch.
132. If torque converter is not in proper position, reseat torque converter
133. Remove transaxle from holding fixture.