Part 2
TransaxleAssembly (Steps 36-70)
36. Using the special tools, install the front planetary/reverse clutch assembly.
37. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.
38. Loosely install the reverse clutch anchor pin.
39. Using the special tool, install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.
40. Install the overdrive band.
41. NOTE: The foot of the overdrive retainer fits against the band.
Install the overdrive band anchor strut with the cross hairs facing upward.
42. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
1. Remove the No. 9 bearing and race.
2. Remove the No. 8 sprocket support.
43. Install only the No. 9 needle bearing with the outer lip upward.
44. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.
45. Install the special tool to make the measurements.
46. When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by 2 to obtain reading A.
47. NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.
Use reading A to select the correct No. 8 thrust washer from the chart.
No. 8 Thrust Washer Selection Chart:
No. 8 Thrust Washer Selection Chart
48. Remove the special tools.
49. Install the special tools to take the measurements.
50. Measure down to the No. 5 thrust washer mating surface of the overdrive drum. Take another reading on the other side of the drum 180 degrees from the first one. Add both readings and divide by 2 to obtain reading B.
51. Remove the special tools.
52. NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D.
53. Use Reading D to select the correct No. 5 thrust washer.
No. 5 Support Thrust Washer Chart:
No. 5 Support Thrust Washer Chart
54. NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
Install the No. 5 front support thrust washer.
55. CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure. Use petroleum jelly to hold bearing and washer in place.
Install the correct bearing.
1. Install the correct No. 8 driven sprocket support thrust washer.
2. Install the No. 9 direct clutch needle bearing.
56. Install the driven sprocket support assembly.
57. Install the neutral/drive accumulator cover.
1. Install the neutral/drive accumulator piston.
2. Install the neutral/drive accumulator spring.
^ The outer spring is yellow in color.
^ The inner spring is grey in color.
3. Install the neutral/drive accumulator cover.
58. Install the bolt.
^ Tighten to 11 Nm (8 ft. lbs.).
59. NOTE: All the fluid supply tubes must have new O-rings installed.
Install the fluid supply tubes.
60. Install the brackets and bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
61. Using the special tool, install the manual control lever shaft seal.
62. Install the parking lever actuating rod.
^ Push in on the park pawl.
^ Slide the parking lever actuating rod down to fit in the park pawl.
63. NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.
Install the manual control lever shaft.
64. NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.
Install the roll pins.
65. NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
Install the thrust washers.
1. Install the No. 2 drive sprocket thrust washer.
2. Install the No. 4 driven sprocket thrust washer.
66. CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent.
NOTE: Lower the assembly into the sprocket supports simultaneously.
Install the drive chain and sprockets.
67. Install the shift accumulator springs.
1. Install the 1-2 shift accumulator piston spring (no color or brown).
2. Install the 2-3 shift accumulator piston spring (no color or brown).
3. Install the reverse shift accumulator piston spring (pink).
4. Install the 3-4 shift accumulator piston spring (pink).
68. NOTE: Make sure that the alignment pins are installed in the case.
Install the new chain cover gasket.
69. CAUTION: Be extremely careful not to damage the cast iron sealing ring.
Use petroleum jelly to hold thrust washers in place during assembly.
1. Install the No. 1 thrust washer.
2. Install the No. 2 thrust washer.
3. Install the chain cover.
70. NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.
Start the 2 bolts.