Part 4
TransaxleAssembly (Steps 58-102)
58. Using the special tools, measure the distance from the top of the special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
^ The special tools must be relocated to carry out the second measurement.
^ Repeat this measurement 180 degrees from the first measurement.
^ The average of these 2 dimensions is dimension B.
59. Use combined thickness of the special tool with long spacers 177.8 mm (7.0 in) as dimension A.
60. Subtract dimension B from dimension A. This is dimension C.
61. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
Differential End Play No. 14 Shim:
62. Install the differential bearing assembly.
1 Install the No. 14 differential bearing shim (selective fit).
2 Install the No. 15 differential bearing.
63. NOTE: Check for correct alignment of the lube tube on the converter housing.
Install the torque converter housing onto the transaxle case.
^ Position and install the split flange gasket.
64. NOTE: Tighten the bolts in the indicated sequence.
Install the torque converter housing-to-transaxle case bolts.
^ Tighten to 23 Nm (17 lb-ft).
65. NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.
Lubricate the assembly with clean transmission fluid.
1 Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
2 Install the intermediate and overdrive servo apply rod and piston assembly.
3 Install the overdrive servo apply rod spring.
66. Install the special tool.
67. NOTE: Struts on the special tool fit into the servo cover retaining ring groove.
Assemble the special tool.
1 Install the struts.
2 Install the bar.
3 Install the bolts.
4 Install the center bolt.
^ Tighten to 4 Nm (35 lb-in).
68. Using the special tool, measure the distance to the bar of special tool.
^ Record this as dimension A.
69. Back off the center bolt of the special tool until the piston movement stops.
70. Using the special tool, measure the dimension to the bar of the special tool, record as dimension B.
^ Subtract dimension A from B to find the travel.
^ If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly.
Intermediate/Overdrive Servo Apply Rod:
71. Wipe the servo piston and the servo cover cap with a lint-free cloth.
72. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and servo cover cap with cleaning solvent, or damage to the sealing surface may result.
Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston attaches to the servo rod.
73. Squeeze the servo piston lip to check for flexibility. If the lip feels brittle, install a new piston.
74. Inspect the servo retainer spring for cracks, breaks or deformation.
75. Install the special tool.
76. CAUTION: If the case is stamped WG, install a wide-groove snap ring or damage to the servo will result.
CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring.
The WG stamp is located on the case toward the passenger side of the overdrive servo. The letters WG are etched into the case and hard to see.
77. NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
Tighten the special tool bolt.
^ Install the servo cover retaining ring, using retaining ring pliers.
78. Loosen the special tool bolt.
^ When spring tension is released, remove the special tool.
79. CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.
NOTE: If any leaks occur, make sure the special tool is correctly seated. Using the special tool, inspect the hydraulic circuits.
Use a rubber-tipped blow gun and 276 kPa (40 psi) of moisture-free regulated compressed air.
1 Reverse clutch test port.
2 Forward clutch test port.
3 Direct clutch test port.
4 Low/reverse clutch test port.
5 Servo release test port.
6 Servo apply test port.
7 Transmission air test plate.
^ If air leakage is detected, disassemble the transaxle and locate source of leakage.
80. Install the thermostatic fluid level control valve.
1 Position the thermostatic fluid level control valve.
2 Install the bracket.
3 Install the thermostatic fluid level control valve bracket bolt.
^ Tighten to 12 Nm (9 lb-ft).
81. CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals can result.
Install the solenoid body electrical connector O-ring seal and install the electrical connector into its bore in the transaxle case.
82. CAUTION: Handle main control valve body with care to prevent manual valve damage.
Connect the manual valve.
1 Lift the main control away from the case.
2 Connect the Z-Link to the manual valve.
83. NOTE: Tighten bolts in sequence shown. Bolts 1, 7 and 9 are longer than the others.
Install the main control valve body mounting bolts.
^ Tighten to 10 Nm (89 lb-in).
84. Install the manual control lever.
^ Tighten to 27 Nm (20 lb-ft).
85. Rotate the manual valve detent lever assembly to the NEUTRAL position.
1 Low 1.
2 Low 2.
3 Drive.
4 Neutral.
5 Reverse.
6 Park.
86. Position the transmission range (TR) sensor.
87. Using the special tool, align the TR sensor and tighten the bolts.
^ Tighten to 11 Nm (8 lb-ft).
88. NOTE: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary.
Install the main control cover gasket.
89. NOTE: Tighten the bolts and studs in the indicated sequence.
NOTE: The cooler bypass valve studs are in locations 3 and 11.
Install the main control valve body cover and bolts.
^ Tighten to 13 Nm (10 lb-ft).
90. Install the vent tube.
91. Install a new transmission filler tube grommet.
92. Install the transmission filler tube assembly.
1 Install the tube.
2 Install the transmission filler tube bolt.
^ Tighten to 8 Nm (71 lb-in).
^ Install the fluid level indicator.
93. Install a new O-ring seal on the turbine shaft speed (TSS) sensor and install the sensor.
1 Using petroleum jelly on the O-ring seal, position the TSS sensor into the case.
2 Install the TSS sensor bolt.
^ Tighten to 12 Nm (9 lb-ft).
94. Using the special tool, install the LH differential seal.
95. If the vehicle is equipped with a power transfer unit (PTU), use the special tools to install the RH differential seal.
96. If the vehicle is not equipped with a PTU, use the special tools to install the RH differential seal.
97. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.
Using the special tool, install the torque converter fluid seal.
^ Coat the torque converter seal garter spring with petroleum jelly.
98. Using a small amount of pipe sealant on the threads, install the transaxle drain plug.
^ Tighten to 25 Nm (18 lb-ft).
99. NOTE: Check for correct rotation of the pump driveshaft.
Install the pump driveshaft.
100. Using the special tool, install the torque converter.
101. NOTE: The torque converter hub must be fully seated into the transaxle pump drive gear.
Check the installation depth of the torque converter.
1 Lay a straightedge on the transaxle converter housing.
2 Check the clearance between the straightedge and the pilot hub.
^ Clearance is 17 mm (0.66 in).
102. Remove the transaxle from the special tool.
