Assembly
ASSEMBLENOTE: The composition clutch plates, valve body gaskets, bands, and synthetic seals should not be cleaned in a vapor degreaser, or with any type of detergent solution. To clean these parts, wipe them off with a lint-free cloth. Soak new clutch plates or bands in specified automatic transaxle fluid for at least two hours before assembly. Apply specified automatic transaxle fluid to all seal rings, rotating parts, 0-rings, and sliding parts.
1. Before installing bearing housing, adjust output gear bearing preload as follows:
Bearing And Stator Support Alignment:
a. Position bearing/stator support using valve body guide pins tool No. T80L-77100-A or equivalent, then press support into converter using step plate adapter tool No. D80L-630-6 or equivalent.
b. Remove bearing cup and adjustment shim(s) from bearing housing, then place bearing cup over output gear bearing.
Collars On Converter Housing Installation:
c. Place four collars, part of shim selection set tool No. T870-77000-J or equivalent, on converter housing.
Shim Selection Gauge On Output Gear:
d. Place shim selector gauge tool No. T880-77000-C1 or equivalent, on output gear. Turn both halves of selector to eliminate any gap between them.
e. Place bearing housing on collars.
f. Install four bolts tool No. T880-77000-C or equivalent, with washers. Torque bolts to 14-18 ft lbs.
g. Position preload torque adapter tool No. T88C-77000-DH or equivalent, on output gear. Using pins provided in shim selection set tool No. T87C-77000J or equivalent, loosen gauge halves until all free play is removed and bearings are seated.
h. Measure drag on output gear bearing using an in lb torque wrench and torque adapter.
i. Using pins provided, turn gauge until a reading of 4.3-7.8 in lbs is obtained on torque wrench.
j. Use feeler gauge to measure gap in between both halves of gauge. Measure gap at four spots, 90° intervals.
k. On 1993-1996 Probe models, select shim from output gear shim selection kit No. F32Z-7F405-A or equivalent.
l. On all other models, select appropriate adjustment shim(s) from chart. Select shim close to measurement or slightly larger.
NOTE: Do not use more than seven shims.
Shim Into Bearing Housing Installation:
m. Remove bolts, washers, bearing housing gauge and bearing cup, then press selected shim(s) and bearing cup into bearing housing, using bearing installer tool No. T60K-4616-A or equivalent.
n. Install bearing housing. Torque housing bolts.
o. Measure bearing preload.
p. On 1993-1996 Probe models, preload reading should be 10-17 in lbs.
q. On all other models, preload reading should be 0.26-7.81 in lbs.
r. If preload measurements are not within limits, repeat gauging process.
2. Adjust differential side bearing preload as follows:
a. Remove rear bearing cup and shims from transaxle case using stator and driven sprocket bearing remover tool No. T86P-70043-A, disc brake piston remover tool No. T73L-2196-A, and impact slide hammer tool No. T50T-100-A, or equivalents.
b. Install front bearing cup in converter housing using driver handle tool No. T80T-4000-W and differential bearing cup replacer tool No. T88C-77000-FH, or equivalents.
c. Install differential into converter housing.
Output Gear Shim Thickness Chart:
d. Place six collars, part of shim selection set tool No. T87C-77000J, or equivalent, on converter housing.
e. Install rear bearing cup over differential bearing.
Shim Selection Gauge:
f. Place shim selection gauge tool No. T880-77000-C1, or equivalent, on output gear. Turn both halves of selector to eliminate any gap between them.
g. Place transaxle case on collars, then install six screws tool No. T88C-77000-C or equivalent, with washers. Torque screws to 27-38 ft lbs.
h. Using pins provided, unthread gauge tool until all free play is removed and bearing cup is seated.
Differential Bearing Drag Measurement:
i. Engage differential rotator tool No. T880-77000-L or equivalent, then use an in lb torque wrench and adapter to measure drag on differential bearing.
j. Turn gauge, using pins provided until reading of 4.3 in lbs is obtained on torque wrench.
k. Use feeler gauge to measure gap in between both halves of gauge. Measure gap at four spots, 90° intervals.
Differential Shim Thickness Chart:
l. Add 0.0079 inch to the largest measurement, then select shim close to measurement or slightly larger.
CAUTION: Do not use any more than three shims.
m. Remove screws, washers, transaxle case, gauge, and bearing cup.
Bearing Cup Into Transaxle Case Installation:
n. Install selected shim(s) and bearing cup into transaxle case using drive handle tool No. T80T-4000-W and differential bearing cup replacer tool No. T88C-77000-FH or equivalents.
o. Install transaxle case. Torque transaxle case to converter housing bolts.
p. Measure bearing preload. Preload reading should be 26-35 in lbs.
q. If preload measurements are not within limits, repeat gauging process.
3. Install idle gear and output gear as an assembly by tapping in with a plastic hammer.
4. Install bearing housing on converter housing. Torque bearing housing mounting bolts.
5. Align groove on idle shaft with matching mark on bearing housing, then tap new roll pin in with suitable punch and hammer.
6. Apply small amount of automatic transaxle fluid to 2-3 accumulator 0-rings, then install 2-3 accumulator in piston assembly. Torque 2-3 accumulator mounting bolts.
7. Install differential adjustment shims and bearing cup, using driver handle tool No. T80T-4000-W and differential bearing cup replacer tool No. T88C-77000-FH or equivalents.
8. On 1992-1994 models, install differential.
9. On all models, install parking pawl and shaft, then the spring and snap ring.
10. Move manual shaft and check operation of parking pawl.
11. Install parking assist lever and snap ring, then the actuator. Torque actuator mounting bolts.
Manual Shaft Components Installation:
12. Install manual plate, spacer, washer and nut. Torque manual shaft nut.
13. Install manual shaft bracket. Torque bracket bolt.
14. Install detent ball, spring, washer, and plug. Torque plug.
15. Apply small amount of automatic transaxle fluid to inner and outer faces of low and reverse clutch piston seal. Face outer seal lip toward inside by gently rolling it down around circumference for easier installation.
16. Install low and reverse clutch piston by pushing evenly around circumference, using care not to damage outer seal.
17. Check operation of low and reverse clutch piston as follows:
a. Pour specified transaxle fluid over piston until it is fully submerged.
b. Apply compressed air through fluid passage. Ensure no bubbles appear from between piston and seals.
18. Install spring and retainer assembly, then compress assembly with return spring compressor tool No. T88C-77000-AH, or equivalent.
19. Install snap ring, then remove spring compressor.
20. Install output shell to output gear, then the bearing race on output shell.
21. Apply thin coat of suitable sealant to converter housing and transaxle case surfaces, then install 0-rings and transaxle to converter housing. Torque transaxle case attaching bolts.
Transaxle Plug Installation:
22. Install differential side gear and insert transaxle plugs tool No. T88C-7025-AH, or equivalent.
CAUTION: Failure to install plugs may cause differential side gears to become improperly positioned.
23. Place 3-4 clutch assembly over turbine shaft, then install assembly into transaxle case.
NOTE: Ensure thrust washer and needle bearing are installed in correct position.
Turbine Shaft Installation:
24. Install turbine shaft holder tool No. T88C-7700-KH, or equivalent, and attach to turbine shaft.
25. Install internal gear, then the internal gear snap ring to 3-4 clutch drum.
26. Install carrier hub assembly. Ensure thrust bearing and race are in correct position.
27. Install carrier hub assembly as follows:
a. Hold turbine shaft to prevent it from rotating.
b. Rotate carrier hub assembly onto turbine shaft and into 3-4 clutch assembly.
Low And Reverse Clutch Pack Installation:
28. Install low and reverse clutch pack, retaining plate and snap ring.
29. Check low and reverse brake clearance as follows:
Low And Reverse Clutch Pressure Plate Thickness Chart:
a. Measure clearance of snap ring and low and reverse brake retaining plate. Clearance should be 0.O83-0.O947 inch. If clearance is not as specified, select a retaining plate which will bring clearance to specification.
b. Check operation by applying compressed air through fluid passage.
30. Install wave washer.
31. Hold one-way clutch in horizontal position and install clutch by turning carrier hub assembly counterclockwise.
32. Install one-way clutch snap ring.
33. Install servo assembly, piston stem, and anchor strut, then install 2-4 brake band so band fully expands in transaxle case. Interlock 2-4 band and anchor strut.
34. Install small sun gear and one-way clutch by rotating.
NOTE: Ensure thrust bearing and race are in correct position.
35. Install piston stem in position while pulling 2-4 brake band with suitable pliers, then tighten piston stem by hand.
36. Install clutch assembly by rotating.
NOTE: Ensure thrust bearing and race are in correct position.
37. Install turbine shaft snap ring, then remove turbine shaft holder.
38. Measure height difference between reverse, coasting and forward drum and transaxle case. Distance should be 0.0028-0.075 inch on non-turbo models or 0.151 inch on turbo models.
39. Install snap ring into bottom ring groove of turbine shaft.
40. Place thrust bearing needle onto clutch assembly.
41. Check total endplay as follows:
a. Remove previous thrust washer and gasket.
b. Place 0.087 inch thrust washer on oil pump.
c. Install oil pump onto clutch assembly, then use feeler gauge to measure clearance between transaxle case and oil pump.
d. Measure several places, then calculate average gap.
Bearing Thrust Washer Thickness Chart:
e. If clearance is not as specified, select thrust washer which will bring clearance to specification.
f. Remove oil pump, then place selected thrust washer and new gasket onto oil pump.
g. Install oil pump onto clutch assembly. Torque oil pump bolts.
42. Adjust 2-4 brake band as follows:
a. Loosen locknut, then tighten piston stem to 78-96 in lbs.
b. Loosen piston stem two turns, then tighten locknut.
c. Torque brake band locknut.
43. Install oil strainer and new 0-rings to transaxle, then install oil pan with new gasket. Ensure oil pan magnets are properly positioned. Torque oil pan bolts.
44. Align manual valve with pin on manual plate, then install valve body with new gasket into transaxle case. Torque valve body mounting bolts.
45. Install electrical connector and new 0-ring into transaxle case.
46. Connect shift solenoid and transaxle oil temperature sensor connectors. Match shift solenoid connector coded colors.
47. Connect throttle cable to throttle cam on control valve body, then install new 0-ring on bracket.
48. Install control valve body cover with new gasket. Torque cover bolts.
49. Install oil pipes, hoses, and switch box as an assembly, then the transaxle vent hose and harness clip. Torque switch box bolts.
50. Install ball, spring, oil pipe, gasket, and plug. Torque outlet oil pipe connector plug to 23-35 ft lbs.
51. Install solenoid connector, then the pulse generator and fluid temperature switch.
52. Turn manual shaft to N position, then install neutral safety or manual lever position switch and loosely tighten bolts.
53. Adjust neutral safety or manual lever position switch as follows:
a. Remove screw, then move neutral safety or manual lever position switch so alignment hole is aligned with bolt hole.
b. Inserting 0.079 inch diameter pin through the hole, then install bolt. Torque bolts.
54. Install oil level gauge and dipstick tube with new 0-ring into transaxle case. Tighten dipstick tube mounting bolts to 71-88 in lbs.
55. Using converter seal replacer tool No. T88C-77000-BH or equivalent, install new converter seal.
56. Install oil pump shaft, then the new 0-ring on oil pump shaft.
57. Fill torque converter with specified transaxle fluid.
58. Install torque converter into converter housing while rotating it to align with splines.
CAUTION: Do not try to force torque converter in. Install it carefully.
59. Ensure torque converter is installed correctly by measuring distance A between end of converter and housing.
60. On 1993-1996 Probe models, distance should be 0.602 inch for 2.0L engine and 0.551 inch for engine.
61. On models except 1993-1996 Probe, distance should be 0.98 inch.