Assembly
ASSEMBLENOTE: Prior to assembly, clean all components (except friction plates and intermediate/overdrive band) in solvent and dry with compressed air. Lubricate all internal components with suitable ATF.
Oil Pump Bolt Tightening Sequence:
1. Slide intermediate and overdrive band assembly into transaxle case, then install oil pump. Tighten pump bolts in sequence shown in the Oil Pump Bolt Tightening Sequence image.
Low/reverse Clutch Piston Outer Seal Installation:
Low/Reverse Clutch Piston Inner Seal Installation:
2. Install low/reverse clutch piston outer and inner seals as shown in the Low/reverse Clutch Piston Outer Seal Installation and the Low/Reverse Clutch Piston Inner Seal Installation images.
Low/Reverse Clutch Piston Seal Protector Installation:
3. Install low/reverse clutch piston in outer seal protector tool No. T94P-77000-D1 and inner seal protector tool No. T94P-77000-D5 or equivalents, then install piston in case and remove tools.
4. Install low/reverse clutch return spring assembly and retaining ring, then the clutch wave spring.
Low/Reverse Clutch Plates:
5. Install low/reverse clutch plates and pressure plate.
6. Temporarily install low one-way clutch thrust plate, then measure clearance between thrust plate and low/reverse clutch pressure plate at two points opposite one another.
7. Average measurements to obtain clearance measurement, noting the following:
a. Standard clearance is 0.02-0.05 inch.
b. If clearance is not within specification, select pressure plate with proper thickness to obtain standard clearance. Pressure plates are available in thicknesses of 0.100-0.097 inch, 0.092-0.088 inch, and 0.085-0.081 inch.
8. Remove low one-way clutch thrust plate, low/reverse clutch pressure plate, low/reverse clutch external spline steel clutch plate, internal spline friction clutch plates, and wave spring.
Pump Support Thrust Bearing Installation:
9. Install pump support thrust bearing as shown in the Pump Support Thrust Bearing Installation image, then remove seal sizer from forward/coast/direct clutch cylinder assembly.
Turbine Shaft Thrust Bearing Installation:
10. Install forward/coast/direct clutch cylinder and reverse clutch drum as an assembly, then the turbine shaft and thrust bearing as shown in the Turbine Shaft Thrust Bearing Installation image.
Low/Intermediate Sun Gear Thrust Bearing Installation:
11. Install forward one-way clutch and low/ intermediate sun gear assembly, then the low/intermediate sun gear thrust bearing.
Low/intermediate Carrier Thrust Bearing Installation:
12. Install low/intermediate carrier assembly and thrust bearing, then the low/intermediate ring gear assembly.
Reverse/Overdrive Sun Gear Thrust Bearing Installation:
13. Install reverse/overdrive sun gear thrust bearing, then the sun gear and shell assembly.
14. Install reverse/overdrive carrier assembly with captured thrust bearing, then the low/reverse clutch plates and selective fit pressure plate.
15. Install low/reverse clutch wave spring, then the low one-way clutch assembly.
NOTE: I.D. ring on inner ring must face up.
16. Install low one-way clutch thrust plate and retaining ring, then snap socket end of manual valve detent lever actuating rod on parking cam actuator lever.
Driven Sprocket Shim Measurement Tool Installation:
17. Snap socket end of manual valve detent lever actuating rod on manual valve detent lever, then install preload tool adapter/aligner set tool No. T94P-77000-R or equivalent on reverse/ overdrive carrier assembly as shown in the Driven Sprocket Shim Measurement Tool Installation image. Torque tool bolts to 10 ft lbs.
18. Select proper driven sprocket shim as follows:
a. Install gauge bar tool No. T94P-77000-Q or equivalent with short spacers across transaxle case, then measure distance from top of gauge bar to driven sprocket bearing surface of transaxle case to obtain dimension A.
b. Using a depth micrometer, measure distance from top of gauge bar to bearing surface on reverse/overdrive carrier assembly. This is dimension B.
Driven Sprocket Shim Thickness Chart:
c. Subtract dimension B from dimension A to obtain dimension C, then refer to the Driven Sprocket Shim Thickness Chart for proper shim thickness.
Driven Sprocket Shim And Bearing Installation:
19. Install selective fit driven sprocket shim on transaxle case, then remove gauge bar and preload tool set.
20. Install driven sprocket bearing assembly, then lubricate needles and driven sprocket bearing.
Reverse/Overdrive Ring Gear Thrust Bearing Installation:
21. Install reverse/overdrive ring gear thrust bearing assembly, then temporarily install reverse/overdrive ring gear assembly.
Drive Sprocket Thrust Washer Measurement Tool Installation:
22. Install preload tool adapter/aligner set tool No. T94P-77000-R or equivalent on reverse overdrive ring gear assembly as shown in the Drive Sprocket Thrust Washer Measurement Tool Installation image, then select proper drive sprocket thrust washer as follows:
a. Install gauge bar tool No. T94P-7700-D or equivalent with short spacers on transaxle case, then use a depth micrometer to measure distance from top of bar to face of reverse/overdrive ring gear assembly. This is dimension A.
b. Using combined thickness of gauge bar and spacers as dimension B, subtract dimension A from dimension B to obtain dimension C.
Drive Sprocket Thrust Washer Thickness Chart:
c. Refer to the Drive Sprocket Thrust Washer Thickness Chart for proper washer thickness.
d. Remove gauge bar and preload tool set.
23. Apply petroleum jelly to selective fit drive sprocket thrust washer, then install washer on converter housing and remove reverse/overdrive ring gear assembly.
24. Install oil filter and seal, then temporarily install valve body guide pin tool No. T94P-77000-N or equivalent in filter eyelet and transaxle case hole.
25. Use shift lever seal replacer tool No. TOOL-77288 or equivalent to install oil filter recirculating regulator exhaust seal, then remove valve body guide pin.
26. Install rear chain cover on transaxle case, then assemble drive chain on driven sprocket assembly and reverse/overdrive ring gear assembly.
WARNING: Wear gloves when handling chain and sprocket to avoid injury.
27. Lower drive chain, driven sprocket, and reverse/overdrive ring gear assemblies together into transaxle case, then install front chain cover.
NOTE: Ensure driven sprocket and reverse/overdrive assemblies seat properly.
Driven Sprocket Thrust Bearing Installation:
28. Install driven sprocket thrust bearing as shown in the Driven Sprocket Thrust Bearing Installation image, then the final drive carrier and differential assembly.
29. Select proper differential bearing shim as follows:
Differential Bearing Shim Measurement Tool Installation:
a. Install gauge bar tool No. T94P-77000-Q and spacer set tool No. T94P-77000T or equivalents on transaxle case. Torque bolts to 10 ft lb.
b. Measure distance between top of gauge bar and shim surface of final drive carrier and differential assembly at two points, then average measurements to obtain dimension.
c. Using combined thickness of gauge bar and spacers as dimension B, subtract dimension A from dimension B to obtain dimension C.
Differential Bearing Shim Thickness Chart:
d. Refer to the Differential Bearing Shim Thickness Chart for proper shim thickness, then remove gauge bar and spacers.
Speedometer Drive Gear, Differential Bearing, And Shim Installation:
30. Install speedometer drive gear, selective fit differential bearing shim and differential bearing as shown in the Speedometer Drive Gear, Differential Bearing, And Shim Installation image.
NOTE: Ensure speedometer drive gear tabs are down and seated properly.
Converter Housing To Transaxle Case Bolt Tightening Sequence:
31. Attach split flange gasket and converter housing to transaxle case, then torque converter housing to transaxle case bolts in sequence shown in the Converter Housing To Transaxle Case Bolt Tightening Sequence image.
32. Lubricate and install intermediate and overdrive servo piston with return spring in transaxle case bore, then install servo piston rod selector tool No. T94P-77000-M or equivalent on piston.
NOTE: Note number of grooves on piston rod.
Servo Piston Rod Selector Tool Installation:
33. Loosely assemble legs and bar from rod selector tool in case bore, then tighten bar to legs and torque center bolt to 36 in lbs.
34. Install a depth micrometer on rod selector tool head, then measure distance to bar of rod selector tool. This is dimension A.
35. Back off center bolt until piston movement stops, then measure distance to bar of rod selector tool. This is dimension B.
Servo Piston Travel Specification Chart:
36. Subtract "dimension A" from dimension "B" to obtain travel distance, then refer to the Servo Piston Travel Specification Chart for travel specifications.
37. If travel distance is not within specifications, replace intermediate and overdrive servo piston and recheck, then remove selector tool.
38. Install servo cover in case, then position remover/replacer tool No. T94P-77000-L or equivalent on cover.
39. Compress servo cover and install retaining ring, then remove tool.
CAUTION: Because servo return spring is under extreme pressure, use caution during installation.
40. Install servo cover cap in transaxle case using servo plug replacer/needle bearing receiver tool No. T94P-77000-E2 or equivalent, then attach transmission test plate tool No. T94P-77000-S or equivalent with mounting screws tool No. T82P-7006-C or equivalent
41. Using a rubber-tip blow gun with 40 psi filtered air pressure, check clutch hydraulic circuits for leaks and function.
NOTE: Do not check coast clutch as piston may be forced out of forward clutch piston. Correct leakage as required.
42. Remove transmission test plate screws and plate, then install thermostatic oil level control valve and bracket in transaxle case and torque bolt.
43. Install 0-ring on transaxle electrical connector, then position main control slightly away from transaxle case and push electrical connector into bore.
Main Control Valve Body Bolt Tightening Sequence:
44. Align Z-link in manual valve, then install wiring harness clip and main control bolts. Torque bolts in sequence shown in the Main Control Valve Body Bolt Tightening Sequence image.
Shifter Shaft Alignment Tool And Pin Installation:
45. Remove manual control lever bolt and lever, then use shifter shaft alignment tool No. T94P-77000-H or equivalent to move manual control lever shaft to Drive position. Install holding pin.
Manual Valve Detent Lever Position:
46. Move manual valve detent lever assembly to Drive position, then loosen nut on ball stud for manual valve detent lever actuating rod.
47. Tighten nut on ball until snug and remove shifter pin, then rotate shifter shaft alignment tool until socket can be placed on nut. Torque nut, then rotate back to Drive position and recheck adjustment.
48. Remove pin and alignment tool, then install manual control lever assembly and bolt and torque bolt.
Manual Valve Detent Lever Ranges:
49. Rotate manual valve detent lever to Neutral position, then place Manual Lever Position (MLP) sensor on manual valve detent lever shaft.
50. Using MLP sensor alignment tool No. T92P-70010-AH or equivalent, align MLP sensor on manual valve detent shaft and transaxle case. Torque sensor bolts.
Main Control Cover Bolt Loosening/Tightening Sequence:
51. Install main control cover gasket on cover, then attach cover assembly to transaxle case. Torque bolts in sequence shown in the Main Control Cover Bolt Loosening/Tightening Sequence image.
52. Install 0-ring on Vehicle Speed Sensor (VSS), then push sensor into bore. Torque VSS bolt.
53. Install new oil filler tube grommet on transaxle case, then the tube and bolt. Torque the bolt.
54. Slide oil level indicator into filler tube, then install 0-ring on transmission speed sensor. Apply a thin film of petroleum jelly to 0-ring.
55. Push transmission speed sensor into bore, then install bolt and torque.
56. Use output seal replacer tool No. T86P-1177-B or equivalent and a hammer to install differential oil seals.
57. Use converter seal replacer tool No. T94P-77000-C or equivalent and a hammer to install converter impeller hub seal, then install transaxle drain plug and torque.
Oil Pump Driveshaft Replacement:
58. Install oil pump driveshaft into end of turbine shaft assembly.
59. Install torque converter handles tool No. T81P-7902-C or equivalent, then install converter on transaxle.
60. Remove transaxle from mounting fixture.