Attachment III - Technical Information

Technical Instructions

NOTE:
This repair procedure requires a transaxle roll pin extractor tool, see dealer letter for ordering instructions.

Inspection

1. Set parking brake. Place transaxle range selector lever in neutral.

2. Raise vehicle and place drain pan under transaxle.

3. Remove the transaxle pan from the transaxle (do not discard elastomeric pan gasket).





4. Insert a 1/16 inch drill bit by hand into the center of the roll pin that secures the park pawl shaft. See Figure 1.

a. The drill bit should go in a minimum of 1-1/8 inch. If it "does", go to step 21. If it "does not", remove and replace the roll pin and park pawl shaft as described below.

Park Pawl Shaft Replacement





1. Use two pan bolts to mount the bridge (from extractor kit) to the transaxle case. Large hole must be over roll pin. Tighten to 10 N-m (88.5 in. lb.). See Figure 2.





2. Assemble extractor. See Figure 3.





3. Insert extractor through the large hole in bridge and turn extractor clockwise three (3) or four (4) turns to thread it on the O.D. of the roll pin. See Figure 4.





4. Using a 15/16 inch wrench, tighten the nut on the extractor while holding the tee handle. See Figure 5.

5. Tighten nut until the roll pin is removed from the transaxle case.

6. Using Vise-grip type pliers to hold the roll pin, turn the extractor counter-clockwise to remove the roll pin from the extractor tip.

7. The extractor tip is removable for cleaning or replacement.





8. If roll pin breaks off in the extractor tip, use a # 1 easy-out to remove the broken piece. See Figure 6.

9. Remove the bridge from the transaxle case.





10. Note the orientation of the park pawl return spring and the park pawl to the case. Remove and discard the park pawl shaft. Pull the park pawl down and remove the park pawl return spring. See Figure 7. Retain park pawl and park pawl return spring for reinstallation later.





11. Install the burnishing tool (from extractor kit) into the case where the shaft was removed. See Figure 8. Do not push burnishing tool through park pawl.





12. Using a 1/4 inch drive ratchet, 6 inch extension and a universal socket, turn the burnishing tool in the case bore until it passes the roll pin hole. See Figure 9. Then, remove burnishing tool and clean the park pawl shaft bore in the transaxle case.





13. Reinstall original park pawl return spring and the park pawl. Make sure park pawl return spring is installed correctly. See Figure 10.





14. Position park pawl and park pawl return spring to the case and install the new symmetrical design park pawl shaft. See Figure 11.





15. Ensure park pawl shaft goes through both coils of the park pawl return spring one coil on each side of the park pawl. See Figure 12.





16. Ensure the groove in the park pawl shaft aligns with the roll pin hole in transaxle case. See Figure 13.





17. Use the tee handle (from extractor kit) to properly install a new roll pin. Install the roll pin by first inserting the large end of the roll pin into the counter-bored end of the tee handle. See Figure 14. Using the tee handle place the small end of the roll pin into the case hole and tap on the tee handle until the roll pin is fully seated. The roll pin will extend outward approximately 4 mm (5/32") from the case surface when fully seated.

18. Verify the park pawl shaft turns and the park pawl moves freely on park pawl shaft. Rotate park pawl shaft one full turn to ensure proper operation.

19. Push on park pawl to ensure park pawl return spring is correctly installed.

20. Verify proper installation of new roll pin by inserting 1/16 inch drill bit into the center of the roll pin as performed in step 4 of INSPECTION PROCEDURE on Page 1. The drill bit should go in a minimum of 1-1/8 inch. If it "does", go to step 21. If it "does not", the roll pin has been damaged during installation and must be replaced as outlined above.

21. Clean, inspect and reuse, if not damaged, the elastomeric pan gasket and install transaxle pan. Tighten retaining bolts to 10-14 N-m (88.5-124 inch lb).

22. Refill transaxle with Mercon Automatic Transmission fluid. Follow refill procedure in the Service Manual to top off fluid level. Be sure to recheck fluid level after transaxle reaches operating temperature.

23. Verify the park mechanism in the transaxle works properly before returning the vehicle to the owner.