AX4N
ASSEMBLE1. Install final drive ring gear with external splines up.
2. Lower final drive assembly and rear planet support assembly into case as one unit.
Lube Tube Hole Alignment:
3. Ensure both lube tube holes in rear planet support align in case window as shown in the Lube Tube Hole Alignment image.
4. Install new beveled retaining ring, then place screwdriver into differential case and pry up to ensure retaining ring is fully seated in top of case groove.
5. Install low/intermediate one-way clutch assembly.
6. Install low/intermediate clutch wave spring, clutch pack, and clutch pressure plate over one-way clutch.
7. Install low/intermediate clutch retaining ring.
8. Apply compressed air, regulated to 40 psi to low/intermediate apply port. Ensure piston moves and no air leaks past piston seal.
9. Use feeler gauge to measure clearance between clutch pressure plate and clutch retainer. Clearance should be 0.050-0.075 inch.
10. If clearance is not within specification, select one of the following retaining rings:
a. 1.54-1.64 mm (0.061-0.065 inch).
b. 2.08-2.18 mm (0.082-0.086 inch).
c. 2.63-2.72 mm (0.103-0.107 inch).
d. 3.16-3.26 mm (0.125-0.128 inch).
e. 3.68-3.78 mm (0.145-0.149 inch).
11. Install coast band into case and align anchor pin pocket on band with anchor pin in case.
12. Install low-intermediate reverse drum. Rotate counterclockwise to seat race of drum and sun gear into low-intermediate one-way clutch.
13. Install park rod abutment and tighten bolts. Ensure parking pawl moves freely.
14. Install coast band apply piston spring, piston and rod assembly, cover and retaining ring using servo piston remover/replacer tool No. T92P-70023-A, or equivalent.
Reverse Clutch Collet Installation:
15. If not already completed, install reverse clutch/planet assembly collets and tube, tool Nos. T94P-77001-FH and T75L-7025-C, or equivalents, over front carrier hub. Slide collet sleeve, No. T77F-7025-C or equivalent, over tube onto collet to hold in place.
16. Align reverse clutch cylinder anchor bolt pocket with anchor bolt case hole.
17. Use reverse clutch and planetary removal/installation tool to install reverse clutch assembly and planetary assembly as one unit.
Reverse Clutch Cylinder Apply Tube Hole Alignment:
18. Ensure reverse clutch cylinder apply tube hole is aligned with case holes as shown in the Reverse Clutch Cylinder Apply Tube Hole Alignment image.
19. Install reverse clutch cylinder anchor pin bolt and locknut finger-tight.
20. Place two 3/4 inch washers between front clutch load in tool No. T86P-70389-A handle an notched block. install front clutch loading tool screw, No T94P-7700l-HH or equivalent, into front clutch loading tool No. T86P-70389-A or equivalent. Install tool to forward intermediate/direct clutch assembly.
21. Lower assembly into case, aligning shell and sun gear splines into front planet.
22. Install overdrive band into case.
23. Install overdrive retainer with cross hairs facing up.
24. Remove No.8 driven sprocket support thrust washer and No. 9 direct clutch hub needle bearing from driven sprocket support.
25. Separate No.8 thrust washer and No. 9 needle bearing. Install No. 9 needle bearing into transaxle over top of output shaft with out lip up.
26. Install gauge tube tool No. T94P-77001-MH or equivalent over output shaft until fully seated into No.9 needle bearing (where No. 8 thrust washer normally sits).
27. Place gauge bar tool No. 194P-77000-Q or equivalent across transaxle case with round legs of gauge bar resting on chain cover gasket surface.
Gauge Bar And Micrometer Installation:
28. Place depth micrometer on gauge bar and measure down to gauge tube. Do this on both sides of output shaft. Add both readings and divide by two to obtain reading "A."
No. 8 Thrust Washer Selection Chart:
29. Reading "A" and dimension "C, from the No. 8 Thrust Washer Selection Chart, will be used in selection of No.5 thrust washer. Use reading "At to select correct No. 8 thrust washer from chart.
30. Remove depth micrometer, gauge bar, and gauge tube.
31. Install gauge bar and depth micrometer as shown in the Gauge Bar And Micrometer Installation. Measure down to No 5 thrust washer mating surface of overdrive drum. Take another reading on other side of shaft. Add both readings and divide by two to obtain reading "B".
32. Subtract reading "A" from reading B" and add this to dimension "C." Record this as reading "D."
No. 5 Thrust Washer Selection Chart:
33. Use reading to select correct No.5 thrust washer from chart in the No. 5 Thrust Washer Selection Chart.
34. Install correct No. 5 thrust washer on driven sprocket support
35. Install correct No. 8 thrust washer and No.9 needle bearing on driven sprocket support. Use petroleum jelly to hold washer and bearing in place.
36. Lightly coat all seals with petroleum jelly before support installation.
37. Install driven sprocket support assembly into case.
38. Install neutral/drive accumulator piston, pin, spring cover, and retaining bolt and tighten.
39. Install new 0-rings on fluid supply tube if removed. Install reverse clutch oil supply tube in position and tap lightly until fully seated.
40. Install new 0-rings as necessary and install coast servo apply fluid transfer tube.
41. Install new 0-rings as necessary and install low/intermediate clutch apply fluid transfer tube.
42. Install rear fluid supply transfer tube and new 0-rings as necessary.
43. Install three lubrication tube support brackets and tighten.
44. Install new manual control lever shaft seal using pinion bearing replacer tool No. T900-3504-DH or equivalent.
Parking Lever Actuating Rod Installation:
45. Install parking lever actuating rod in case. Push in parking pawl and locate rod between parking pawl and abutment.
Manual Control Lever Shaft Installation:
46. Slide manual control lever shaft into case and slide manual control lever onto manual control lever shaft. Attach parking lever actuating rod to control lever and tap manual control lever shaft into case hole.
47. Install three new roll pins in manual valve detent lever and manual control lever in case.
48. Install No. 2 drive sprocket thrust washer and No. 4 driven sprocket thrust washer onto drive and drive sprocket supports. Align tabs on thrust washers with holes in sprocket supports.
49. Install drive chain on drive sprocket and driven sprockets. Lower assembly into sprocket supports simultaneously with drive chain parallel to case surface, rotating sprockets to ensure they are fully seated.
Accumulator Spring Installation:
50. Install accumulator springs as shown in the Accumulator Spring Installation image.
51. Install new chain cover gasket.
52. Install No. 1 and No. 3 thrust washers on chain cover. Ensure tabs align with slots in chain cover.
53. Carefully align chain cover input shaft bore with input shaft. Apply gentle downward pressure on chain cover to overcome spring pressure and start two chain cover bolts.
54. Start remaining chain cover bolts and tighten.
55. Install overdrive servo piston and overdrive servo rod and tighten.
56. Install overdrive servo cover, piston, rod, and spring assembly and tighten.
57. Install four new Teflon pump shaft rear seals and front seals on pump shaft.
58. Install pump shaft, then connect manual control valve actuating rod link to manual valve detent lever.
59. Position pump and main control valve body over pump shaft and connect manual control valve actuating rod to manual control valve. Push main control valve body down until seated.
60. Install main control valve body bolts and tighten from center outward.
61. Install electrical connectors to solenoids and sensor.
62. Install main control cover and tighten bolts.
63. Tighten reverse clutch locator bolt and locknut.
64. Install new fluid filter and seal assembly.
65. Install clean ceramic case magnet in transaxle pan in correct location.
66. Install pan gasket and transaxle pan and tighten bolts.
67. Install remaining chain cover bolts in converter housing and tighten.
68. Install turbine shaft speed sensor and tighten.
69. Install Transaxle Range (TR) sensor and slightly tighten two retaining bolts.
70. Using suitable wrench on manual shaft flats, rotate shaft counterclockwise to Park detent.
71. Rotate two detent positions clockwise to Neutral position.
72. Align TR sensor slots using transaxle range sensor alignment Manual Lever Position (MLP) sensor tool No. T92P-7001-AH or equivalent.
73. Tighten TR sensor retaining bolts.
74. Install fluid filler tube grommet into case then the filler tube and tighten.
75. Install vehicle speed sensor and tighten.
76. Install left output shaft seal using tool No. T87P-1177-B or equivalent.
77. Install right output shaft seal using output seal replacer and pilot, tool Nos. T86P-1177-B and T94P-77001-JH or equivalents.
78. Install identification tag on case, if removed.
79. Install torque converter using torque converter handles, tool No. T81P-7902-C or equivalent.