Part 1

ASSEMBLY






1. If removed, install parking pawl, parking pawl return spring, and parking pawl shaft.

NOTE: Make sure that the parking pawl engages the park gear and returns freely.





2. Install a new roll pin using a drift.





3. Install cup plug to case using Pinion Bearing Replacer T90C-3504-DH.





4. If bearing was removed, install new drive sprocket bearing using Stator & and Driven Sprocket Bearing Replacer T86P-70043-B and Driver Handle T80T-4000-W.











5. If removed, install driven sprocket support. Install six T-30 Torx bolts and tighten to 9-12 Nm (80-106 inch lbs.).

NOTE: Bolt holes are offset. Driven sprocket can only be aligned one way. Drain hole points downward.





6. Install converter impeller hub seal using Front Pump Seal Replacer T87L-77837-AH and a dead blow (lead-filled) hammer.





7. Install No. 19 differential carrier thrust bearing assembly over case boss with flat side facing up, outer lip facing down. Install No. 18 differential carrier thrust washer (tabs down) over No. 19 differential carrier thrust bearing and race.





8. Install final drive ring gear with external splines up.





9. Install rear support spacer on top of final drive ring gear and case splines.





10. Lower final drive/differential assembly into case as one unit.





11. Make sure both lube tube holes in rear planet support align in case window.





12. Install a new service part beveled retaining ring with notches using Retaining Ring Pliers T95P-77001-AH in the notches at ring ends and bevel facing downward. Carefully tap beveled retaining ring into place. Use care not to damage retaining ring, support or case.

WARNING: Use caution when unloading beveled retaining ring.

NOTE:
^ Do not install the original beveled retaining ring if notches are not present. Obtain a new service part beveled retaining ring with notches. The new service part beveled retaining ring must be the same size as the original discarded beveled retaining ring.
^ Make sure beveled retaining ring seats properly in case groove with bevel down.

13. Perform the end clearance check for the planetary support.





14. Make sure beveled retaining ring is properly seated and final drive support must be visible on the inside diameter of the retaining ring but must not seat against case wall.

CAUTION: If support is not visible on inside diameter of retaining ring, the low/intermediate piston could be damaged.





15. Place screwdriver into differential case and pry up to make sure that retaining ring is fully seated in top of case groove.





16. Install Step Plate Adapter D80L-630-3 or equivalent and End Play Tool T87P-70014-AH and two bolts over RH output shaft opening.





17. Remove No. 15 needle bearing from the rear planet support hub for this procedure.





18. Check for correct selective fit beveled retaining ring. Place Gauge Bar T94P-77000-Q across case with round legs of gauge bar resting on chain cover gasket surface. Place Dial Indicator Extension Rod T94P-77001-NH through hose in gauge bar.

NOTE: Gauge Bar must set on rear planet support No.15 bearing surface.





19. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent. Zero indicator. Tighten end play tool to 1.13-1.70 Nm (10-15 inch lbs.). Read and record dial indicator reading.








20. If dial indicator reading indicates movement more than 0.0127 mm (0.0005 inch), select the next largest beveled retaining ring from the Selective Fit Beveled Retaining Ring Chart and repeat the check procedure to verify specification.





21. Remove dial indicator, dial indicator extension rod and gauge bar. Install No. 15 thrust bearing.





22. Check end clearance for selective fit of No. 16 thrust race. Mount Dial Indicator with Bracketry with stylus on end of output shaft as shown. Zero dial indicator. Tighten end play tool screw to 4-5 Nm (36-44 inch lbs.). Read dial indicator.
23. Dial indicator reading should be 0.10-0.40 mm (0.004-0.016 inch). If clearance is not within specification, select a thicker or thinner washer from the No. 16 Thrust Race (Washer) Chart and repeat the clearance check.

NOTE: The beveled retaining ring and rear planet support must be removed to change No. 16 thrust race.

No. 16 Thrust Race (Washer) Chart
I.D. Thickness
Green (No. 1) 2.19-2.09 mm
Blue (No. 2) 2.32-2.22 mm
Black (No. 3) 2.45-2.35 mm
White (No. 4) 2.58-2.48 mm
Brown (No. 5) 2.71-2.61 mm
Gold (No. 6) 2.84-2.74 mm

24. After completing clearance check for No. 16 thrust race and clearance is within specification, remove end play tool and adapter.





25. Install low/intermediate one-way clutch assembly.

NOTE: Make sure No. 15 needle bearing is on rear planet support hub and the black plastic No. 15 thrust washer is in place on top of low/intermediate clutch spring retainer.





26. Install low/intermediate clutch wave spring, low/intermediate clutch pack and low/intermediate clutch pressure plate over the one-way clutch.

NOTE: The friction plate internal splines will center the one-way clutch.





27. Install low/intermediate clutch retaining ring.

CAUTION: Make sure retaining ring is seated in case groove.





28. Apply dry compressed air, regulated to 40 psi, to low/intermediate apply port (located in rear planet support). Make sure the piston strokes. Check for air leaking past the piston seal.

WARNING: To prevent injury, wear eye protection when using pressurized air.





29. Use a feeler gauge to measure the clearance between the clutch pressure plate and the clutch retainer. The clearance should be 1.27-1.90 mm (0.050-0.075 inch).
30. If the clearance is not within specification, select a retaining ring from the Selective Retaining Ring Thickness Chart. After installing the selected retaining ring, verify the clearance is correct.

Selective Retaining Ring Thickness Chart
1.54-1.64 mm (0.061-0.065 inch)
2.08-2.18 mm (0.082-0 086 inch)
2.62-2.72 mm (0.103-0.107 inch)
3.16-3.26 mm (0.125-0.128 inch)
3.68-3.78 mm (0.145-0.149 inch)





31. Install coast band into case and align anchor pin pocket on band with anchor pin in case.





32. Install low-intermediate drum. Rotate counterclockwise to seat the race of low-intermediate drum and sun gear into the low-intermediate one-way clutch.





33. Install park rod abutment and tighten bolts to 27-30 Nm (20-22 ft. lbs.). Make sure park pawl moves freely.





34. Install coast band apply piston spring, piston and rod assembly, cover and retaining ring using Servo Piston Remover/Replacer T92P-70023-A.








35. If not already completed, install Reverse Clutch/Planet Assembly Collet T94P-77001-FH and Remover/Replacer Tube T75L-7025-C over the front carrier hub. Slide Bearing Collet Sleeve T77F-7025-C over tube onto collet to hold in place.





36. Use the reverse clutch and planetary removal and installation tool to install the reverse clutch assembly and planetary assembly as one unit.

NOTE: Align reverse clutch cylinder anchor bolt pocket with anchor bolt case hole.





37. Make sure reverse clutch cylinder apply tube hole is aligned with case holes. Remove installation tool.





38. Install reverse clutch cylinder anchor pin bolt and locknut finger-tight. Do not tighten to specified torque at this time.





39. Place two 3/8-inch washers between the Front Clutch Loading Tool T86P-70389-A handle and notched block. Install Front Clutch Loading Tool Screw T94P-77001-HH into Front Clutch Loading Tool T86P-70389-A. Install tool to forward/intermediate/direct clutch assembly.

CAUTION: Do not overtighten.





40. Lower assembly into case, aligning shell and sun gear splines into front planet.

CAUTION: Make sure the assembly is fully seated before removing the tool or transaxle may not be assembled correctly, resulting in improper operation.





41. Install overdrive band into case.





42. Install overdrive retainer with cross-hairs facing up.

NOTE: Foot goes down against band.

No. 8 Thrust Washer And No. 9 Needle Bearing:

43. Remove No. 8 driven sprocket support thrust washer and No. 9 direct clutch hub needle bearing from the driven sprocket support.

Installing No. 9 Clutch Hub Needle Bearing:

44. Separate No. 8 thrust washer and No.9 direct clutch hub needle bearing. Install No.9 direct clutch hub needle bearing (only) into transaxle over the output shaft with outer lip up.

Installing Gauge Tube:

45. Install Gauge Tube T94P-77001-MH over output shaft until fully seated into No. 9 needle bearing. (This is where the No. 8 thrust washer normally sits.)

Reading A:

46. Place Gauge Bar T94P-77000-Q across case with round legs of Gauge Bar resting on chain cover gasket surface. Place Depth Micrometer D92P-4201-A or equivalent on Gauge Bar and measure down to gauge tube. Do this on both sides of output shaft (180° apart). Add both readings, divide by two to obtain reading A.

No. 8 Thrust Washer Chart:

47. Use reading A to select the correct No. 8 thrust washer from the No. 8 Thrust Washer Chart.

NOTE: Reading A and Dimension C from the No. 8 Thrust Washer Chart will be used in selection of No. 5 thrust washer.

Reading B:

48. Remove depth micrometer, gauge bar and gauge tube. Install gauge bar and depth micrometer. Measure down to the No. 5 thrust washer mating surface of overdrive drum. Take another reading on the other side of the shaft (180° apart). Add both readings, divide by two to obtain reading B. Remove gauge bar, depth micrometer and gauge tube from case.

Reading B: ____
- Reading A: ____
= Difference: ____
+ Reading C: ____
= Reading D: ____

49. Subtract Reading A from Reading B. Add difference between A and B to Dimension C. Record this as Reading D.

NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 Thrust Washer Chart.

Washer Thickness Chart:

50. Use Reading D to select the correct No. 5 front support thrust washer from the Washer Thickness Chart.

Installing No.5 Front Support Thrust Washer:

51. Install correct No. 5 front support thrust washer on driven sprocket support.

NOTE: Use petroleum jelly to hold washer in place for this step.

No. 8 Thrust Washer And No. 9 Needle Bearing:

52. Install the correct No. 8 driven sprocket support thrust washer and No. 9 direct clutch hub needle bearing on driven sprocket support. Use petroleum jelly to hold washer and bearing in place.

NOTE: No. 9 direct clutch hub needle bearing may still be inside transaxle from No. 8 driven sprocket support thrust washer selection procedure.

Driven Sprocket Support Assembly:

53. Lightly coat all seals with petroleum jelly before support installation. Install driven sprocket support assembly into case, making sure it is fully seated.