Assembly
1. Position case in horizontal position.Drive Sprocket Bearing Installation:
2. If bearing was removed, install drive sprocket bearing using Stator and Driven Sprocket Bearing Replacer T86P-70043-B. If removed, install driven sprocket support. Install six T-30 Torx bolts and tighten to 7-9 Nm (62-79 inch lbs.).
NOTE: Bolt holes are offset. Driven sprocket can only be aligned one way. Drain hole points downward.
3. Clean filter with compressed air and install.
Converter Hub Seal Installation:
4. Install converter impeller hub seal using Converter Hub Seal Replacer T87L-77837-AH and dead blow (lead-filled) hammer.
NOTE: After installation, verify presence of garter spring on seal.
5. Install RH differential seal using Output Seal Replacer T86P-1177-B with Output Shaft Seal Replacer Pilot T94P-77001-JH.
End Play Tool:
6. Loosely install End Play Tool T87P-70014-AH with Step Plate Adapter D80L-630-3 or equivalent and two bolts over RH output shaft opening Tool will be used later to perform selective thrust washer checks.
No. 19 Needle Bearing Installation:
7. Place case in vertical position Install No. 19 needle bearing over case boss with flat side facing up, outer lip facing down.
8. Install final drive ring gear with external splines up. Using a hammer handle if necessary, tap gently to fully seat into case splines
9. Assemble No. 18 thrust washer to differential assembly using petroleum jelly.
10. Lower final drive assembly into case. Use hammer to gently tap into place.
11. Install snap ring and align opening of snap ring with rear lube transfer tube passage.
12. Perform end clearance check for No. 18 selective thrust washer as follows.
a. Place screwdriver under case and pry up.
b. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent with stylus on end of output shaft.
c. Back out screw End Play Tool T87P-70014-AH installed in Step 6 until it no longer touches output shaft.
d. Zero dial indicator.
e. Tighten screw to 4-5 Nm (36-44 inch lbs.).
No. 18 Selective Thrust Washer Chart:
f. Observe reading on dial indicator. The clearance should be 0.10-0.40 mm (0.004-0.016 inch). If the clearance is not within specification, selective thrust washers are available in the No. 18 Selective Thrust Washers Chart:
NOTE: After completing end clearance check, back off screw on tool and leave tool in position for No. 5 and No. 8 selective thrust washer clearance check to be performed later.
13. After installing the correct thrust washer, check the clearance.
14. Install low and intermediate band into case and align anchor pin pocket with anchor pin.
15. Install No. 15 rear sun gear thrust bearing and race with rear sun gear and drum.
16. Install reverse clutch onto planet assembly.
17. 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.
18. Use the removal and installation tool to install the reverse clutch assembly and planetary assembly as one unit. Then remove the tool.
NOTE:
^ Align reverse clutch cylinder anchor bolt pocket with anchor bolt case hole.
^ Make sure the reverse clutch cylinder apply tube hole is aligned with case hole upon installation.
19. Start reverse anchor pin bolt and nut but DO NOT tighten at this time.
20. Attach Front Clutch Loading Tool T86P-70389-A to forward/intermediate/direct clutch assembly.
NOTE: Modify Front Clutch Loading Tool T86P-70389-A to fit lube holes by removing 0.50 mm (0.02 inch) of material off of each side of tool.
21. Lower assembly into case, front sun shell gear splines into front planet.
22. Remove Front Clutch Loading Tool T86P-70389-A.
CAUTION: Make sure the assembly is fully seated before removing the tool.
23. Tighten screw on End-Play Tool T87P-70014-AH previously installed to 4-5 Nm (36-44 inch lbs.).
24. Install overdrive band into case.
25. Install overdrive retainer with cross-hairs facing up.
26. Perform the following steps to check the driven sprocket end-play clearance for No.8 selective thickness thrust washers.
No. 8 Thrust Washer And No. 9 Needle Bearing:
27. 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:
28. Separate No. 8 thrust washer and No.9 needle bearing. Install No. 9 needle bearing (only) into transaxle over the output shaft with outer lip up.
Installing Gauge Tube:
29. 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:
30. Place Gauge Bar T94P-77000-Q across case with round legs of gauge bar resting on chain cover gasket surface of case. 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 Selective Thrust Washer Chart:
31. Use reading A to select the correct No. 8 thrust washer from the No. 8 Selective Thrust Washer Chart.
NOTE: Reading A and Dimension C from this chart will be used in selection of No. 5 thrust washer.
Reading B:
32. Remove depth micrometer, gauge bar and gauge tube. Install gauge bar and depth micrometer as shown in the Reading B image. Measure down to the No. 5 thrust washer mating surface of overdrive drum. Take another reading down to the No. 5 thrust washer mating surface of overdrive drum 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.
33. 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 No. 8 Selective Thrust Washer Chart.
Reading B ___.___
- Reading A ___.___
Difference ___.___
+ Dimension C ___.___
Reading D ___.___
No.5 Thrust Washer Selection Chart:
34. Use Reading D to select the correct No. 5 thrust washer from the No. 5 Selective Thrust Washer Chart.
35. Install correct No. 5 driven sprocket 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:
36. 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 thrust washer selection procedure.
Driven Sprocket Support Assembly:
37. Lightly coat all seals with petroleum jelly before support installation. Install driven sprocket support assembly into case, making sure it is fully seated.
End Play Tool:
38. Remove End Play Tool T87P-70014-AH and Step Plate Adapter D80L-630-3 or equivalent from case.
Parking Pawl Components:
39. Install parking pawl, parking pawl return spring, parking pawl shaft and locator pin.
NOTE: Make sure that the parking pawl engages the park gear and returns freely.
Parking Lever Actuating Rod:
40. install parking lever actuating rod in case. Install park rod abutment and start abutment bolts. Push in parking pawl and locate rod between parking pawl and abutment.
41. Replace any tubes removed from the case. Install new tubes in position and tap lightly until fully seated.
NOTE:
^ All fluid transfer tubes that were removed from the case must be discarded and replaced with new tubes. The tubes become distorted during removal and will not seal properly when reinstalled. The new tubes have a press fit and are not distorted from prior removal and installation. Do not remove tubes unless it is necessary to service the transaxle. Do not replace the tubes unless they have been removed for servicing.
^ When installing the rear lube tube, install the long end into the rear planet support and seal first.
42. Install tube support brackets.
43. Install manual control lever seal by tapping into case.
44. Start manual control shaft through manual control shaft seal and slide manual detent lever onto manual control shaft.
Manual Control Shaft Removal:
45. Slide manual control shaft through parking lever actuating rod and tap into case hole.
46. Install new manual shaft retaining pin through case hole, aligning with groove in manual control shaft.
Manual Control Shaft Components:
47. Install new roll pins in manual detent lever and parking lever actuating rod.
No. 2 & No. 4 Thrust Washers:
48. Install No. 2 and No. 4 tabbed thrust washers onto drive and drive sprocket supports. Align tabs on thrust washers with holes in sprocket supports. Apply grease to washers to help hold in position.
49. Install drive chain on drive sprocket and driven sprocket. Lower assembly into sprocket supports simultaneously with drive chain parallel to case surface, rotating sprockets to make sure that they are fully seated.
CAUTION: Be careful not to damage or bend tabs on exciter ring.
50. Install No. 1 and No. 3 thrust washers on chain cover. Use petroleum jelly to hold in place. Make sure tabs align with slots in chain cover.
51. Install new chain cover gasket on case.
Accumulator Springs:
52. Install accumulator springs in correct position in case.
53. Make sure chain cover alignment pins are on case.
54. Carefully align chain cover turbine shaft bore with turbine shaft. Apply gentle downward pressure on chain cover to overcome accumulator spring pressure and start two chain cover bolts.
CAUTION: Be extremely careful to prevent damage to the turbine shaft front seal (cast iron).
Chain Cover Bolts Torque Sequence:
55. Install remaining chain cover bolts. Tighten bolts as illustrated in the Chain Cover Bolts Torque Sequence starting from the inside.
NOTE: After installing chain cover, turbine shaft should have some end play and should rotate freely. If it will not rotate freely, remove chain cover and inspect turbine shaft front seal (cast iron) for damage.
Turbine Shaft Speed Sensor:
56. Install Turbine Shaft Speed (TSS) sensor to case. Tighten retaining bolt to 10-14 Nm (89-123 inch lbs.).
57. Install LH output shaft seal using Differential Seal Replacer T86P-1177-B.
Chain Cover Bolts:
58. Install remaining chain cover bolts in bellhousing. Tighten (10 mm socket) bolts to 25-28 Nm (18-21 ft. lbs.). Tighten (8 mm socket) bolts to 9-12 Nm (80-106 inch lbs.).
Reverse Drum Anchor Bolt:
59. Tighten 6 mm Allen-head reverse drum anchor bolt to 10-12 Nm (89-106 inch lbs.) and 19 mm locknut to 34-47 Nm (25-34 ft. lbs.).
60. Install fluid filter seal onto fluid filter and press fluid filter into case.
Transmission Pan Magnet:
61. Install pan magnet in transaxle pan.
62. Clean and inspect original pan gasket. If not damaged install original pan gasket on case and install transaxle pan. Tighten bolts to 10-12 Nm (89-106 inch lbs.).
Operating And Test Springs:
63. Install test spring from Overdrive Servo rod Tool T86P-70023-B in case.
CAUTION: The test spring from the Overdrive Servo Tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
64. Install overdrive servo piston and overdrive servo rod into case.
65. Install Overdrive Servo Rod Tool T86P-70023-B and secure using servo cover bolts. Tighten bolts to 9-12 Nm (89-106 inch lbs.).
66. Tighten center screw on tool to 1.13 Nm (10 inch lbs.).
Dial Indicator:
67. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent and position stylus through hole in Overdrive Servo Rod Tool. Make certain indicator stylus has contacted overdrive servo piston on a flat surface. DO NOT contact step on piston. Zero dial indicator.
68. Back off center screw until piston movement stops and read dial indicator. The reading should be 1.8-3.8 mm (0.070-0.149 inch). If measurement does not meet specifications, refer to the Overdrive Piston Rod Selection Chart to determine which overdrive servo rod to install.
Overdrive Piston Rod Selection Chart
Number of Grooves (groves are at the tip): Rod Length
0: 99.33 mm (3.91 inch)
1: 98.05 mm (3.86 inch)
2: 96.78 mm (3.81 inch)
69. Install new overdrive servo rod and repeat Steps 77 through 80 to verify amount of piston travel. If within specification, remove tool and test spring.
70. Install low and intermediate servo spring retainer on test spring, from Low/Intermediate Servo Rod Tool T86P-70023-A. Install test spring into case.
CAUTION: The test spring from the Low/Intermediate Servo Rod Tool is plain in color and has a thinner wire diameter than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
71. If not done prior, remove servo piston small seal from servo band piston. Install servo band piston and rod into case.
72. Install Low/Intermediate Servo Rod Tool T86P-70023-A and secure using servo cover bolts. Tighten bolts to 9-12 Nm (80-106 inch lbs.).
73. Tighten center screw on tool to 3.4 Nm (30 inch lbs.).
Dial Indicator:
74. Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent and position stylus through hole in Low/Intermediate Servo Rod Tool. Make certain indicator stylus has contacted servo band piston on a flat surface. Do not contact step on servo band piston. Zero dial indicator.
75. Back off center screw until piston movement stops and read dial indicator. The reading should be 5.5-6.5 mm (0.216-0.255 inch). If measurement does not meet specifications, refer to Low/Intermediate Servo Rod Selection Chart to determine which rod to install.
NOTE: If a new low and intermediate band is installed, reading should be 5-6 mm (0.197-0.236 inch).
Low/Intermediate Servo Rod Selection Chart
Number of Grooves (groves are at the tip): Rod Length
0: 114.26 mm (4.50 inch)
1: 113.72 mm (4.48 inch)
2: 113.18 mm (4.46 inch)
3: 112.64 mm (4.43 inch)
4: 112.10 mm (4.41 inch)
76. Install new piston rod and repeat Steps 71 through 74 to verify amount of piston travel. If within specifications, remove tool and test spring. Remove retainer from test spring.
77. Install servo piston small seal on servo band piston. Install low and intermediate servo spring retainer on low/intermediate operating spring.
CAUTION: The test spring from the Low/Intermediate Servo Rod Tool is plain in color and has a thinner wire diameter than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
78. Install servo piston springs and servo band pistons. Make sure that they are fully seated.
Operating And Test Springs:
CAUTION: The test spring from the Overdrive Servo Tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.
79. Install servo covers for overdrive and low/intermediate servo using new gaskets and seals. Tighten bolts evenly to 9-12 Nm (80-106 inch lbs.).
NOTE: Be sure to align tab on servo cover with port on case.
CAUTION: Tighten bolts two or three turns at a time to prevent cocking servo covers.
Speedometer Drive Gear Components:
80. Install speedometer driven gear retainer and shaft. Install speedometer drive gear and shaft making sure that slots in gear align with roll pin in shaft. Install speedometer thrust bearing and race.
Speedometer Cover And Components:
81. Install speedometer cover with new seal. Tighten bolts to 9-12 Nm (80-106 inch lbs.).
82. Perform air pressure checks using Transmission Test Plate T91P-7006-A. After pressure checks have been performed, remove tool.
NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when clutch or band is applied.
83. Install pump shaft.
84. Connect manual valve link to manual detent lever.
85. Start pump assembly and main control valve body over pump shaft and connect manual valve link to manual shift valve. Push main control valve body down until seated.
Pump Assembly And Main Control Valve Body Bolt Installation Sequence:
86. Install main control valve body bolts and tighten in sequence to 9-12 Nm (80-106 inch lbs.).
87. Install electrical connectors on proper solenoids and sensor until a slight click is felt.
88. Clean, inspect and install original main control cover gasket if not damaged onto main control cover.
89. Install main control cover and tighten to 10-12 Nm (89-106 inch lbs.).
90. Rotate transaxle to horizontal position.
91. Place manual lever in the NEUTRAL position.
92. Install Transmission Range (TR) sensor and loosely install two retaining bolts.
93. Align TR sensor slots using Transmission Range (TR) Sensor (MLPS) Alignment Tool T92P-70010-AH.
Transmission Range Sensor:
94. Tighten retaining bolts to 9-12 Nm (80-106 inch lbs.). Remove tool.
95. Install fluid level indicator seal onto fluid level indicator, then install fluid level indicator into fluid filler tube. Attach fluid filler tube to case. Tighten bolt to 9-12 Nm (80-106 inch lbs.).
Installing Torque Converter Handles:
96. Install torque converter.