Steps 51-102

51. Install the filter recirculating regulator exhaust seal.

NOTE: Lubricate the filter recirculating regulator exhaust seal prior to installation.





52. Install the chain pan in the transaxle case.





53. Assemble and install the drive chain assembly.
1 Drive chain (copper colored link facing upward).
2 Driven sprocket assembly.
3 Reverse/overdrive ring gear assembly.
- Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.

WARNING: WEAR GLOVES AS PROTECTION FROM SHARP CHAIN AND SPROCKET TEETH. FAILURE TO FOLLOW THIS INSTRUCTION WILL RESULT IN PERSONAL INJURY.





54. Install the chain pan cover by snapping it into place.





55. Install the driven sprocket thrust bearing (number 13).





56. Install the final drive carrier and differential assembly.





57. Install Gauge Bar Tool
1 Install Gauge Bar and spacers.
2 Install Gauge Bar Spacers and bolts.

NOTE: Plastic washers should be placed between bolts heads and gauge bar.





58. Measure the distance from the top of Gauge Bar to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
- Repeat this measurement on the other side of the hub 180 degrees from the first measurement.
- The average of these two dimensions is the first dimension.
59. Use combined thickness of Gauge Bar with long Spacers 177.8 mm as the second dimension.
60. Subtract the first dimension from the second dimension.
61. Use the third dimension to select the proper differential bearing shim (number 14) from the differential bearing shim chart in specifications. Specifications





62. Install the differential bearing assembly.
1 Install the speedometer drive gear with the tabs down.
2 Install the differential bearing shim (Number 14) (selective fit)
3 Install the differential bearing (number 15)





63. Install the torque converter housing onto the transaxle case.
- Position and install the split flange gasket.

NOTE: Check for correct alignment of the lube tube on the converter housing.





64. Install the torque converter housing to transaxle case bolts.





65. Lubricate the assembly before installation.
1 Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
2 Install the intermediate and overdrive servo apply rod and piston assembly.

NOTE: Note the number of grooves on the intermediate and overdrive servo apply rod.





66. Install Servo Piston Rod Selector.





67. Assemble the Servo Piston Rod Selector.
1 Install struts.
2 Install bar.
3 Install bolts.
4 Install the center bolt

NOTE: Struts on the tool fit into the servo cover retaining ring groove.





68. Measure the distance to Guide Bar.
- Record the first dimension.





69. Back off the center bolt until the piston movement stops.





70. Measure the dimension to Guide Bar (second dimension).
- Subtract the first dimension from the second dimension to find the travel.
- If the travel is not within the specification, select a new intermediate and overdrive servo apply rod assembly from the servo apply rod chart in specifications. Band Apply Servo





71. Install the servo cover.





72. Install the nut with washer on Servo Cover Remover/Replacer.

WARNING: SERVO RETURN SPRING FORCE IS VERY HIGH. FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN PERSONAL INJURY.

NOTE: To aid in the installation of the servo cover, install a nut with an integral washer (using permanent thread sealer) onto the forcing bolt of the servo cover.





73. Install Servo Cover Remover/Replacer.





74. Tighten the Servo Cover Remover/Replacer bolt.
- Install the servo cover retaining ring.

NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.





75. Loosen the Servo Cover Remover/Replacer bolt.
- When spring tension is released remove the Servo Cover Remover/Replacer.





76. Inspect the hydraulic circuits.
- Use a rubber tipped blow gun and 276 kPa of moisture free regulated compressed air.
1. Reverse clutch test port
2. Forward clutch test port
3. Direct clutch test port
4. Low/reverse clutch test port
5. Servo release test port
6. Servo apply test port
- If air leakage is detected, disassemble the transaxle and locate source of leakage.

CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.

NOTE: If any leaks occur ensure the test plate is properly seated.





77. Install the thermostatic fluid level control valve.
1 Position the thermostatic fluid level control valve.
2 Install the bracket.
3 Install the thermostatic fluid level control valve bracket bolt.





78. Install forward clutch circuit filter (if equipped).





79. Install the solenoid body electrical connector O-ring and install the electrical connector into its bore in the transaxle case.

CAUTION: Do not pull wires or damage the solenoid body electrical connector. Damage to the connector and terminals may result.





80. Connect the manual valve.
1 Lift the main control away from the case.
2 Connect the Z-link to the manual valve.
- Install the solenoid body retaining clip.

CAUTION: Handle main control valve body with care to prevent manual valve damage.





81. Install the main control valve body mounting bolts.

NOTE: Tighten bolts in sequence shown. Bolts 1, 7, and 9 are longer than the others.





82. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly. Remove the manual control lever.
1 Remove the bolt.
2 Remove the manual control lever assembly.





83. Move the manual control lever shaft to the "D" position.
- Install pin to hold tool in place.





84. Install the manual valve detent lever ball stud nut.
- Rotate Shifter Shaft Alignment Tool until socket can be fitted on nut.
- Tighten the detent nut.
- Rotate back to "D" position and recheck the adjustment.





85. Install the manual control lever assembly.
1 Position the manual control lever assembly.
2 Install the manual control lever bolt.





86. Rotate the manual valve detent lever assembly to the Neutral position.
1 Low 1
2 Low 2
3 Drive
4 Neutral
5 Reverse
6 Park





87. Position the Transmission Range (TR) sensor.





88. Align the TR sensor.
1 Use Transmission Range (TR) Sensor Alignment Tool to align the TR sensor.
2 Install the TR sensor bolts.
89. Install the main control cover gasket.





90. Install the main control cover.
- Install the main control cover bolts.





91. Install the speedometer driven gear.
- Install the O-ring.
- Push the speedometer driven gear assembly into the bore.





92. Install the Vehicle Speed Sensor (VSS) assembly bolt.





93. Replace the transmission filler tube grommet.





94. Install the transmission filler tube assembly.
1 Install the tube.
2 Install the transmission filler tube bolt.
- Install the fluid level indicator.





95. Install the Turbine Shaft Speed (TSS) sensor.
1 Use petroleum jelly on the O-ring and position the TSS sensor.
- Install a new O-ring.
2 Install the TSS sensor bolt.





96. Install the differential seals.





97. Install the torque converter fluid seal.
- Coat the torque converter seal garter spring with petroleum jelly.

NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, replace the torque converter seal.





98. Install the drain plug.





99. Install the pump drive shaft.

NOTE: Check for proper rotation of the pump drive shaft.





100. Install the Torque Converter Handles and install the torque converter.
101. Remove the transaxle from the Bench Mounted Holding Fixture.
102. Install the transaxle into the vehicle.