Steps 51-104

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

Using the special tool, install the filter recirculating regulator exhaust seal.





52. Install the chain pan in the transaxle case.





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

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.





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





55. Install the No. 13 driven sprocket thrust bearing.





56. Install the final drive carrier and differential assembly.





57. NOTE: Plastic washers should be placed between bolt heads and special tool.

Install the special tools.
1 Install the special tool.
2 Install the special tool and bolts.





58. Using the special tools, measure the distance from the top of special tool 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 special tool 307-300 with long Spacers 177.8 mm as the second dimension.
60. Subtract the first dimension from the second dimension.
^ This is the third dimension.





61. Use the third dimension to select the correct No. 14 differential bearing shim from the differential bearing shim chart in specifications.





62. Install the differential bearing assembly.
1 Install the speedometer drive gear with the tabs down.
2 Install the No. 14 differential bearing shim (selective fit).
3 Install the No. 15 differential bearing.





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

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





64. NOTE: Tighten the bolts in the indicated sequence.

Install the torque converter housing to transaxle case bolts.





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

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.





66. Install the special tool.





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

Assemble the special tool.
1 Install struts.
2 Install bar.
3 Install bolts.
4 Install the center bolt





68. Using the special tool 300-D026 measure the distance to the bar of special tool 307-S296.
^ Record the first dimension.





69. Back off the center bolt of special tool 307-S296 until the piston movement stops.





70. Using the special tool 300-D026, measure the dimension to the bar of special tool 307-S296 (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. Refer to Specifications.





71. 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 N621943-52 (using permanent thread sealer) onto the forcing bolt of the servo cover.

Assemble the special tool.





72. Install the special tool.





73. 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.

Tighten the special tool bolt.
^ Install the servo cover retaining ring





74. Loosen the special tool bolt.
^ When spring tension is released remove the special tool.





75. 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 special tool is correctly seated.

Using the special tool, 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.





76. 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.





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





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

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





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

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.





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

Install the main control valve body mounting bolts.





81. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.





82. Move the manual control lever shaft to the "D" position.
^ Install pin to hold special tool in place.





83. Move the manual valve detent lever assembly to the "D" position.





84. Tighten the nut on the ball.
^ Remove the shifter pin from the special tool.





85. Rotate special tool 307-S290 (T94P-77000-H) until socket can be fitted.
^ Tighten the detent nut.
^ Rotate back to "D" position to recheck the adjustment.





86. Using the special tool, recheck the manual control lever assembly setting.





87. Install end 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





88. Position the transmission range (TR) sensor.





89. Using the special tool, align the TR sensor.
1 Align the TR sensor.
2 Install the TR sensor bolts.
90. Install the main control cover gasket.





91. NOTE: Tighten the bolts in the indicated sequence.

Install the main control cover.
^ Install the vent tube.





92. Install the speedometer driven gear.
^ Install the O-ring seal.
^ Push the speedometer driven gear assembly into the bore.





93. Install the vehicle speed sensor(VSS) assembly bolt.





94. Replace the transmission filler tube grommet.





95. Install the transmission filler tube assembly.
1 Install the tube.
2 Install the transmission filler tube bolt.
^ Install the fluid level indicator.





96. Install the turbine shaft speed (TSS) sensor.
1 Use petroleum jelly on the O-ring seal and position the TSS sensor.
^ Install a new O-ring seal.
2 Install the TSS sensor bolt.





97. Using the special tool install the differential seals.





98. NOTE: Make sure the torque converter seal garter spring does not become dislodged during fitting. If the garter spring does become dislodged, install a new torque converter seal.

Using the special tool, install the torque converter fluid seal.
^ Coat the torque converter seal garter spring with petroleum jelly.





99. Install the drain plug.





100. Install the output shaft speed (OSS) sensor.





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

Install the pump drive shaft.





102. Using the special tool, install the torque converter.





103. Remove the transaxle from the special tool.
104. Install the transaxle into the vehicle.