Steps 1-50

Special Tools:

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

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

2. Install a new roll pin using a drift.

3. Install cup plug to case using Pinion Bearing Replacer 211-161 (T9OC-3504-DH).

4. If bearing was removed, install new drive sprocket bearing using Stator & Driven Sprocket Bearing Replacer 307-164 (T86P-70043-B) and Driver Handle 205-153 (T80T-4000-W).

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

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

6. Install converter impeller hub seal using Front Pump Seal Replacer 307-186 (T87L-77337-AH) and a dead blow (lead-filled) hammer.

7. Install No. 19 differential carrier thrust bearing and race 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.

Final Drive Assembly:

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

10. Lower final drive assembly and rear planet support assembly into case as one unit.

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

12. 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 discard beveled retaining ring.

NOTE: Make sure beveled retaining ring seats properly in case groove with bevel down.

Install a new service part beveled retaining ring using Retaining Ring Pliers 307-343 (T95P-77001-AH)R. Carefully tap beveled retaining ring into place. Use care not to damage retaining ring, support or case.
13. Perform the end clearance check for the planetary support. If end clearance is not within specification, replace the selective fit beveled retaining ring to obtain proper clearance.

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

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.

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 205-D014 (D80L-630-3) or equivalent and End Play Tool 307-187 (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. NOTE: Gauge bar must set on rear planet support No.15 bearing surface.

Check for correct selective fit beveled retaining ring. Place Gauge Bar 307-300 (T94P-77000-Q) across case with round legs of gauge bar resting on chain cover gasket surface. Place Dial Indicator Extension Rod 307-320 (T94P-77001-MH) through hole in gauge bar.

19. Mount Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent as shown. Zero indicator. Tighten end play tool to 1.13-1.70 Nm (10-15 inch lbs.). Read and record dial indicator reading.

Beveled Retaining Ring Installation:

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

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

22. Check end clearance for selective fit of No. 16 thrust race. Mount Dial Indicator with Bracketry 100-002 (TOOL-4201-C,) or equivalent 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. NOTE: The beveled retaining ring and rear planet support must be removed to change No. 16 thrust race.

NO 16 Thrust Race (Washer) 7F451:

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 chart below and repeat the clearance check.
24. After completing clearance check for No. 16 thrust washer and clearance is within specification, remove end play tool and adapter.

25. 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.

Install low/intermediate one-way clutch assembly.

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

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

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

Install low/intermediate clutch retaining ring.

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.

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).

Selective Retaining Rings:

30. If the clearance is not within specification, select a retaining ring from the chart below. After installing the selective retaining ring, verify the clearance is correct.

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 307-251 (T92P-70023-A).

35. If not already completed, install Reverse Clutch/Planet Assembly Collets 307-314 (T94P-77001-FH) and Tube 308-025 (T75L-7025-C) over the front carrier hub. Slide Collet Sleeve 308-049 (T77F-7025-C) over tube onto collet to hold in place.

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

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

37. Make sure reverse clutch cylinder apply tube hole is aligned with case holes as shown. 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. CAUTION: Do not overtighten.

Place two 3/8 inch wasters between the Front Clutch Loading Tool 307171 (T86P-70389-A) handle and notched block Install Front Clutch Loading Tool Screw 307-316 (T94P-77001-HH) into Front Clutch Loading Tool 307-171 (T86P-70389-A). Install fool to forward/intermediate/direct clutch assembly.

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

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

41. Install overdrive band into case.

42. NOTE: Foot goes down against band.

Install overdrive retainer with crosshairs facing up.

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

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

Installing No. 9 Clutch Hub Needle Bearing:

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

Installing Gauge Tube:

45. Install Gauge Tube 307-320 (T94P-77001-MH) over output shaft until fully seated into No. 9 thrust bearing. (This is where the No. 8 thrust washer normally sits.)

Reading A:

46. Place Gauge Bar 307-300 (T94P-77000-Q) across transaxle case with round legs of gauge bar resting on chain cover gasket surface. Place Depth Micrometer 303-D075 (D92P-4201-A) or equivalent on gauge bar and measure down to gauge tube. Do this on both sides of output shaft (180 degrees apart). Add both readings, divide by two to obtain reading A.

47. NOTE: Reading A and Dimension C from this chart will be used in selection of No.5 thrust washer.

Use reading A to select the correct No. 8 thrust washer from the chart below.

Reading B:

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

49. NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on No. 8 thrust washer selection chart following the selected No. 8 thrust washer.

Subtract Reading A from Reading B. add difference between A and B to Dimension Record this as Reading D.

50. Use Reading D to select the correct No. 5 thrust washer from the chart below.