Steps 101-124
Transaxle
Disassembled Views
101. Using the straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.
102. Subtract measurement B from measurement A and add 1.6 mm (0.063 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.90 mm (0.035 in) and 2.24 mm (0.088 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack.
103. Install the rear sun gear and shell assembly.
104. Install the No. 3 rear sun gear thrust bearing.
105. Install the overdrive/direct clutch hub and turbine shaft assembly.
106. Install the No. 1 cover assembly thrust bearing.
107. Install the cover assembly gasket.
108. Route the Turbine Shaft Speed (TSS) sensor harness through the transaxle case to the valve body area and install the cover assembly.
109. Install the cover assembly bolts and tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
110. Install the Output Shaft Speed (OSS) sensor and the bolt.
- Tighten to 12 Nm (106 lb-in).
111. NOTICE: Be careful not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses under the valve body, or damage to the wiring harness or connectors may occur.
NOTE: Make sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts.
1. Manual pin.
2. Manual valve.
112. Install the main control valve body bolts. Tighten the bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
113. NOTICE: Make sure not to pinch the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS) or Transmission Range (TR) sensor wiring harnesses behind the solenoid body when positioning the solenoid body in place.
NOTE: Install the different length bolts in the locations noted during disassembly.
Install the solenoid body bolts hand tight.
1. 42 mm (1.65 in) bolt
2. 63 mm (2.48 in) bolts
3. 80 mm (3.14 in) bolts
4. 95 mm (3.74 in) bolts
114. Tighten the solenoid body bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
115. Route the OSS sensor wiring harness into the retainer.
116. Connect the TSS and OSS sensor electrical connectors.
117. Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
118. Inspect the transaxle main control cover seal for damage and install new if necessary.
119. NOTE: Install the studbolts in the locations noted during disassembly.
Install the transaxle main control cover and install the bolts.
1. Bolt location
2. Studbolt location
120. Tighten the main control cover bolts in the sequence shown.
- Tighten to 12 Nm (106 lb-in).
121. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.
122. NOTICE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the nut.
- Tighten to 18 Nm (159 lb-in).
123. NOTICE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) in the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur, causing torque converter failure.
Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transaxle.
124. Remove the bolts from the torque converter.
