Part II
Transmission
- Remove the low/reverse clutch piston retainer gasket (2).
- Using a hammer and suitable drift (2), drive out the inner output bearing cup (1).
- Using remover (6062A) (1), remove the outer output bearing cup (2).
- Remove the underdrive compounder assembly (2) snap ring (1).
- Using a Torx driver (2), remove the four compounder bearing retainer bolts (1).
- Install puller adapter (9908) (2) to the compounder bearing retainer.
- Install oil pump puller (C-3752) (1) to puller adapter (9908) (2) and pull the underdrive compounder assembly from the case.
• Insure that the planetary gear set/output hub is removed as part of the underdrive compounder assembly.
- Using puller adapter (9908) (2), remove the underdrive compounder assembly (2).
- Remove the remote pinion cover bolts (1).
- Remove the remote pinion (1) and the remote pinion cover (2) from the case.
- Remove the remote pinion cover (1) from the remote pinion (2).
- Using remover (8913) (2) and kukko support (8915) (1) remove the remote pinion cover bearing cup (3) and selective shim.
- Using remover (8912) (1) and kukko support (8915) (2) remove the remote pinion small bearing cup (3) from the case.
- Remove the differential output bearing cover bolts (1).
- Remove differential output bearing cover (2).
- Remove the differential cover bolts (1).
- Remove the differential cover (1).
- Remove the outer seal (2), oil slinger (3) and the small bearing cup (4).
- Remove the large bearing cup.
- Remove the differential.
- Remove the manual lever and TRS. Refer to => [ Transmission Range Sensor ] Service and Repair.
- Using a screwdriver (1), remove the set screw for the park pawl shaft.
- Remove the snap ring (1) for the park guide assembly (2).
- Remove the park guide assembly (1).
- Remove the plug (1) in order to allow the park pawl shaft to be removed.
- Slide the shaft (1) out of the park pawl (3).
- Remove the park pawl shaft (1).
- Remove the park pawl (1) and the park pawl spring (2).
Assembly
The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
• If the transaxle is being overhauled, clutch and/or seal replacement, the PCM/TCM quick learn procedure must be performed. Refer to => Non-DTC Based Diagnostics 00 Engine Mechanical, Fuel Injection and Ignition.
- Install both output bearing cups (2) using installer (5050A) (1).
• Ensure that the gasket and case holes (1) align.
- Install the low/reverse clutch piston retainer gasket (2).
- Install the low/reverse clutch piston retainer (1).
- Using a Torx driver (2), install the low/reverse clutch piston retainer screws (3) and tighten the screws to 5 Nm (44 in lbs).
• The low/reverse clutch piston has bonded seals (2 and 3) which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
- Install the low/reverse clutch piston (1).
- Install the low/reverse piston return spring (1).
- Assemble the disc (6057) (1), compressor (5059A) (2) and compressor bar (5058-3) (3).
- Using the assembled disc (6057) (3), compressor (5059A) (4) and compressor bar (5058-3) (5) compress the low/reverse spring (1).
• The snap ring (1) opening must be between the spring levers.
- Using snap ring pliers (2), install the low/reverse spring piston snap ring (1).
- Using and arbor press (1) and installer (6053) (1), press the new rear carrier bearing cone (3) onto the rear carrier assembly (4).
- Install the rear carrier assembly (1) to the transaxle case.
- Using an arbor press (1) and driver handle (C-4171) press the output gear bearing cone onto the output gear (4).
OUTPUT GEAR BEARING ADJUSTMENT
- With the output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, use grease to hold the shim in place.
- Install the output gear (4), bearing assembly and bolt. Tighten the bolt to 271 Nm (200 ft lbs).
- Measure the bearing end play. Attach gear checking plate (L-4432) (1) to the gear using bolts (6260).
- Push and pull the gear while it rotating back and forth to ensure seating of bearing rollers.
- Using a dial indicator (2) mounted to the transaxle case, measure the output gear end play.
- Refer to => [ Output Gear Bearing Shim Part Numbers ] Output Gear Bearing Shim Part Numbers, for the required shim to obtain the proper bearing setting.
- Remove the output gear bolt and washer. To remove the output gear, use puller (L-4407A).
- Remove the gauging shim and install the proper shim determined by the chart. Refer to => [ Output Gear Bearing Shim Part Numbers ] Output Gear Bearing Shim Part Numbers. Use grease to hold the shim in place.
- Install the output transfer gear (3) and bearing assembly.
- Install a new output transfer gear bolt and washer.
- Install holder (9739) (1) onto the output transfer gear (2).
- Tighten the output transfer gear bolt to 271 Nm (200 ft lbs).
- Using an inch pound torque wrench, test the output shaft turning torque. Output shaft turning torque should be within 3 to 8 in lbs If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3 to 8 in lbs is obtained.
- Install the low/reverse clutch pack (1 - clutch plates, five each) and (2 - clutch discs, five each). Leave the uppermost disc out the until snap ring is installed.
- Using a screwdriver (1), install the low/reverse reaction plate flat snap ring (2), insure you do not scratch clutch plate (3).
- Install the remaining (uppermost) low/reverse clutch disc (1).
- Install the low/reverse reaction plate (1).
- Ensure that the plate is installed with the bevel / lug side up.
- Use this graphic as a reference while installing the tapered snap rings.
- Install the tapered snap ring (2) with tapered side up. Use a screwdriver (1) in ensure the snap ring is properly installed.
- Set up the dial indicator (1) with dial indicator rod (6268) to measure the low/reverse clutch clearance. Press down on the clutch pack with your finger tips and zero the dial indicator. The low/reverse clutch pack clearance is 0.89 to 1.47 mm (0.035 to 0.058 in). Using the dial indicator measure in four places and record the measurements. Take the average of the readings and select the proper low/reverse reaction plate as determined by the chart. Refer to => [ Low/Reverse Reaction Plate Shim Part Numbers ] Low/Reverse Reaction Plate Shim Part Numbers, in order to achieve the correct specification.
- Install the 2/4 clutch pack (1 - clutch plates, four each) and (2 - clutch discs, four each).
• The 2/4 clutch piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
- Orient (1) and install the 2/4 clutch return spring (2) onto the clutch retainer (3).
- Install the 2/4 clutch retainer (1) to the transaxle.
- Using compressing tool (5058A) (1), compress the 2/4 clutch return spring just enough to install the snap ring (3).
- Install the snap ring (3).
- Set up the dial indicator (1) with dial indicator rod (6268) (3) and measure the 2/4 clutch clearance. Press down on clutch pack with your finger tips and zero the dial indicator. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 in.). Measure the clutch pack in four places and record the measurements. Take the average of the four readings. If the clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.
• The number seven needle (1) bearing has three anti-reverse tabs and is common with the number five needle bearing. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum grease can be used in order to hold the bearing to the rear sun gear (2).
- Install the number seven needle bearing (1) to the rear sun gear (2).
- Install the rear sun gear (2) and the number seven needle bearing (1) to the transaxle.
- Install the front carrier/rear annulus assembly (2) and the number six needle bearing (1).
- Install the front sun gear assembly (1) and the number four thrust washer (2).
- Select the thinnest number four thrust plate (2) and install onto the input clutch assembly (1). Use petrolatum grease to retain (3).
- Install the input clutch assembly into position and verify that it is completely seated by viewing through the input speed sensor hole (3). If view through input speed sensor hole is not as shown, the input clutch assembly (2) is not seated properly.
- Remove the oil pump O-ring (2). Be sure to reinstall the oil pump O-ring after selecting the proper number four thrust plate.
- Install the oil pump and gasket to the transaxle. Install and tighten the bolts.
- Set up the input shaft for measurement with the dial indicator (3) and end play set (8266A) (1 and 2).
- Measure the input shaft end play with the transaxle in the vertical position. The input shaft end play must be within 0.13 to 0.64 mm (0.005 to 0.025 in). For example, if the end play reading is 0.055 in, use a number four thrust plate which is 0.071 to 0.074 inches thick. This should provide an input shaft end play reading of 0.020 inches which is within specifications.
- Refer to => [ Number 4 Thrust Plate Shim Part Numbers ] Number 4 Thrust Plate Shim Part Numbers, in order to select the proper number four thrust plate.
- Install the input clutch assembly (1).
• The caged needle bearing is installed with the tanged side out (2).
- Install the number one caged needle bearing (1).
