Service Part Two

- Install transfer bearing retainer onto the low clutch.

- Install all of the bearing retainer screws and tighten to 12 Nm (105 in.lbs.).

- Install the selectable shim.

Note:
The selectable shim will determine turning torque.





- Install the transfer gear onto the transfer shaft (1) and Holder Part No. 9739 onto the transfer gear (2).





Note:
Care must be taken not to overtighten the vise as damage to the underdrive compounder low clutch may result.

- Install transfer gear nut (1).





- Clamp Holder 9739 into vise as shown.

- Tighten transfer gear (2) nut to 271 Nm (200 ft.lbs.).

- Remove holder 9739 from transfer gear.

- Carefully clamp the underdrive compounder low clutch into a soft jaw vise.





- Rotate the transfer gear (2) four complete revolutions clockwise, and then four complete revolution counter-clockwise to seat the new bearings.

- Check turning torque using an inch pound beam style torque wrench (1). Initial break away torque should be disregarded. Turning torque should be between 4.0 and 12.0 in. lbs. (drag). If more than 12.0 in. lbs. (drag), choose a larger shim and recheck turning torque. If less than 4.0 in.lbs. (drag), choose a smaller shim and recheck turning torque.





- Install Holder 9739 (1) onto transfer gear and clamp the holder into a vise.

- Remove transfer gear nut and gear.

- Install the Bearing Retainer Assembly Adaptor 9908 onto the low clutch.

- Clamp adapter into a vise to support the underdrive compounder during assembly process.





- Install overrunning clutch (1) into low clutch (2).





- Install thrust bearing (1) onto transfer shaft.





- Install the direct clutch (1) onto the low clutch (2).





- Install split bearing (2) and lock into place.





- Install sun gear onto the shaft.

- Install the new sun gear retaining clip (1) Part No. 7BO323433AE onto the transfer/underdrive shaft.





- If necessary, install the helical shim (1).

Note:

- If the helical shim is not on the sun gear, then it still may be located in the planetary gear set. It will not be necessary to remove the helical shim from the planetary gear set/output hub.





- Install the planetary gear (1) set/output hub onto the direct clutch (2).





- Install the underdrive compounder (1) assembly into the transaxle case.

- Remove Adaptor 9908 from compounder bearing retainer.

- Install all the bolts at the compounder bearing retainer and tighten to 12 Nm (105 in. lbs.)





- Install underdrive compounder snap ring at top of the compounder bearing retainer





- Make sure select fit shim (2) is located on the transfer shaft (1) prior to installing the transfer gear.





- Install transfer gear (3) onto transfer shaft.

- Install Holder (2) 9739 onto the transfer gear (underdriver compounder side).

- Install new transfer gear (underdrive compounder side) nut Part No. WHT004510 and tighten to 271 Nm (200 ft. lbs.).

- Use stake tool 9721 and stake new nut.





- Clean the transfer gear cover sealing surface and mating surface.

- Install the oil scavenger (2).





- Spread a bead of sealant Part No. D 17632110 onto the transfer gear cover sealing surface.

- Install transfer gear cover (1) to case bolts (2) and tighten to 12 Nm (105 in.lbs.).





- Install the underdrive compounder oil transfer tubes (1) into the underdrive compounder.





- Position the valve body near the underdrive compounder oil transfer tubes and slide the valve body manual valve pin (1) into the slot in the rooster comb.





- Slide the valve body onto the underdrive compounder transfer tubes (2).





- Install the twenty one valve body to case bolts and tighten to 6 Nm (50 in.lbs.).

Note:
Valve body to case bolt torque is critical during valve body installation. Failure to torque bolts could result in improper operation.





- Install the detent arm (1) onto the pin at the valve body.

- Install the screw (3) at the detent arm and tighten to 6 Nm (50 in. lbs.).





- Install the electrical connector at the valve body.

- Install new transmission filter and nuts, tighten to 5 Nm (40 in. lbs.).

- Clean the oil pan and magnet.





- Spread a bead of Sealant Part No. D 17632110 onto the oil pan sealing surface.

- Install oil pan and tighten oil pan bolts to 6 Nm (50 in.lbs.).

- Spread a bead of Sealant Part No. D 17632110 onto the valve body oil pan sealing surface.

- Install the valve body oil pan and tighten bolts to 12 Nm (105 in. lbs.).

Note:
Install the three oil pan studs in the locations recorded in removal procedure.

- If equipped, install the ground cable and tighten bolt.
- If equipped, install the ground cable clip at the valve body pan.
- Install the disc brake caliper and adaptor bracket assemble over the rotor and knuckle.
- Install the mounting bolts securing the caliper adapter bracket to the knuckle and tighten bolts to 169 Nm (125 ft.lbs.).

- Place wheel and tire into position on hub and lightly snug all five wheel mounting nuts. DO NOT tighten wheel at this time.

- Lower vehicle.
- Progressively tighten all wheel mounting nuts in the proper sequence. Tighten nuts to a final torque of 135 Nm (100 ft.lbs.)
- If applicable, install wheel center cap.
- Install the wire harness retaining clip onto the valve body oil pan.
- Install the three valve body sound deadener retaining clips Part No. WHT004266.
- Reposition the engine coolant heater tube and secure the tube with the hold down bolt located on the left side of the engine, and the hold down clamp bolt attached to the front of the engine.
- Attach the solenoid pack connector at the valve body oil pan and secure it with the connector lock.
- Install the shift cable onto the manual lever.
- Reconnect the oil cooler lines onto the transaxle.
- 3.8L vehicles, install the exhaust crossover pipe.
- Reconnect radiator over flow hose onto the radiator fill neck and install the recovery bottle.
- Install Battery.
- Top off transmission fluid with Part No. ATF Part No. GUS 00016210 (VW ATF+4).