Part III
Transmission
The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
- Install the cooler bypass valve (1) with the O-ring end towards the rear of the case.
- Install the oil pump gasket (2).
- Install the oil pump (2).
- Install the oil pump bolts (1) and tighten the bolts to 30 Nm (22 ft lbs).
- Install the output gear stirrup (1) with the serrated side out.
- Install the retaining strap (1).
- Install the strap bolts (3) but do not tighten at this time.
- Rotate the stirrup (2) clockwise against the flats of the retaining bolt.
- Tighten the stirrup (2) strap bolts to 23 Nm (17 ft lbs).
- Bend the tabs (1) on the strap (2) up against the flats of the bolts.
- Install the differential (2), large bearing cup (4), outer seal (2), oil slinger and small bearing cup.
- Install the differential cover (1).
- Install the differential cover bolts (1) and tighten the bolts to 61 Nm (45 ft lbs).
- Install the differential output bearing cover (2).
- Install the differential output bearing cover bolts (1) and tighten the bolts to 12 Nm (106 in lbs).
• The remote pinion gear must NOT be installed while testing the turning torque.
- Using the turning torque tool (9735) (1) and an inch pound torque wrench (2) test the differential turning torque, there should be 10 to 22 in lbs of drag. If the turning torque is more than 22 in lbs of drag, decrease the shim size behind the end cover and retest. If the turning torque is less than 10 in lbs of drag, increase the shim size.
- After proper turning torque is achieved for the differential remove the differential from the case and set aside keeping the correct shim with the differential.
- Install the remote pinion bearing cup in the case (small cup) using installer (9730) and driver handle (C-4171).
- Install the remote pinion bearing cup in the cover using installer (9730) and driver handle (C-4171).
- Install the remote pinion (2) into the transaxle case.
- Install the remote pinion cover (2) into transaxle case.
- Install the remote pinion cover bolts (1) and tighten the bolts to 12 Nm (106 in lbs).
• The differential assembly must not be installed when testing for pinion drag torque.
- Test turning torque using differential bearing torque tool (C-4995A) (2) and an inch pound torque wrench (1). Turning torque for the remote pinion gear should be 2 to 8 in lbs of drag. If more than 8 in lbs of drag, decrease the shim size under the remote pinion bearing cover cup. If turning torque is less than 2 in lbs of drag, increase the shim size under the remote pinion bearing cover cup.
- Install puller adapter (9908) (2) onto the compounder bearing retainer to help in installation.
- Install the compounder bearing retainer into the transaxle case.
- Remove the puller adapter (9908) from the compounder bearing retainer.
- Using a Torx driver (2), install the compounder bearing retainer Torx bolts (1) tighten to the bolts 12 Nm (106 in lbs).
- Install the snap ring (1) for the compounder bearing retainer (2).
• Insure the end play tool (9951) is not binding in the support plate that is bolted to the case.
• Always use the original shim to determine end play.
- Remove the plug from the case (3).
- Install the compounder end play tool (9951) (2) through the hole in the front case.
- Install dial indicator (1) onto the end play tool (9951).
- Using moderate downward pressure on the end play tool (9951) , zero the dial indicator.
- Using moderate upward pressure on the end play tool (9951) take the reading from the dial indicator.
- Remove the end play tool (9951) and dial indicator.
- Adjust the shim thickness in the underdrive unit to 0.010 to 0.020 in.
- Install the correct (select) helical shim and assemble the underdrive compounder. Refer to => [ Underdrive Compounder ] Underdrive Compounder.
- Using thread adhesive install the plug back into the case and tighten the plug to 24 Nm (18 ft lbs).
- Using and arbor press ram (1) and driver handle (C-4171) , install the transfer gear (4) (underdrive compounder side) cone using installer (6756) (3).
- Install holder (9739) (1) onto the transfer gear (underdrive compounder side) (2).
- Install a new transfer gear (underdrive compounder side) nut and tighten the nut to 271 Nm (200 ft lbs).
- Use staking tool (9721) and stake the new nut.
- Install the differential (2) , bearing cups (4), shim and oil slinger into the case.
- Install a bead of RTV sealant.
- Install the differential cover (1).
- Install the differential cover bolts (1) and tighten the bolts to 61 Nm (45 ft lbs).
- Install a bead of RTV sealant.
- Install the differential output bearing cover (2).
- Install the differential output bearing cover bolts (1) and tighten the bolts to 12 Nm (106 in lbs).
- Install the differential oil seals into the case using seal installer (MD998334).
- Install the oil scavenger (2).
- Install the transfer gear cover (1), use a bead of RTV sealant.
- Install the transfer gear cover bolts (2) and tighten the bolts to 12 Nm (106 in lbs).
- Install the park pawl tube (1) into the case (2) making sure the guide pin aligns with hole in case.
- Install the snap ring (1) for the park pawl tube.
- Install the park pawl (1) and the park pawl spring (2).
- Install the park pawl shaft (1).
- Install the park pawl shaft and park pawl pipe plug (1), tighten the plug to 27 Nm (20 ft lbs).
- Using a screwdriver (1), install the set screw for the park pawl shaft and tighten to 1 Nm (8.8 in lbs).
