Assemble

1. All parts and components should be cleaned in a suitable solvent, then dried with clean compressed air to ensure oil passages are not clogged.
2. Arrange parts in proper order to facilitate assembly.
3. Apply a suitable lubricant to all seal rings, clutch discs, clutch plates rotating parts and sliding surfaces prior to assembly.
4. Replace all gaskets and rubber O-rings.
5. Ensure ends of snap rings are not aligned with cutouts and are properly installed.
6. Soak new brakes and clutches in a suitable lubricant for at least 2 hours, prior to installation.
7. If necessary to replace bushings, also replace the subassembly.
8. Check thrust bearings and races for wear and damage and replace as necessary.
9. Place parking pawl into case, then hook spring ends to case and pawl. Insert pin into hole of case through spring and pawl.
10. Install parking lock rod, then the parking lock pawl bracket.
11. Ensure proper operation of parking lock pawl by checking that counter driven gear is locked when manual valve lever is in "P" range.
12. Install intermediate shaft.
13. Install transaxle rear cover with new gasket, then insert retaining bolts and torque to 18 ft lbs.
14. Check intermediate shaft end play. If play is not within specifications, check for proper installation of intermediate shaft ensure intermediate shaft rotates smoothly.
15. Install first and reverse brake into case. Install inner flange with flat end facing toward oil pump side.
16. Install discs and plates as follows: Disc-plate-disc-plate-plate-disc-plate-disc.
17. Install outer flange with flat end facing toward piston, then the snap ring with end gap in groove.
18. Check clearance of first and reverse brake as previously described. If clearance exceeds specifications, replace discs. If clearance is less than specified, components may be improperly installed and should be reassembled.
19. Check for proper operation of first and reverse brake piston by applying compressed air to oil passage and ensuring piston moves.
20. Apply petroleum jelly to No. 2 Planetary carrier thrust washer, then install onto planetary carrier. Ensure different lug shapes match openings in carrier, see first image.
21. Apply petroleum jelly to ring gear races, then assemble to ring gear. Install ring gear into case.
22. Align splines of planetary carrier with flukes on discs, then insert planetary gear into first and reverse brake discs.
23. Install No. 2 one-way clutch into case inner race, shiny side up, while turning planetary gear clockwise. Apply petroleum jelly to thrust washer, then install it into planetary gear.
24. Check for proper operation of planetary gear by ensuring it rotates freely clockwise but locks when rotated counterclockwise.
25. Install planetary gear snap ring, inserting end gap into groove.
26. Install second coast brake band guide, ensuring tip contacts case.
27. Install second brake into case, then the flange, ensuring flat end is facing outward.
28. Install discs and plates as follows: Disc, plate, plate, disc, plate, plate.
29. Install piston return spring assembly, ensuring each spring is inserted over protrusion in case.
30. Align groove of second brake drum with bolt, then insert drum into case.
31. Compress piston return spring assembly over drum using mallet handles, then install snap ring, ensuring end gap is inserted in groove.
32. Check clearance of second brake as previously described. If clearance exceeds specifications, replace discs. If clearance is less than specified, parts may be improperly installed and should be reassembled.
33. Check for proper operation of second brake by applying compressed air to case oil passage and ensuring piston moves.
34. Install new second brake drum gasket until clearance between surface of case and top of gasket is 1.14 +\- .0020 inch. Tap in drum gasket until it contacts 2nd brake drum.
35. Install No. 1 one-way clutch and second brake hub as follows:

a. Align flukes on discs in second brake.
b. Align spline of hub with flukes of discs, then install hub onto 2nd brake discs.

36. Install sun gear and sun gear input drum by turning sun gear clockwise, and inserting it into one-way clutch.
37. Apply petroleum jelly to races and bearing, then install front planetary gear and ring onto ring gear. Apply petroleum jelly to race and bearing, then assemble them to planetary gear.
38. Install planetary gear into case, then the race and bearing. Install intermediate shaft oil seal ring, then the ring gear. If the planetary gear and other components are correctly installed, the end of bushing with ring gear flange will be flush with intermediate shaft shoulder.
39. Apply petroleum jelly to race, then install it onto tip of ring gear flange.
40. Install second coast brake band by inserting pin through oil pump mounting bolt hole.
41. Install forward clutch into case, then apply petroleum jelly to races and bearings and assemble them to both sides of clutch drum.
42. Align flukes on disc in forward clutch. Retain sun gear input drum, then rotate input shaft to mesh hub with clutch discs on forward clutch.
43. Align center of input shaft and intermediate shaft, then while pushing on input shaft, rotate it to mesh hub and disc. If flukes of discs are properly meshed with hub, protrusion of input shaft drum will be deeper than tip of sun gear input drum.
44. Install direct clutch into case. Apply petroleum jelly to clutch drum thrust washer, then install it, oil groove facing upward toward drum. Align flukes of discs in direct clutch.
45. Retain input shaft, then insert direct clutch drum through 2nd coast brake band. Mesh hub with flukes of direct clutch, while turning clutch drum. If flukes of discs are properly meshed with hub, end of bushing with direct clutch drum will be flush with thrust bearing on forward clutch.
46. Install oil pump into case. Apply petroleum jelly to race, then install it onto stator shaft.
47. Apply petroleum jelly to oil pump race, then install new O-ring around oil pump body.
48. Position oil pump on input shaft so pump body bolt holes are aligned with transaxle case holes.
49. Retain input shaft, then carefully press oil pump body into case, so stator shaft oil seal rings slide through direct clutch drum. Excessive force on oil pump body will cause stator shaft oil seal rings to stick in direct clutch drum.
50. Install seven oil pump retaining bolts, then torque to 16 ft lbs.
51. Measure input shaft thrust play. Thrust play should be .012-035 inch. If thrust play is excessive, select one of two available races to bring thrust play within specifications. Races are available in thicknesses of .031 inch and .055 inch. Ensure input shaft rotates freely.
52. Install second brake coast piston, without outer spring, into bore, then install snap ring.
53. Install tool No. J-35679, then observe move on tool plunger. Firmly push button on tool. This will push brake apply rod into case. If groove is visible, piston stroke is within specifications (.059-.118 inch). If stroke is more than specified, replace piston rod with longer one. Pistons are available in lengths of 2.870 and 2.811 inch. If stroke is still more than specified, replace brake band.
54. Install second coast brake piston as follows:

a. Remove installed parts from bore.
b. Install outer spring with piston.
c. Place cover into bore.
d. Install snap ring, using tool No. J35549, while pressing cover.

55. Check operation of second coast brake by applying compressed air to hole in case and ensure piston rod moves.
56. Install accumulator pistons and springs as follows:

a. Install springs and pistons into bore.
b. Install cover with new gasket, then insert attaching bolts of proper length as indicated in second image. Securely tighten bolts.

57. Install governor apply gasket, then the overnor oil strainer.
58. Push throttle cable through case, using care not to damage C-ring, then ensure proper seating.
59. Install valve body as follows:

a. Hold down cam, then slip cable end into slot.
b. Lower valve body into place.
c. Install 14 valve body attaching bolts as previously described, then torque to 7 ft lbs.

60. Place manual valve and body on transaxle as previously described, then torque to 7 ft lbs.
61. Install detent spring as previously de scribed, then torque to 7 ft lbs.
62. Install oil tubes, using care not to bend or damage.
63. Install tube bracket, then torque attaching bolt to 7 ft lbs.
64. Install oil strainer, then torque attaching bolts to 7 ft lbs.
65. Install oil pan with new gasket, then torque attaching bolts to 43 inch lbs.
66. Install governor body adapter, then the governor body with plate washer.
67. Install thrust washer on governor body, then the O-ring and cover.
68. Install governor cover bracket, then insert and securely tighten two attaching bolts.
69. Install neutral start switch seal gasket, lip facing inward, then the nut lock washer and nut. Torque nut to 61 inch lbs., then stake to lock washer.
70. Install manual shift lever.
71. Adjust neutral start switch as follows:

a. Connect a suitable ohmmeter between terminals.
b. Shift lever into "N" position.
c. Adjust switch to where there is continuity between terminals.
d. Retain switch with two bolts, then torque to 48 inch lbs.

72. Install two oil cooler pipes as follows:

a. Install bracket onto case.
b. Clamp two pipes to union, then to bracket.
c. Torque union nuts to 25 ft. lbs.