Assemble
TRANSAXLE ASSEMBLY1. 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 cut-outs and are properly installed.
6. Soak new brakes and clutches in a suitable lubricant for at least 2 hours, prior to installation.
7. necessary to replace bushings, also replace the subassembly.
8. Check thrust bearings and races for wear and damage and replace as necessary.
9. Using service tool 09351-32090, install bearing to transaxle housing.
10. Install oil strainer and oil tube apply cover.
11. Using a plastic hammer, install oil tubes.
12. Install oil tube clamps.
13. Using suitable press, install bearing to transmission case.
14. Install B4 accumulator piston and spring.
15. Install oil gallery cover and gasket, then tighten six attaching bolts.
16. Install oil seal rings to transmission case.
17. Slide in manual shaft and install washer, spacer and manual lever, then install retaining spring.
18. Insert pin into shaft.
19. Stake spacer.
20. Install cam guide bracket, then insert parking lock rod into bracket
21. Place stopper plate on protruding portion of lock sleeve.
22. Install guide sleeve and spring.
23. Install parking lock pawl, pawl shaft and shaft clamp.
24. Install new 0-rings on brake piston and apply ATF. Place piston into case with cup side up, being careful not to damage O-rings.
25. Install brake piston return spring.
26. Install plates and discs as follows: Plate-disc-plate-disc-plate-disc. Install flange facing flat end upward.
27. Using tool No. 09350-32013, compress return spring with press and install snap ring.
28. Install underdrive one-way clutch.
29. Install anti-rattle clip in space between one-way clutch outer race and case.
30. Align flukes of discs in underdrive brake. Install clutch assembly. Assembly should turn freely counterclockwise and should lock clockwise.
31. Check height of clutch assembly by measuring height from sleeve, to inner race, using calipers.
32. Install race with bearing.
33. Install snap ring to sun gear with suitable tool.
34. Install sun gear to case.
35. Align flukes of discs in underdrive clutch and install countershaft assembly.
36. Using caliper, measure distance between tip of countershaft and bolt seat of clutch support Distance should be 1.598-1.594 inch.
37. Install thrust needle bearing.
38. Using suitable press, install counter driven gear.
39. Using tool No. 09351-32031, hold driven gear and tighten new locknut Torque to 116 ft. lbs.
40. Using a dial indicator, measure end-play of countershaft. Endplay should be 0.0091 - 0.0350 inch.
41. Stake locknut.
42. Install snap ring to transmission case.
43. Install intermediate shaft.
44. Apply seal and install transaxle rear cover and thirteen bolts. Torque bolts to 22 ft. lbs.
45. Install thrust washer and governor driven gear.
46. Install new oil seals.
47. Ensure intermediate shaft turns smoothly.
48. Install first and reverse brake in case, by first installing inner flange, facing flat end toward you.
49. Install Plates and discs as follows: Disc-plate-disc-plate-disc-plate-disc. Install outer flange, facing flat end toward inner side.
50. Install snap ring, ensuring end gap is not aligned with an cut-outs.
51. Check operation of first and reverse brake by applying compressed air into the oil passages and checking piston movement.
52. Coat thrust washer with petroleum jelly and install it onto planetary carrier.
53. Coat races and bearings with petroleum jelly and install them onto ring gear.
54. Align flukes of discs and install rear planet ring gear into case.
55. Align spline of planetary carrier with flukes of discs and install planetary gear into first and reverse brake discs.
56. Place No.2 one-way clutch into case, facing shiny side upward. Install one-way clutch onto inner race while turning planetary gear clockwise.
57. Coat thrust washer with petroleum jelly and install onto planetary gear.
58. Turn planetary carrier. Carrier should turn freely clockwise and lock counterclockwise. Install snap ring.
59. Install second coast brake band guide so its tip touches the case.
60. Install second brake into case by first installing flange, facing flat end upward. Install discs an plates as follows: Disc-plate-disc-plate-disc-plate.
61. Install piston return spring assembly.
62. Align groove of second brake drum wit bolt and place it into case.
63. Install snap ring in groove. Ensure end gap is not aligned with any cut-outs.
64. Check operation of second brake by applying compressed air into oil passage of case. Ensure piston movement.
65. Install new drum gasket until it makes contact with 2nd brake drum.
66. Align flukes of discs in 2nd brake, and align spline of hub with flukes of discs and install hub to the 2nd brake discs.
67. Check distance between surface of 2nd brake hub and rear planetary gear. Distance should be 0.20 inch.
68. While turning sun gear clockwise, install it into one-way clutch.
69. Coat race and bearing with petroleum jelly and install them onto planetary gear.
70. Install front planetary gear.
71. Coat races and bearing with petroleum jelly and install them onto planetary gear.
72. Install front planetary ring gear.
73. Coat race with petroleum jelly and install it onto tip of ring gear flange. Coat race and bearing and install them.
74. Place second coast brake band into case and install pin through oil pump mounting bolt hole.
75. Coat race and bearing with petroleum jelly, and install them onto forward clutch drum. Coat clutch drum thrust washer with petroleum jelly and install it with oil groove facing upward onto direct clutch drum.
76. Align flukes of discs in direct clutch. Mesh hub-with flukes of direct clutch while turning clutch drum or forward clutch.
77. If flukes of discs are meshed with hub correctly, end of bushing with direct clutch drum will be flush with surface of forward clutch.
78. Place direct clutch and forward clutch into case. Rotate forward clutch to mesh the front planetary ring gear and discs.
79. Measure distance between "A" and "B," see image.
80. Install differential.
81. Apply sealant and install transaxle housing. Torque eighteen bolts to 22 ft lbs.
82. Check preload of differential side bearing by rotating differential in both directions to snug bearing down. Using service tool 09564-32011 and torque meter, measure preload. Preload of new bearing should be 6.9-12.2 inch lbs. For reused bearing it should be 3.5-6.1 inch lbs.
83. Apply a suitable lubricant to O-ring and install around oil pump body.
84. Place oil pump through input shaft, and align bolt holes of pump body with transmission case.
85. Hold input shaft, and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum.
86. Insert six attaching bolts and torque to 18 ft lbs.
87. Measure thrust play of input shaft in axial direction. Thrust play should be 0.008-0.035 inch.
88. Ensure input shaft rotates smoothly.
89. Install outer spring with second coast brake piston.
90. Place cover into bore, press down and install snap ring.
91. Check second coast brake piston stroke by applying and releasing compressed air. Piston stroke should be 0.059-0.118 inch.
92. Coat new O-rings with ATF and install on accumulator pistons. Install new piston and springs.
93. Install new gasket and accumulator cover and torque to 7 ft lbs.
94. Install second brake apply gasket.
95. Install throttle cable in case, being careful not to damage O-ring.
96. Install solenoid wire in case.
97. While holding cam down with your hand, slip cable end into slot. Connect connecting rod to manual valve lever and lower valve body into place.
98. Install twelve bolts in valve body and torque to 7 ft lbs.
99. Connect solenoid connector.
100. Install detent spring and torque to 7 ft lbs.
101. Install oil tubes with plastic hammer. Install oil tube clamp.
102. Install oil strainer and torque bolts to 7ft lbs.
103. Install oil tube bracket
104. Install magnets in pan. Ensure magnets do not interfere with oil tubes.
105. Install oil pan with new gasket and torque bolts to 43 inch lbs.
106. Install new gasket with governor adapter. Install governor body with thrust washer. Install cover over O-ring. Install cover brackets with two bolts.
107. Install rotor adapter, rotor, cover and speed sensor.
108. Install throttle cable retaining plate.
109. Install solenoid wire retaining plate.
110. Install neutral start switch an torque nut to 61 inch lbs.
111.Adjust neutral start switch.
112. Install manual shift lever.
113. Install oil cooler pipes and torque to 25 ft lbs.