Step 49-96

Caution: Original retaining nut must not be roused. Always use a new retaining nut when reassembling.





49. Install Dial Indicator with Fixture L-4432 and Special Bolts 6260.
50. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
51. Measure transfer shaft gear end play.
52. 0nce bearing end play has been determined, refer to the Transfer Bearing Shim Chart for the required shim.
53. End play should be between 0.05 to 0.10 mm (0.0020 to 0.0039 inch).
If end play is too high, install a 0.04 mm (0.0016 inch. thinner shim.
If end play is too low, install a 0.04 mm (0.0016 inch. thicker shim combination.
Repeat until 0.05 to 0.10 mm (0.0020 to 0.0039 inch. end play is obtained.

Part 1 Of 2:

Part 2 Of 2:

TRANSFER GEAR BEARING SHIM CHART





54. Install transfer shaft gear and proper shim.





55. Install transfer shaft gear, using Gear Installer 6261 and two wrenches as shown.





56. Install transfer shaft gear nut and lock washer.





57. Tighten transfer shaft gear nut to 271 Nm (200 ft. lbs.. while holding transfer shaft gear with Holder 6259.

Caution: Always use new retaining nut. Never reuse old retaining nut.





58. Install rear cover.

Note: Apply a 1/8 inch wide bead of Loctite 18718 or equivalent as shown.





59. Install rear cover bolts.





60. Install low/reverse clutch pack.





61. Using a screwdriver, install new/low/reverse reaction plate flat snap ring.





62. Check clutch clearance. Set up Dial Indicator using Dial Indicator Tip 6268 as shown. Press down on the clutch pack with finger and zero dial indicator. Raise one clutch disc with a hook tool. Read the dial indicator.
63. Select the proper low/reverse reaction plate to achieve specification:
Low/reverse clutch pack clearance is 1.04 to 1.65 mm (0.0409 to 0.0650 inch).





64. Install last disc from low/reverse clutch.





65. Install low/reverse reaction plate with its flat side facing up.





66. Install new tapered snap ring with a screwdriver as shown with its tapered side facing up.





Note:
- Do not reuse the old snap ring.
- When installing a new snap ring, position the snap ring ends as shown.
- Follow A - H sequence for best results.





67. Install 2/4 clutch pack.





68. Note correct position of clutch return spring in relation with clutch retainer.
Line up the piston spring cut-outs with the long tab and notch.





69. Install 2/4 clutch retainer.





70. Install Spring Compressor 5058. Using a screwdriver, install the 2/4 clutch retainer snag ring.





71. Check clutch clearance. Set up Dial Indicator set using Dial Indicator Tip 6268 as shown. Press down on the clutch pack with finger and zero dial indicator. Raise one clutch disc with a hook tool. Read the dial indicator.
72. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.0299 to 0.1039 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance.





73. Install rear sun gear and No. 7 needle bearing.





74. Install front carrier and rear annulus assembly, push in and twist.





75. Install front sun gear assembly.





76. To determine the proper thickness of the No. 4 thrust plate, select the thinnest No. 4 "test" thrust plate. Using petrolatum to hold thrust plate in position, install input clutches assembly. Be sure the input clutches assembly is completely seated.





Caution: If view through input speed sensor hole is not as shown above, the input clutches assembly is not seated properly.





77. Remove the oil pump O-ring. You can install and remove the oil pump and gasket very easily to select the proper No. 4 thrust plate.

Caution:
- Be sure to install Wring on oil pump after selecting the proper No. 4 thrust plate.
Temporarily secure oil pump with 2 oil pump bolts. Insert a small bolt into end of input shaft.
- Measure input shaft end play.
- If end play readings are not within specifications, the transaxle assembly will be damaged.





78. Input shaft end play must be 0.13 to 0.64 mm (0.0051 to 0.0252 inch.. Subtract end play specifications from end play readings. Add the result to "test" shim to select proper shim.
For example if end play reading is 1.40 mm (0.0551 inch), subtract end play specifications. 1.40 mm (0.0551 inch) - [0.13 mm (0.0051 inch) to 0.64 mm (0.0252 inch) ] = 1.27 mm to 0.76 mm (0.0500 inch to 0.0299 inch). Add "test" shim. 0.76 mm to 1.27 mm (0.0299 inch to 0.0500 inch) + 0.81 mm (0.0319 inch) = 1.75 mm to 2.08 mm (0.0618 inch to 0.0819 inch). Select shim closest to mid point or 1.69 mm to 1.91 mm (0.0665 inch to 0.0752 inch).





79. Install No. 4 thrust plate.





80. Install input clutches assembly.





81. Install No. 1 caged needle bearing with its tanged side facing out.





82. Install cooler bypass valve.

Caution: The cooler bypass valve must be replaced if a transaxle failure has occurred. Do not reuse or attempt to clean old valve. When installing bypass value, insert with O-ring end toward rear of case.





83. Install oil pump gasket.





84. Install oil pump.

Caution: Be sure oil pump O-ring is installed.





85. Install pump attaching bolts.





86. Install two return springs.





87. Install the snap ring holding the low/reverse accumulator plug (cover) in place.








88. Install return spring (overdrive) or two return spring (underdrive) and two seal rings from the overdrive and underdrive clutch accumulator pistons.





89. Install underdrive clutch accumulator and overdrive clutch accumulator with return springs and seal rings.





90. Position detent as shown.





91. Install valve body.





92. Using a screwdriver, push guide bracket away from park sprag rollers.





93. Install valve body attaching bolts (18).





94. Install oil filter.





95. Install oil pan.

NOTE: Apply a 1/8 inch wide bead of Loctite 18718 or equivalent.





96. Install oil pan bolts.

NOTE: Use Loctite 18718 or equivalent under bolt beads.