Part 2

ASSEMBLY

31. Install snap ring.










32. Set up dial indicator (1) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.). Set up indicator and record measurement in four places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.










NOTE: The number seven needle (1) bearing has three anti-reversal tabs and is common with the number five position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2).











33. Install rear sun gear (2) and number seven needle bearing (1).










34. Install front carrier/rear annulus assembly (2) and number six needle bearing (1).










35. Install front sun gear assembly (1) and number four thrust washer (2).










36. Select the thinnest number four thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to retain (3).





37. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (3). If view through input speed sensor hole is not as shown in the view, the input clutch assembly (2) is not seated properly.










38. Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper number four thrust plate.
39. Install pump and gasket to transmission. Install and torque bolts.










40. Set up input shaft for measurement with Indicator Set (3) and End Play Set (1,2).
41. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.13-0.64 mm (0.005 to 0.025 in.) For example, if end play reading is 0.055 in. select number four Thrust Plate which is 0.071-0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. which is within specifications.
42. Refer to the number four thrust plate chart NO. 4 THRUST PLATE CHART to select the proper number four thrust plate.

NO. 4 THRUST PLATE CHART















43. Install input clutch assembly (1).










44. Install number one caged needle bearing (1)
note: tanged side out (2).

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.






45. Install cooler bypass valve (1) with O-ring end towards rear of case.





46. Install oil pump gasket (1).





47. Install oil pump (2).
48. Install oil pump-to-case bolts (1) and tighten 30 Nm (265 in. lbs.).










49. Install output gear stirrup (1) with serrated side out.










50. Install retaining strap (1).
51. Install strap bolts (3) but do not tighten at this time.










52. Rotate stirrup (2) clockwise against flats of retaining bolt.










53. Tighten stirrup strap bolts to 23 Nm (200 in. lbs.).










54. Bend tabs (1) on strap up against flats of bolts.





55. Install the differential, bearing cups, shim, seals and oil slinger into case.





56. Install the differential cover.





57. Install the differential cover bolts (1) and tighten to 61 Nm (45 ft. lbs.).





58. Install the differential output bearing cover (2).
59. Install the differential output bearing cover bolts (1) and tighten to 12 Nm (105 in. lbs.).






NOTE: Remote pinion gear must NOT be installed while checking turning torque.

60. Using the Turning Torque Tool (1) and an inch pound torque wrench (2) check the differential turning torque, it should be 10 to 22 in-lbs (drag). If turning torque is more than 22 in-lbs (drag) decrease shim size behind the end cover and recheck. If turning torque is less than 10 in-lbs (drag) increase shim size.