Part 1

ASSEMBLY

Special Tools:



























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

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed Quick Learn Procedure .

1. Install both output bearing cups using Installer (3)(Figure 1).










2. Install low/reverse piston retainer gasket (2)(Figure 2). Make sure gasket holes line up with case (1).










3. Install low/reverse piston retainer (1)(Figure 3).










4. Install low/reverse piston retainer-to-case screws (3)(Figure 4) and tighten to 5 Nm (45 in. lbs.).










NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

5. Install low/reverse clutch piston (1)(Figure 5).










6. Park guide bracket assembly - anti-ratchet spring (1)(Figure 6), guide bracket (2), split sleeve (3), spacer (4), pawl (5), and stepped spacer (6).










7. Assemble park guide bracket assembly(Figure 7).










8. Install guide bracket (2)(Figure 8) into position and insert pivot shaft (3).










9. Install anchor shaft and plug (3)(Figure 9). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.










10. Install low/reverse piston return spring (1)(Figure 10).










11. Install low/reverse spring compressor Disc (3)(Figure 11), Compressor (4) and Bar (5) into position.










12. Compress low/reverse piston and install snap ring. Snap ring opening must be between spring levers (1)(Figure 12).










13. Install rear carrier bearing cone using Installer (2) using an Arbor Press (1)(Figure 13).










14. Install rear carrier assembly (1)(Figure 14) to transaxle case.










15. Install output gear bearing cone using Installer (3)(Figure 15) Handle (2) and an Arbor Press (1).










16. OUTPUT GEAR BEARING ADJUSTMENT:
a. With output gear (3)(Figure 16) installed, install a 4.50 mm (0.177 in.) gauging shim (2) on the rear carrier assembly hub (1), using grease to hold the shim in place.
b. Using Holder , install output gear and bearing assembly. Tighten to 271 Nm (200 ft. lbs.).










17. OUTPUT GEAR BEARING ADJUSTMENT: cont.
a. Measure bearing end play. Attach Gear Checking Plate (1)(Figure 17) to the gear (4).
b. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
c. Using a Dial Indicator (2) (Figure 17) mounted to the transaxle case, measure output gear (4) end play.
d. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
e. Use Holder to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller.
f. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.

OUTPUT GEAR BEARING SHIM CHART















18. Install the output gear and bearing assembly using Installer (2)(Figure 18).










19. Install NEW output gear retaining bolt (2)(Figure 19) and washer (3).










20. Using Holder (4)(Figure 20), tighten output gear retaining bolt to 271 Nm (200 ft. lbs.).










21. Using an Inch Pound Torque Wrench (1)(Figure 21), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs. If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.










22. Install output gear stirrup (1)(Figure 22) with serrated side out.










23. Install retaining strap (1)(Figure 23).
24. Install strap bolts (3) but do not tighten at this time.










25. Rotate stirrup (2)(Figure 24) clockwise against flats of retaining bolt.










26. Tighten stirrup strap bolts to 23 Nm (200 in. lbs.)(Figure 25).










27. Bend tabs (1)(Figure 26) on strap up against flats of bolts.










28. Install transfer shaft bearing cone using Installer (1)(Figure 27).










NOTE: Insure O-ring is installed on the bearing cup before the cup is installed.

29. Install bearing cup (1)(Figure 28) and oil baffle (4) to transfer shaft (3).










30. Using Remover/Installer (1)(Figure 29), install transfer shaft (2).