Step 1 - 53
TransaxlePart 1 Of 4:
Part 2 Of 4:
Part 3 Of 4:
Part 4 Of 4:
Special Tool(s)
Assembly
All applications
1. Prepare the transaxle for assembly by proceeding with the following steps:
^ Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
^ Dry all parts with moisture-free regulated compressed air (do not use shop towels).
^ Lubricate all internal parts (including friction plates) with clean automatic transmission fluid.
^ Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
^ Drive sprocket thrust washers.
^ Driven sprocket thrust bearing shims.
^ Differential case thrust bearing shims.
^ Low/reverse clutch pressure plates.
^ During assembly, use petroleum jelly to hold the parts in place (do not use grease).
^ Lightly coat bolt and nut threads with automatic transmission fluid for correct installation torque specifications.
2. Install intermediate and overdrive band assembly into the transaxle case.
3. Install the No. 1 pump support thrust bearing.
^ Lubricate the seal rings with clean automatic transmission fluid.
4. NOTE: Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.
Install pump assembly into the case.
5. NOTE: Tighten the bolts in the indicated sequence.
Install the pump assembly bolts.
6. Using the special tools, install the low/reverse clutch piston.
^ Lubricate seals and piston bore with clean automatic transmission fluid.
7. Install the low/reverse clutch return spring assembly.
8. Install the low/reverse clutch return spring retaining ring.
9. CAUTION: The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
Install the low/reverse clutch wave spring.
10. Install the low/reverse clutch plates.
1 Install the low/reverse clutch external spline (steel) clutch plates.
2 Install the low/reverse clutch internal spline (friction) clutch plates.
3 Install the thin eight wave low/reverse clutch cushion spring.
4 Install the low/reverse clutch pressure plate.
11. CAUTION: The low one-way clutch thrust plate is fitted in the position for measurement purposes only.
Install the low one-way clutch thrust plate.
12. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate.
^ Take a second measurement on the opposite side.
^ Average the two measurements to get the clearance.
^ If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
^ Pressure plate sizes:
^ 2.57 - 2.46 mm (0.101 - 0.097 inch)
^ 2.36 - 2.26 mm (0.092 - 0.089 inch)
^ 2.16 - 2.06 mm (0.085 - 0.081 inch)
13. NOTE: One tooth of the low/reverse clutch pressure plate is notched for identification.
Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction).
1 Low one-way clutch thrust plate.
2 Low/reverse clutch pressure plate.
3 Low/reverse clutch external spline clutch plates (steel).
4 Low/reverse clutch wave spring.
5 Low/reverse clutch internal spline clutch plates (friction).
14. Install the No. 1 pump support thrust bearing assembly.
15. NOTE: Remove the seal sizer from forward/coast/direct clutch cylinder.
Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
16. Install the turbine shaft.
17. Install the No. 4 turbine shaft thrust bearing.
18. Install the forward one-way clutch and low/intermediate sun gear assembly.
19. Install the No. 5 low/intermediate sun gear thrust bearing.
20. Install the low/intermediate carrier assembly.
21. Install the No. 6 low/intermediate carrier thrust bearing.
22. Install the low/intermediate ring gear assembly.
23. Install the No. 7 reverse/overdrive sun gear thrust bearing.
24. Install the reverse/overdrive sun gear and shell assembly.
25. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
26. Install the thick, ten-wave low/reverse clutch wave spring.
27. Install the low/reverse clutch plates (model dependent).
1 Install the low/reverse clutch external spline (steel) clutch plates.
2 Install the low/reverse clutch internal spline (friction) clutch plates.
3 Install the low/reverse clutch pressure plate previously selected.
28. NOTE: Early production vehicles may not have a wave spring.
If equipped, install the thin, eight-wave low/reverse clutch wave spring.
29. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
30. install the low one-way clutch thrust plate.
31. NOTE: Make sure to position the low one-way clutch retaining ring as shown.
Install the low one-way clutch retaining ring.
32. Install the manual valve detent lever actuating rod assembly.
^ Install the parking cam actuator lever.
33. Install the manual valve detent lever.
34. Install the special tools.
35. Install the special tool with short spacers.
36. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
^ Record this dimension.
^ This dimension is designated with A.
37. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
^ Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
^ The average of these two dimensions is dimension B.
^ Remove the special tools.
38. Subtract dimension B from dimension A to get dimension C.
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Part 2 Of 2:
Driven Sprocket Alignment Shim No. 11
39. Use the third dimension to select the correct No. 11 driven sprocket shim.
^ Select a shim from the driven sprocket shim chart.
40. Install and lubricate the following:
1 Lubricate the needles and seals in the No. 18 driven sprocket bearing.
2 Install the selected No. 11 driven sprocket shim.
3 Install the No. 12 driven sprocket bearing.
41. Install the No. 9 reverse/overdrive ring gear thrust bearing.
42. NOTE: Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
Install the reverse/overdrive ring gear assembly.
43. Install the special tools.
44. Install the special tool with short spacers.
45. Using the special tools, measure the distance from the top of special tool to the face of the reverse/overdrive ring gear assembly surface area.
^ Repeat this measurement 180 degrees from the first measurement.
^ The average of these two dimensions is dimension A.
^ Remove the special tools.
46. Add 25.4 mm (1.01 inch) (thickness of special tool) and thickness of short spacers.
^ This is the dimension B.
47. Subtract dimension A from dimension B.
^ This is dimension C.
Driven Sprocket Alignment No. 10 Thrust Washer
48. Select No. 10 thrust washer from the drive sprocket thrust washer chart.
^ Use the third dimension to select the No. 10 drive sprocket thrust washer.
49. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
50. Remove the reverse/overdrive ring gear assembly.
51. Install the filter and seal assembly.
52. NOTE: Refer to the illustration for correct tool usage.
Install the special tool in the filter eyelet and transaxle hole.
53. NOTE: Lubricate the filter recirculating regulator exhaust seal before installation.
Using the special tool, install the filter recirculating regulator exhaust seal.
54. Install the chain pan in the transaxle case.
55. Assemble and install the drive chain assembly.
1 Drive chain (copper colored link facing upward).
2 Driven sprocket assembly.
3 Reverse/overdrive ring gear assembly.
^ Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
56. Install the chain pan cover by snapping it into place.