Part 2

Transaxle









Transmission Exploded View


















55. NOTICE: Do not apply grease or other lubricants to the clutch actuator lever fingers, the engagement system bearing, or the Z-washers or clutch contamination can occur.

NOTE: The engagement system bearing unit should be installed easily.
Install the engagement system bearing unit.






56. NOTICE: Do not tilt transmission after the Z-washers are installed, they may come off center and damage can occur.

Install the Z-washers onto the engagement system bearing unit and center them correctly.






57. If installing a new clutch go to step 70.

58. NOTE: Make sure the special tool washer is also installed.
Install the special tool in a vise.






59. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.





60. Install the special tool loosely on the clutch.





61. Install the special tool on the clutch making sure the legs are inserted in the slots.





62. Turn the special tool clockwise to the stops and hold.





63. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.






64. Install the special tool loosely on the clutch.





65. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.





66. NOTICE: Make sure the clutch self-adjuster is held to the stops before compressing the clutch or damage will occur to the clutch.

NOTE: An audible click can be heard when the clutch locks lock.
While holding the clutch self-adjuster to the stops, use the special tool and compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.






67. Remove the special tools.





68. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.
Visually check the locks to make sure they have locked. 4 locks shown, 12 total.






69. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.

70. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.





71. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.





72. Using the special tools, install the new inner input shaft seal.





73. Apply a small amount of transmission fluid on the input shaft bearing surface.





74. Apply a small amount of DPS6 Grease on both input shaft splines.





75. Verify the Z-washers are installed correctly.





76. NOTICE: Verify the clutch locks are locked prior to installation or the transmission may not operate correctly and damage can occur. If the clutch locks are not locked go to step 56 within this procedure.

NOTE: Make sure the angled lifting leg is installed in the location shown.
Using the special tools, install the clutch in the transmission.






77. Remove all the special tools.





78. Install the special tools onto the transmission case.





79. NOTICE: Do not overtighten the special tool or damage can occur.

Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.






80. NOTE: Make sure the hollow input shaft snap ring is fully seated.
Install the new hollow input shaft snap ring.






81. NOTE: Align the index marks on the clutch hub and clutch.
Install the clutch hub.






82. Install the new clutch hub snap ring in the position shown.





83. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using the special tool, release the clutch 1 locks by slowly turning the special tool counterclockwise. An audible click will be heard when the clutch 1 lock is released. Repeat step to release clutch 2 locks.






84. Apply High Temperature Nickel Anti-Seize Lubricant to both clutch motor surfaces where indicated.





85. Apply High Temperature Nickel Anti-Seize Lubricant to the clutch actuator lever splines as shown.





86. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
- Tighten to 5 Nm (44 lb-in).






87. Install the clutch motor 1 and the 4 clutch motor 1 bolts.
- Tighten to 5 Nm (44 lb-in).






88. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can occur to the transmission.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 2.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.

Install the input shaft speed sensor 2.
1. Install the input shaft speed sensor 2 shim.

2. Install the input shaft speed sensor 2.

3. Install the input shaft speed sensor 2 bolt.
- Tighten to 10 Nm (89 lb-in).






89. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft speed sensor 1 or damage can occur to the transmission.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 1.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.

Install the input shaft speed sensor 1.
1. Install the input shaft speed sensor 1 shim.

2. Install the input shaft speed sensor 1.

3. Install the input shaft speed sensor 1 bolt.
- Tighten to 10 Nm (89 lb-in).






90. NOTE: If installing the old OSS (Output Shaft Speed) sensor, install a new O-ring.
Install the OSS (Output Shaft Speed) sensor and the OSS (Output Shaft Speed) sensor bolt.

- Tighten to 10 Nm (89 lb-in).






91. Install the TR (Transmission Range) sensor and the 2 TR (Transmission Range) sensor bolts.
- Tighten to 10 Nm (89 lb-in).






92. Carefully inspect the TCM (Transmission Control Module) and the transmission bore for debris or damage. Clean and/or repair as needed.

93. NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.
Install new O-rings if the TCM (Transmission Control Module) is being reused.






94. NOTICE: Do not force the TCM (Transmission Control Module) onto the transmission or damage may occur.

NOTICE: Make sure the TCM (Transmission Control Module) sits flush on the transmission, or damage can occur.

Install the TCM (Transmission Control Module). Apply light pressure to seat the O-rings. If the TCM (Transmission Control Module) does not push in place with light pressure, remove the TCM (Transmission Control Module) and slightly turn the TCM (Transmission Control Module) gears and retry installing the TCM (Transmission Control Module).





95. Install the 4 TCM (Transmission Control Module) bolts.
- Tighten to 27 Nm (20 lb-ft).






96. Install the wiring harness.