Assembly
ASSEMBLE1. Before installing bearing housing, adjust output gear bearing preload.
2. Check bearing preload as follows:
Aligning Bearing And Stator Support:
a. Position bearing/stator support using valve body guide pins tool No. T80L-77100-A or equivalent, then press support into converter using step plate D80L-630-6 or equivalent.
b. Remove bearing cup and adjustment shim(s) from bearing housing. Place bearing cup over output gear bearing.
Installing Collars On Converter Housing:
c. Place four collars, part T870-77000-J on converter housing at position shown in the Installing Collars On Converter Housing image.
Shim Selection Gauge On Output Gear:
d. Place shim selector gauge tool No. T88C-77000-C1 or equivalent, on output gear. The two halves of selector must be turned too eliminate any gap between them.
e. Place bearing housing on collars with washers, then install four screws T88C-77000-C with washers. Torque screws to 14-18 ft lbs.
f. Position torque adapter T880-77000-DH on output gear. Using pins provided T87C-77000-J, loosen gauge halves until all free play is removed and bearings are seated.
g. Measure drag on output gear bearing using an (in lb) torque wrench and torque adapter.
h. Turn gauge, using pins provided until a reading of 4.3-7.8 in lbs. is obtained on torque wrench.
Output Gear Shim Thickness Chart:
i. Use a feeler gauge to measure gap in between the two halves of gauge. Measure gap at four spots, 90° intervals. Select appropriate adjustment shim(s), as shown in the Output Gear Shim Thickness Chart. Select a shim that is close to measurement or slightly larger. No more than seven shims may be used.
Installing Shim Into Bearing Housing:
j. Remove screws, washers, bearing housing gauge, and bearing cup. Then press selected shim(s) and bearing cup into bearing housing, using bearing installer T6OK-4616-A.
k. Install bearing housing. Torque bolts to 14-19 ft lbs.
l. Measure bearing preload. Preload reading should be 0.26-7.81 in lbs.
m. If preload measurements are not within limits, repeat gauging process.
3. Check differential side bearing preload as follows:
a. Remove rear bearing cup and shims from transaxle case using stator and driven sprocket bearing remover T86P-70043-A, piston remover T73L-2196-A, and slide hammer T5OT-1O0-A or equivalent.
b. Install front bearing cup in converter housing using driver handle T80T-4000-W or equivalent and bearing cup replacer T88C-7700-FH or equivalent.
c. Install differential into converter housing.
Installing Collars On Converter Housing:
d. Place six collars, part of T87C-77000-J on converter housing at position shown in the Installing Collars On Converter Housing image.
e. Install rear bearing cup over differential bearing.
Shim Selection Gauge:
f. Place shim selector gauge T88C-77000-C1 or equivalent on output gear. The two halves of selector must be turned to eliminate any gap between them.
g. Place transaxle case on collars, then install six screws T88C-77000-C with washers. Torque screws to 27-38 ft lbs.
h. Unthread gauge tool, using pins provided, until all free play is removed and bearing cup is seated.
Measuring drag on differential bearing:
i. Engage differential rotator T88C-77000-L, then using an (in lb) torque wrench and adapter measure drag on differential bearing.
j. Turn gauge, using pins provided until a reading of 4.3 in lbs is obtained on torque wrench.
Differential Shim Thickness Chart:
k. Use a feeler gauge to measure gap in between the two halves of gauge. Measure gap at four spots, 90 degree intervals. Add 0.0079 inch to the largest measurement. Select a shim, from the Differential Shim Thickness Chart, that is close to measurement or slightly larger no more than three shims may used.
Installing Bearing Cup Into Transaxle Case:
l. Remove screws, washers, transaxle case, gauge, and bearing cup. Then install selected shim(s) and bearing cup into transaxle case using drive handle T80T-4000-W and differential bearing cup replacer T88C-77000-FH.
m. Install transaxle case and torque bolts.
n. Measure bearing preload. Preload reading should be 26-35 in lbs.
o. If preload measurements are not within limits, repeat gauging process.
4. Install idle gear and output gear as an assembly by tapping in with a plastic hammer.
5. Install bearing housing on converter housing and torque bolts.
6. Align groove on idle shaft with matching mark on bearing housing, than tap roll pin in with suitable punch and hammer.
7. Apply a small amount of automatic transmission fluid to 0-rings of 2-3 accumulator. Then install the 2-3 accumulator in piston assembly and torque bolts.
8. Install parking pawl and shaft, then the spring and snap ring.
9. Move manual shaft and check operation of parking pawl.
10. Install parking assist lever and snap ring, then the actuator support. Torque to 8-10 ft lbs.
Installing Manual Shaft Components:
11. Install manual plate, spacer, washer, and nut. Torque nut to 30-41 ft lbs.
12. Install manual shaft bracket. Torque to 7 ft lbs.
13. Install detent ball, spring, washer, and plug. Torque plug to -13 ft lbs.
14. Apply small amount of automatic transmission fluid to inner and outer faces of low and reverse brake piston seal. Face outer seal lip toward the inside by gently rolling it down around the circumference for easier installation.
15. Install low and reverse brake piston by pushing evenly around circumference, ensuring not to damage outlet seal. Check operation by applying compressed air through fluid passage.
16. Install spring and retainer assembly, then compress assembly and install snap ring.
17. Install output shell to output gear, then the bearing race on output shell.
Installing Transaxle Plugs:
18. Apply a thin coat of suitable sealant to the surface of converter housing and transaxle case, then install 0-rings and transaxle to converter housing and torque bolts. When the differential gear is installed, insert transaxle plugs T88C-7025-AH or equivalent. If adapter is not inserted, the side gear may become improperly aligned.
19. Assemble turbine shaft and 3-4 clutch assembly.
20. Ensure thrust bearing and bearing race are in correct position.
21. Install turbine shaft and 3-4 clutch assembly into transaxle case.
Installing Turbine Shaft:
22. Adjust turbine shaft holder T88C-7700-KH or equivalent so it contacts and holds turbine shaft.
23. Install internal gear to 3-4 clutch drum and snap ring.
24. Install carrier hub assembly. Ensure thrust bearing and race are in correct position.
25. Hold turbine shaft with one hand to prevent shaft from rotating, then install carrier hub assembly into 3-4 clutch by rotating drum.
Installing Low And Reverse Clutch Pack:
26. Install low and reverse clutch pack.
27. Install retaining plate and snap ring.
28. Check low and reverse brake clearance as follows:
Low And Reverse Clutch Pressure Thickness Chart:
a. Measure clearance of snap ring and low and reverse brake retaining plate. Clearance should be 0.083-0.0947 inch. If clearance is not as specified, select a retaining plate which will bring clearance to specification.
b. Check operation by applying compressed air through fluid passage.
29. Hold one-way clutch, in horizontal position and install by turning the carrier hub assembly counterclockwise.
30. Install servo assembly and anchor strut, then install 2-4 brake band so band expands full in transaxle case. Interlock 2-4 ban and anchor strut.
31. Install small sun gear and one-way clutch, then check thrust bearing and race are in correct position.
32. Install piston stem in position while pulling 2-4 brake band with suitable pliers, then loosely tighten by hand.
33. Install clutch assembly, then check thrust bearing and race are in correct position.
34. Measure height difference between reverse and forward drum and transaxle case. Distance should be 0.032 inch on models without turbo or 0.151 inch on models with turbo.
35. Install snap ring into bottom ring groove of turbine shaft.
36. Check total endplay as follows:
a. Place thrust bearing onto clutch assembly.
b. Remove previous race and gasket.
c. Place the thickest bearing race 0.087 inch on oil pump.
d. Install oil pump onto clutch assembly, then using a feeler gauge measure clearance between transaxle case and oil pump.
Bearing Thrust Race Thickness Chart:
e. If clearance is not as specified, select a bearing race which will bring clearance to specification.
f. Remove oil pump, then place selected bearing race and new gasket onto oil pump.
g. Install oil pump onto clutch assembly and torque.
37. To adjust 2-4 brake band, loosen locknut and tighten piston stem to 78-96 in lbs. Then loosen piston stem two turns and tighten locknut. Torque to 18-29 ft lbs.
38. Install oil strainer and new O-rings to transaxle case, then install oil pan with new gasket and torque oil pan.
39. Align manual valve with pin on manual plate, then install control valve body into transaxle case and torque.
40. Install solenoid connector and new O-ring in transaxle case.
41. Connect throttle cable to throttle cam on control valve body, then install new O-ring on bracket.
42. Install control valve body cover with new gasket and torque.
43. Install oil pipes, hoses, and switch box as an assembly, then install harness clip. Torque switch box to 12-17 ft lbs.
44. Install ball, spring, oil pipe, gasket, and plug. Torque to 23-35 ft lbs.
45. Install solenoid connector, then pulse generator and fluid temperature switch.
46. Turn manual shaft to Neutral position, then install neutral switch and loosely tighten bolts.
47. Remove screw and move neutral switch so alignment hole is aligned with screw hole, then adjust switch by inserting a 0.079 inch diameter pin through the holes, then install screw and torque bolts.
48. Install oil level gauge and tube with a new O-ring into transaxle case.
49. Install oil pump shaft, then new O-ring on turbine shaft.
50. Fill torque converter with suitable fluid, then install converter in converter housing while rotating it to align with splines. To ensure torque converter is installed correctly, measure distance A between end of converter and housing, distance should be 0.98 inch.