Part 2

68. Use combined thickness of gauge bar with long spacers 177.8 mm (7.00 inch) as dimension B.
69. Subtract dimension A from dimension B to get dimension C.
70. Use dimension C to select the proper No. 14 differential bearing shim from the following chart.
Dimension C: No. 14 Shim Thickness
130.76-130.46 mm (5.148-5.136 in): 1.08-0.98 mm (0.043-0.039 in)
130.45-130.16 mm (5.136-5.124 in): 1.38-1.28 mm (0.054-0.050 in)
130.15-129.87 mm (5.123-5.113 in): 1.67-1.57 mm (0.066-0.062 in)
129.86-129.57 mm (5.113-5.101 in): 1.97-1.87 mm (0.078-0.074 in)
129.56-127.27 mm (5.100-5 089 in): 2.27-2.17 mm (0.089-0.085 in)
71. Remove the gauge bar and spacers.
72. Install the speedometer drive gear with the tabs down and fully seated.
73. Install the selected No. 14 differential bearing shim.





74. Install the No. 15 differential carrier thrust bearing and race.





75. Position the new transaxle split flange gasket to the case.





76. Lower the converter housing onto the case.





77. Use a 10 mm socket to install the 20 converter housing-to-transaxle case bolts. Torque the converter housing-to-transaxle case bolts to 20-25 Nm 15-18 ft. lbs.) in the sequence shown.





78. Lubricate and install the intermediate and overdrive servo piston and return spring assembly in the transaxle case bore.

NOTE: Note the number of grooves on the piston rod.





79. Install Servo Piston Rod Selector T94P-77000-M on the piston.





80. Loosely assemble the legs and bar from Servo Piston Rod Selector T94P-77000-M in case bore.

NOTE: Legs of the tool fit into servo cover retaining ring groove.





81. Tighten the bar to the legs using bolts provided.





82. Tighten the center bolt of selector tool to 4 Nm (36 inch lbs.).





83. Install a depth micrometer on the head of the selector tool. Measure and record the distance to the bar of the selector tool (distance A).
84. Back off the center bolt on the servo tool until the piston movement stops. Measure and record distance to bar (distance B).
85. Subtract A from B to obtain travel C. The travel specification for all rods is 2.40-4.90 mm (0.094-0.192 inches). If the measurement is not within specification, select a new piston and rod assembly using the following chart:
Part Number: Number of Grooves: Rod Length
F3RP-74188-CB: 0: 108 1 mm (4.26 in)
F3RP-74188-BB: 1: 107.1 mm (4.22 in)
F3RP-74188-AB: 2: 105.7 mm (4.16 in)
86. If the distance is not within the travel specification, replace the intermediate and overdrive servo piston and recheck.
87. Remove the servo piston selection tool and lubricate the servo cover seal and intermediate and overdrive servo case with a light coat of transmission fluid.





88. Install the servo cover in the case.
89. Install Servo Cover Remover/Replacer T94P-77000-L.

NOTE: To aid in the installation of the servo cover, install a nut with an integral washer (using a permanent thread sealer) onto the forcing bolt of the Servo Cover Remover/Replacer.

90. Compress the servo cover and install the servo cover retaining ring.

WARNING: SERVO RETURN SPRING FORCE IS VERY HIGH.

NOTE: If the servo cover will seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.

91. Remove the Servo Cover Remover/Replacer.
92. Install Transmission Test Plate T94P-77000-S and Test Plate Mounting Screws T82P-7006-C.





93. Use a rubber tipped blow gun and 276 kPa (40 psi) of filtered compressed air to check the following clutch hydraulic circuits for function and leakage.

CAUTION: Do not check the coast clutch since the piston may be forced out of the forward clutch piston.

94. If air leakage is detected, disassemble the transaxle and locate source of leakage.
95. Remove Transmission Test Plate T94P-77000-S and Test Plate Mounting Screws T82P-7006-C.





96. Install the thermostatic fluid level control valve in the case.
97. Install the bracket and the bolt. Tighten the thermostatic fluid level control valve bracket bolt to 11-13 Nm (98-115inch lbs.).





98. Install forward clutch circuit filter (if equipped).
99. Install the O-ring on transaxle electrical connector.
100. Place the main control slightly away from the case and push the electrical connector into its bore.

CAUTION: Do not pull wires or damage connector body. Damage to connector and terminals may result.

101. Align the Z-link in the manual valve.
102. Install wiring harness clip.





103. Install the 12 main control bolts. Tighten the main control bolts to 9-11 Nm (80-97 inch lbs.) in the sequence shown.

NOTE: Tighten bolts in sequence as shown. Bolts 1, 7 and 9 are longer than the rest.





104. Loosen the nut on the ball stud for the manual valve detent lever actuating rod assembly.
105. Remove the manual control lever bolt and the manual control lever.





106. Use Shifter Shaft Alignment Tool T94P-77000-H to move the manual control lever shaft to the D position and install the pin to hold the tool in position.





107. Move the manual valve detent lever assembly to the D position.





108. Use a 10 mm wrench to initially tighten the nut on the ball. Remove the shifter pin.





109. Rotate the shifter shift alignment tool until socket can be installed on nut. Tighten the manual valve detent lever ball stud nut to 11-13 Nm (98-115 inch lbs.). Rotate back to D position and recheck adjustment.
110. Remove the pin and shifter shaft alignment tool.
111. Install the manual control lever assembly and bolt using 10 mm socket. Tighten the manual control lever bolt to 24-30 Nm (18-22 ft. lbs.).





112. Rotate manual valve detent lever assembly to N position.





113. Place the transmission range (TR) sensor on the manual valve detent lever shaft.
114. Use TR Sensor Alignment Tool (MLPS Alignment Tool) T92P-70010-AH to align the TR sensor on the manual valve detent shaft and case.





115. Install and tighten the TR sensor bolts to 11-13 Nm (96-117 inch lbs.).
116. Install the main control cover gasket on the main control cover assembly.
117. Place the main control cover assembly on the case.





118. Install the 14 main control cover bolts. Tighten the main control cover bolts 14-18 Nm (124-159 inch lbs.) in the sequence shown.





119. Install the O-ring on the speedometer driven near assembly
120. Push the speedometer driven gear assembly into the bore.





121. Install the vehicle speed sensor (VSS) assembly bolt. Use an 8 mm socket to tighten the speedometer driven gear assembly bolt to 5-6 Nm (43-53 inch lbs.).





122. Install a new fluid tube filler grommet into the
123. Install the fluid filler tube.





124. install the fluid filler tube bolt. Tighten the fluid filler tube bolt to 7-9 Nm (62-79 inch lbs.).
125. Install the fluid level indicator in the fluid filler tube.
126. Install the turbine shaft speed sensor O-ring on the turbine shaft speed sensor. Apply a light coat of petroleum jelly to the O-ring.
127. Push the turbine shaft speed sensor into the bore.





128. Install the turbine shaft speed sensor bolt. Tighten the turbine shaft speed sensor bolt to 12-14 Nm (107-123 inch lbs.).





129. Use Output Seal Replacer T86P-1177-B and a hammer to install the differential seals.





130. Coat the converter seal garter spring with petroleum jelly and use Converter Seal Replacer T94P-77000-C with a dead blow hammer to install the converter impeller hub seal.

NOTE: Make sure converter seal garter spring does not become dislodged during installation. If garter spring does become dislodged, replace the converter seal.





131. Install the transaxle drain plug. Use a 3/8 inch ratchet to tighten the plug to 25-29 Nm (19-21 ft. lbs.).





132. Install the pump drive shaft into the end of the turbine shaft assembly. Check rotation of pump drive shaft.





133. Install Torque Converter Handles T81P-7902 and install the torque converter in the transaxle.
134. Remove the transaxle from Bench Mounting Holding Fixture.
135. Dry the transaxle exterior and prepare it for installation.