Assembly

CAUTION: If the clutch plates or the 2-4 band are replaced, soak the new parts in the specified automatic transaxle fluid (ATF) for at least two hours before assembly. Apply the specified ATF to all seal rings, rotating parts, O-rings and sliding parts.

NOTE:
- Clean all bearings thoroughly in solvent and blow dry with compressed air. Inspect the bearings for pitting and rough operation. Replace as necessary.
- All O-rings, seals, and gaskets must be replaced with new ones.

1. Prior to installation, inspect the transaxle case for damage, cracks, or wear. Replace as necessary.





2. Use (A) Valve Body Guide Pins T80L-77100-A to align the torque converter stator support. Use (B) Step Plate D80L-630-6 or equivalent to press the (C) torque converter stator support into the converter housing.





3. Use (A) Driver Handle T80T-4000-W and (B) Bearing Cup ReplacerT77F-1217-B to install the bearing cup into the converter housing.





4. Install the eight bearing cover bolts.

NOTE: Tighten the torque converter stator support bolts evenly and gradually.





5. Install the (A) idler gear and (B) output shaft as an assembly.
- Install the idler gear and output shaft by tapping them in with a plastic hammer.





6. Install the bearing housing onto the converter housing.

NOTE: Tighten the bearing housing bolts evenly and gradually.





7. Install a new bearing housing roll pin.
- Align the holes on the idler gear shaft with the mark on the bearing housing. Tap the roll pin in using a 5/32 inch pin punch and hammer.





8. Install the differential.





9. Install the parking pawl assembly.
(1) Install the parking pawl.
(2) Install the parking pawl shaft.
(3) Install the parking pawl return spring.
(4) Install the parking pawl shaft E-clip.
- Move the manual shaft and verify that the parking pawl operates.





10. Install the detent lever spring and actuator support.
(1) Install the actuator support.
(2) Install new actuator support bolts.
(3) Install the detent lever spring.





11. Install the detent lever. Attach the detent lever spring to the detent lever.





12. Install the manual shaft plate and the lever holder.
(1) Install the lever holder.
(2) Install the manual shaft plate.
(3) Install the lever holder nut.
13. Install the manual shaft lever.





(1) Push the manual shaft lever into the manual shaft plate.





(2) Install the manual shaft washer and nut.





14. Install the output shell. Set the thrust bearing onto the output shell.
- The output shell thrust washer outer diameter is 72.1 mm (2.84 inch).





15. Apply a thin coat of silicone sealant to the surfaces of the (A) converter housing and transaxle case. Carefully install new (B) O-rings.





16. Attach the transaxle case to the converter housing and install the transaxle case bolts.

NOTE: Tighten the transaxle bolts evenly and gradually.





17. Install Turbine Shaft Holder T88C-77000-KH.





18. Install the (A) turbine shaft and 3-4 clutch assembly with the (B) thrust bearing between the 3-4 clutch and output shell.
- Assemble the turbine shaft and 3-4 clutch assembly.
- Install the turbine shaft and 3-4 clutch assembly into the transaxle case.





19. Install the ring gear to the output shell.
- Install the ring gear with the external gear side down.





20. Install the ring gear retainer snap ring.





21. Install the carrier hub assembly.
(1) Use petroleum jelly to install the thrust washer to the carrier hub assembly.
(2) Install the thrust bearing between the carrier hub assembly and the 3-4 clutch assembly.





(3) Install the carrier hub assembly.
- Hold the turbine shaft with one hand to keep it from rotating while installing the carrier hub.
- Install the carrier hub into the 3-4 clutch cylinder by rotating it to align the carrier hub with the 3-4 clutch pack.





22. Install the (A) low/reverse clutch pressure plate and the (B) low/reverse clutch disc pack.





23. Install the low/reverse clutch pressure plate snap ring.





24. Install the wave washer.





25. Install the one-way clutch horizontally. Use the rear sun gear to rotate the carrier counterclockwise while installing the one-way clutch.

CAUTION: The one-way clutch can be installed improperly. Be certain that after installing the one-way clutch, you can rotate the carrier by hand in a counterclockwise direction while working from the rear side of the transaxle. If the one-way clutch is installed improperly, gear ranges may not function or the gear train may lock up. This may cause overheating of the transaxle and unnecessary overhauling of the unit.





26. Install the one-way clutch and carrier hub assembly snap ring.





27. Install the (A) servo band lever and the (B) 2-4 band actuating lever shaft into the transaxle case





28. Install the 2-4 band in the transaxle
- Interlock one end of the 2-4 band and the servo band levers.
- Interlock the tend of the 2-4 band to the servo apply arm.





29. Install the (A) primary sun gear and one-way crutch assembly.

NOTE: Use petroleum jelly to hold the thrust bearing and thrust washer in position.

- Verify, that the (B) thrust bearing and the (C) thrust washer are installed in the correct positions.
- Install the primary sun gear and one-way clutch assembly while rotating it.





30. Install the (A) forward and reverse clutch drum assembly.
- Verify that the (B) thrust bearing is installed in the correct position.
- Install the forward and reverse clutch drum assembly while rotating it.
31. Rotate the rear sun gear, the one-way clutch, and the F/C/R clutch drum assembly to line up to the clutch pack and gears.





32. Carefully install the turbine shaft snap ring it the bottom ring groove of the turbine shaft.





33. Remove the Turbine Shaft Holder T88C-77000-KH.





34. Measure the height difference between the reverse clutch drum and the transaxle case;

NOTE: If the clearance is greater than 0.9 mm (0.035 inch), recheck/reassemble the clutch pack(s) as needed.





35. Install the F/C/R clutch drum thrust bearing.

NOTE: Use petroleum jelly to hold the thrust bearing in position.
36. Use the following procedure to adjust the total end play and select a suitable bearing race.

NOTE: Take several measurements and calculate the average value.





(1) Set the thickest thrust washer, 2.2 mm (0.087 inch) onto the oil pump. Set the oil pump onto the forward and reverse clutch drum assembly.





(2) Measure the clearance between the transaxle case and the oil pump. Select a suitable thrust washer from the following chart:
Clearance: Select Thrust Washer
0.91-1.10 mm (0.036-0.043 inch): 1.2 (0.047 inch)
0.71-0.90 mm (0.028-0.035 inch): 1.4 (0.055 inch)
0.51-0.70 mm (0.020-0.027 inch): 1.6 (0;063 inch)
0.31-0.50 mm (0.012-0.020 inch): 1.8 (0.071 inch)
0.11-0.30 mm (0.004-0.012 inch): 2.0 (0.079 inch)
0.00-0.10 mm (0.000-0.004 inch): 2.2 (0.087 inch)





38. Place the selected (A) thrust washer and a new (B) oil pump gasket onto the oil pump

NOTE: Use petroleum jelly to hold the thrum washer in position.





39. Install the oil pump onto the forward and reverse clutch drum assembly.

NOTE: Tighten the on pump bolts evenly and gradually in a cross hatch pattern.





40. Install a new Oaring on the throttle valve contra, actuating cable bracket, then feed the throttle valve control actuating cable into the transaxle case and connect it to the throttle pulley.





41. Install the new throttle valve control actuating cable bolt.





42. Install the (A) solenoid connector with a new O-ring in the transaxle case, then connect the (B) solenoid electrical connector.





43. Position the main valve body to the transaxle case. Align the (A) manual valve with the (B) pin on the-manual valve detent lever.








44. Install the main control valve body bolts and a new filter. Connect the solenoid electrical connectors.
- Bolt length (measured from below the head)
A: 30 mm (1.18 inch) C: 50 mm (1.97 inch).

NOTE: Tighten the main control valve body bolts evenly and gradually.





45. Install the oil pan and new oil pan gasket.

NOTE:
- Tighten the transaxle oil pan bolts Land gradually.
- Apply a thin coat of silicone sealant to each side of the new gasket.





46. Install the turbine shaft (TSS) speed sensor.





47. Install the vehicle speed sensor.





48. Use the following procedure to install the transmission range (TR) switch.
(1) Rotate the manual shaft to the N position.
(2) Turn the TR switch so that the NEUTRAL mark is in line with the flat, straight surfaces on either side of the manual shaft.
(3) Hand tighten the TR switch, then tighten the TR switch mounting bolts.





49. Install the manual shaft lever, (A) spring washer, and the (B) manual shaft lever nut.





50. Install a new O-ring on the fluid filler tube, then install the fluid filler tube and dipstick assembly.





51. Install the fluid cooler line.
(1) Install the check ball.
(2) Install the drain back valve spring.
(3) Install the fluid cooler line washers.
(4) Install the fluid cooler line bolt.
(5) Install the fluid cooler line nut.





52. Install the oil pump shaft.





53. Install a new converter turbine shaft seal on the turbine shaft.
- The converter turbine shaft seal inner diameter has 20 mm (0.787 inch).





54. Install the torque converter into the converter housing while rotating it to align the splines.

CAUTION: If a new torque, converter is being installed or the torque converter has been drained and washed, pour 6.31 (6.7 qt) into the torque converter before installation. Hold the torque converter in an erect position when filling it with the specified ATF.

NOTE: The torque, converter should slide into the transaxle easily. Do not force the torque converter into the transaxle.





55. To ensure that the torque converter is installed properly, measure the distance between the (A) torque converter and the edge of the (B) converter housing.
56. Install the drain plug with a new washer.





57. Remove the transaxle from the Bench Mounted Holding Fixture T57L-500-B.