Part 1 of 2
1. Position case in horizontal position.Drive Sprocket Bearing Installation:
2. If bearing was removed, install drive sprocket bearing using Stator and Driven Sprocket Bearing Replacer 307-164 (T86P-70043-B).
If removed, install driven sprocket support. Install six (T-30) Torx~ bolts and tighten to 7-9 Nm (62-79 in lb).
NOTE: Bolt holes are offset. Driven sprocket can only be aligned one way. Drain hole points downward.
3. Clean filter with compressed air and install.
Converter Hub Seal Installation:
4. Install converter impeller hub seal using Converter Hub Seal Replacer 307-186 (T87L-77837-AH) and dead blow (lead-filled) hammer.
NOTE: After installation, verify presence of garter spring on seal.
5. Install RH differential seal using Output Seal Replacer 307-157 (T86P-1177-13) with Output Shaft Seal Replacer Pilot 307-317 (T94P-77001-JH).
End Play Tool:
6. Loosely install End Play Tool 307-187 (T87P-70014-AH) with Step Plate Adapter 205-DO14 (D80L-630-3) or equivalent and two bolts over RH output shaft opening. Tool will be used later to perform selective thrust washer checks.
No. 19 Needle Bearing Installation:
7. Place case in vertical position. Install No. 19 needle bearing over case boss with flat side facing up, outer lip facing down.
Final Drive Ring Gear:
8. Install final drive ring gear with external splines up. Using a hammer handle if necessary, tap gently to fully seat into case splines.
9. Assemble No. 18 thrust washer to differential assembly using petroleum jelly.
10. Lower final drive assembly into case. Use hammer to gently tap into place.
11. Install snap ring and align opening of snap ring with rear lube transfer tube passage.
12. Perform end clearance check for No. 18 selective thrust washer as follows:
- Place screwdriver under case and pry up.
- Mount Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent with stylus on end of output shaft.
- Back out screw End Play Tool 307-187 (T87P-70014-AH) installed in Step 6 until it no longer touches output shaft.
- Zero dial indicator.
- Tighten screw to 4-5 Nm (36-44 in lb).
- Observe reading on dial indicator.
The clearance should be 0.10-0.40 mm (0.004-0.016 inch). If the clearance is not within specification, selective thrust washers are available in the following thicknesses:
13. After installing the correct thrust washer, check the clearance.
14. Install low and intermediate band into case and align anchor pin pocket with anchor pin.
15. Install No. 15 rear sun gear thrust bearing and race with rear sun gear and drum.
16. Install reverse clutch onto planet assembly.
17. If not already completed, install Reverse Clutch/Planet Assembly Collet 307-314 (T94P-77001-FH) and Remover/Replacer Tube 308-025 (T75L-7025-C) over the front carrier hub. Slide Bearing Collet Sleeve 308-049 (T77F-7025-C) over tube onto collet to hold in place.
18. Use the removal and installation tool to install the reverse clutch assembly and planetary assembly as one unit. Then remove the tool.
NOTE: Align reverse clutch cylinder anchor bolt pocket with anchor bolt case hole.
NOTE: Make sure the reverse clutch cylinder apply tube hole is aligned with case hole upon installation.
19. Start reverse anchor pin bolt and nut but do not tighten at this time.
20. Attach Front Clutch Loading Tool 307-171 (T86P-70389-A) to forward/intermediate/direct clutch assembly.
NOTE: Modify Front Clutch Loading Tool 307-171 (T86P-70389-A) to fit lube holes by removing 0.50 mm (0.02 inch) of material off of each side of tool.
21. Lower assembly into case, front sun shell gear splines into front planet.
CAUTION: Make sure the assembly is fully seated before removing the tool.
22. Remove Front Clutch Loading Tool 307-171 (T86P-70389-A).
23. Tighten screw on End-Play Tool 307-187 (T87P-70014-AH) previously installed to 4-5 Nm (36-44 in lb).
24. Install overdrive band into case.
25. Install overdrive retainer with crosshairs facing up.
26. Perform the following steps to check the driven sprocket end-play clearance for No. 8 selective thickness thrust washers.
No. 8 Thrust Washer And No. 9 Needle Bearing:
27. Remove No. 8 driven sprocket support thrust washer and No. 9 direct clutch hub needle bearing from the driven sprocket support.
Installing No. 9 Clutch Hub Needle Bearing:
28. Separate No. 8 thrust washer and No. 9 thrust bearing. Install No. 9 thrust bearing (only) into transaxle over the output shaft as shown with outer lip up.
Installing Gauge Tube:
29. Install Gauge Tube 307-320 (T94P-77001-MH) over output shaft until fully seated into No. 9 thrust bearing. (This is where the No. 8 thrust washer normally sits.)
30. Place Gauge Bar 307-300 (T94P-77000-Q) across case with round legs of gauge bar resting on chain cover gasket surface of case. Place Depth Micrometer 303-DO75 (D92P-4201-A) or equivalent on gauge bar and measure down to gauge tube. Do this on both sides of output shaft (180° apart). Add both readings, divide by two to obtain reading A.
31. Use reading A to select the correct No. 8 thrust washer from the chart below.
NOTE: Reading A and Dimension C from this chart will be used in selection of No. 5 thrust washer.
32. Remove depth micrometer, gauge bar and gauge tube. Install gauge bar and depth micrometer as shown. Measure down to the No. 5 thrust washer mating surface of overdrive drum. Take another reading down to the No. 5 thrust washer mating surface of overdrive drum on the other side of the shaft (180° apart). Add both readings, divide by two to obtain reading B. Remove gauge bar, depth micrometer and gauge tube from case.
33. Subtract Reading A from Reading B, add difference between A and B to Dimension C. Record this as Reading D.
NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on No. 8 thrust washer selection chart following the selected No. 8 thrust washer.
34. Use Reading D to select the correct No. 5 thrust washer from the chart below.
Installing No.5 Front Support Thrust Washer:
35. Install correct No. 5 driven sprocket support thrust washer on driven sprocket support.
NOTE: Use petroleum jelly to hold washer in place for this step.
No. 8 Thrust Washer And No. 9 Needle Bearing:
36. Install the correct No. 8 driven sprocket support thrust washer and No. 9 direct clutch hub thrust bearing on driven sprocket support. Use petroleum jelly to hold washer and bearing in place.
NOTE: No. 9 direct clutch hub thrust bearing may still be inside transaxle from No. 8 thrust washer selection procedure.
Driven Sprocket Support Assembly:
37. Lightly coat all seals with petroleum jelly before support installation. Install driven sprocket support assembly into case, making sure it is fully seated.
End Play Tool:
38. Remove End Play Tool 307-187 (T87P-70014-AH) and Step Plate Adapter 205-DO14 (D80L-630-3) or equivalent from case.
Parking Pawl Components:
39. Install parking pawl, parking pawl return spring, parking pawl shaft and locator pin.
NOTE: Make sure that the parking pawl engages the park gear and returns freely.
Parking Lever Actuating Rod:
40. Install parking lever actuating rod in case. Install park rod abutment and start abutment bolts. Push in parking pawl and locate rod between parking pawl and abutment.
41. Replace any tubes removed from the case. Install new tubes in position and tap lightly until fully seated.
NOTE: All fluid transfer tubes that were removed from the case must be discarded and replaced with new tubes. The tubes become distorted during removal and will not seal properly when reinstalled. The new tubes have a press fit and are not distorted from prior removal and installation. Do not remove tubes unless it is necessary to service the transaxle. Do not replace the tubes unless they have been removed for servicing.
NOTE: When installing the rear lube tube, install the long end into the rear planet support and seal first.
42. Install tube support brackets.
43. Install manual control lever seal by tapping into case.
44. Start manual control shaft through manual control shaft seal and slide manual detent lever onto manual control shaft.
Manual Control Shaft Removal:
45. Slide manual control shaft through parking lever actuating rod and tap into case hole.
46. Install new manual shaft retaining pin through case hole, aligning with groove in manual control shaft.
Manual Control Shaft Components:
47. Install new roll pins in manual detent lever and parking lever actuating rod.
No. 2 & No. 4 Thrust Washers:
48. Install No. 2 and No. 4 tabbed thrust washers onto drive and drive sprocket supports. Align tabs on thrust washers with holes in sprocket supports. Apply grease to washers to help hold in position.