Part 2 of 2

Drive Chain And Sprockets:

49. Install drive chain on drive sprocket and driven sprocket. Lower assembly into sprocket supports simultaneously with drive chain parallel to case surface, rotating sprockets to make sure that they are fully seated.

CAUTION: Be careful not to damage or bend tabs on exciter ring.





50. Install No. 1 and No. 3 thrust washers on chain cover. Use petroleum jelly to hold in place. Make sure tabs align with slots in chain cover.
51. Install new chain cover gasket on case.

Accumulator Springs:

52. Install accumulator springs in correct position in case.
53. Make sure chain cover alignment pins are on case.





54. Carefully align chain cover turbine shaft bore with turbine shaft. Apply gentle downward pressure on chain cover to overcome accumulator spring pressure and start two chain cover bolts.

CAUTION: Be extremely careful to prevent damage to the turbine shaft front seal (cast iron).





55. NOTE: After installing chain cover, turbine shaft should have some end play and should rotate freely. If it will not rotate freely, remove chain cover and inspect turbine shaft front seal (cast iron) for damage. Install remaining chain cover bolts. Tighten bolts as illustrated starting from the inside.

Turbine Shaft Speed Sensor:

56. Install Turbine Shaft Speed (TSS) sensor to case. Tighten retaining bolt to 9-11 Nm (80-97 in lb).





57. Install LH output shaft seal using Differential Seal Replacer 307-157(T86P-1177-13).

Chain Cover Bolts:

58. Install remaining chain cover bolts in bellhousing. Tighten (10 mm socket) bolts to 25-28 Nm (19-20 ft lb). Tighten (8 mm socket) bolts to 9-12 Nm (80-106 in lb).

Reverse Drum Anchor Bolt:

59. Tighten 6 mm Allen-head reverse drum anchor bolt to 10-12 Nm (89-106 in lb) and 19 mm locknut to 34-47 Nm (25-34 ft lb).





60. Install fluid filter seal onto fluid filter and press fluid filter into case.

Transmission Pan Magnet:

61. Install pan magnet in transaxle pan.
62. Clean, inspect and install original pan gasket on case if not damaged and install transaxle pan. Tighten bolts to 12 Nm (106 in lb).

Operating And Test Springs:

63. Install test spring from Overdrive Servo Rod Tool 307-162 (T86P-70023-B) in case.

CAUTION: The test spring from the Overdrive Servo Tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.





64. Install overdrive servo piston and overdrive servo rod into case.
65. Install Overdrive Servo Rod Tool 307-162 (T86P-70023-B) and secure using servo cover bolts. Tighten bolts to 9-12 Nm (80-106 in lb).
66. Tighten center screw on tool to 1.13 Nm (10 in lb).

Dial Indicator:

67. Mount Dial Indicator with Bracketry 100-002 (TOOL-4201-Q) or equivalent and position stylus through hole in Overdrive Servo Rod Tool. Make certain indicator stylus has contacted overdrive servo piston on a flat surface. DO NOT contact step on piston. Zero dial indicator.





68. Back off center screw until piston movement stops and read dial indicator. The reading should be 1.8-3.8 mm (0.070-0.149 inch). If measurement does not meet specifications, refer to overdrive piston rod selection chart to determine which overdrive servo rod to install.
69. Install new overdrive servo rod and repeat Steps 77 through 80 to verify amount of piston travel. If within specification, remove tool and test spring.
70. Install low and intermediate servo spring retainer on test spring, from Low/Intermediate Servo Rod Tool 307-161 (T86P-70023-A). Install test spring into case.

CAUTION: The test spring from the Low/Intermediate Servo Rod Tool is plain in color and has a thinner wire diameter than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.





71. If not done prior, remove servo piston small seal from servo band piston. Install servo band piston and rod into case.
72. Install Low/Intermediate Servo Rod Tool 307-161 (T86P-70023-A) and secure using servo cover bolts. Tighten bolts to 9-12 Nm (80-106 in lb).
73. Tighten center screw on tool to 3.4 Nm (30 in lb).

Dial Indicator:

74. Mount Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent and position stylus through hole in Low/Intermediate Servo Rod Tool. Make certain indicator stylus has contacted servo band piston on a flat surface. Do not contact step on Servo band piston. Zero dial indicator.





75. Back off center screw until piston movement stops and read dial indicator. The reading should be 5.5-6.5 mm (0.216-0.255 inch). If measurement does not meet specifications, refer to low/intermediate servo rod selection chart to determine which rod to install.

NOTE: If a new low and intermediate band is installed, reading should be 5-6 mm (0.197-0.236 inch).

76. Install new piston rod and repeat Steps 71 through 74 to verify amount of piston travel. If within specifications, remove tool and test spring. Remove retainer from test spring.
77. Install servo piston small seal on servo band piston. Install low and intermediate servo spring retainer on low/intermediate operating spring.

CAUTION: The test spring from the Low/Intermediate Servo Rod Tool is plain in color and has a thinner wire diameter than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.

Operating And Test Springs:

78. Install servo piston springs and servo band pistons. Make sure that they are fully seated.

CAUTION: The test spring from the Overdrive Servo Tool is plain in color and has a shorter free height than the operational spring. Extreme care must be used not to assemble the transaxle using the test spring.








79. Install servo covers for overdrive and low/intermediate servo using new gaskets and seals. Tighten bolts evenly to 9-12 Nm (80-106 in lb).

CAUTION: Tighten bolts two or three turns at a time to prevent cocking servo covers.

NOTE: Be sure to align tab on servo cover with port on case.

Speedometer Drive Gear Components:

80. Install speedometer driven gear retainer and shaft. Install speedometer drive gear and shaft making sure that slots in gear align with roll pin in shaft. Install speedometer thrust bearing and race.

Speedometer Cover And Components:

81. Install speedometer cover with new seal. Tighten bolts to 9-12 Nm (80-106 in lb).





82. Perform air pressure checks using Transmission Test Plate 307-239 (T91P-7006-A). After pressure checks have been performed, remove tool.

NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when clutch or band is applied.





83. Install pump shaft.





84. Connect manual valve link to manual detent lever.
85. Start pump assembly and main control valve body over pump shaft and connect manual valve link to manual shift valve. Push main control valve body down until seated.

Pump Assembly And Main Control Valve Body Bolt Installation Sequence:

86. Install main control valve body bolts and tighten in sequence to 9-12 Nm (80-106 in lb).





87. Install electrical connectors on proper solenoids and sensor until a slight click is felt.





88. Clean, inspect and install original main control cover gasket if not damaged onto main control cover.
89. Install main control cover and tighten to 12 Nm (106 in lb).
90. Rotate transaxle to horizontal position.
91. Place manual lever in the NEUTRAL position.
92. Install digital Transmission Range (TR) sensor and loosely install two retaining bolts.
93. Align TR sensor slots using Transmission Range Sensor Alignment Tool 307-351 (T97L-7001O-A).





94. Tighten retaining bolts to 9-12 Nm (80-106 in lb). Remove tool.





95. Install fluid level indicator seal onto fluid level indicator, then install fluid level indicator into fluid filler tube. Attach fluid filler tube to case. Tighten bolt to 9-12 Nm (80-106 in lb).





96. Install torque converter.