Steps 51-102

51. NOTE: Use petroleum jelly to hold washer in place for this step.

Installing No.5 Front Support Thrust Washer:

Install correct No. 5 thrust washer on driven sprocket support.

No. 8 Thrust Washer And No. 9 Needle Bearing:

52. NOTE: No. 9 thrust bearing may still be inside transaxle from No. 8 thrust washer selection procedure.

Install the correct No. 8 thrust washer and No. 9 thrust bearing on driven sprocket support. Use petroleum jelly to hold washer and bearing in place.

No. 8 Thrust Washer And No. 9 Needle Bearing:

53. Lightly coat all seals with petroleum jelly before support installation. Install driven sprocket support assembly into case, making sure it is fully seated.





54. Install neutral/drive accumulator piston, pin, spring, cover and retaining bolt. Tighten retaining bolt to 11-15 Nm (98-132 inch lbs.).

55. CAUTION: Make sure tubes are firmly seated or they may leak, resulting in improper transaxle operation.





Install new O-rings on the fluid supply tube if removed. Install reverse clutch oil supply tube in position and tap lightly until fully seated.





56. Install new O-rings as necessary and install coast servo apply fluid transfer tube.





57. Install new O-rings as necessary and install low intermediate clutch apply fluid transfer tube.





58. Install new O-rings as necessary and install rear fluid supply transfer tube.





59. Install three lubrication tube support brackets. Tighten bracket bolts to 12 Nm (106 inch lbs.).





60. Install new manual control lever shaft seal using Pinion Bearing Replacer 211-161 (T9OC-3504-DH).





61. Install parking lever actuating rod in case. Push in parking pawl and locate rod between parking pawl and abutment.





62. Slide manual control lever shaft into case and slide manual control lever onto manual control lever shaft. Attach parking lever actuating rod to control lever and tap manual control lever shaft into case hole.

Manual Control Shaft Components:

63. Install three new roll pins in manual valve detent lever and manual control lever and case.





64. Install No. 2 drive sprocket thrust washer and No. 4 driven sprocket thrust washer onto drive and drive sprocket supports. Align tabs on thrust washers with holes in sprocket supports. Apply petroleum jelly to washers to help hold in position.





65. CAUTION: Be careful not to damage or bend exciter tabs on driven sprocket speed sensor wheel. TSS will not operate properly if exciter tabs are bent.

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





66. NOTE: The 1-2 shift accumulator spring must be installed facing down into the chain cover bore (SHO only).

Install accumulator springs previously identified in correct position in case.





67. NOTE: Make sure alignment pins are installed in case.

Install new chain cover gasket on case.





68. 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.





69. CAUTION: Be extremely careful to prevent damage to the input shaft cast iron sealing ring.

NOTE: No. 1 and No. 3 thrust washers installed in previous step must stay installed to case. If accumulator piston shafts fall out of chain cover, reinstall to their bores.

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

70. NOTE: After installing chain cover, input shaft should have some end play and should rotate freely. If it will not rotate freely, remove chain cover and inspect cast iron seal for damage.





Start remaining chain cover bolts. Tighten bolts evenly, working from the center outward.





71. Install remaining chain cover bolts in converter housing. Tighten the two (10 mm socket size) bolts to 24-32 Nm (18-23 ft. lbs.). Tighten the five TORX (R) bolts to 11-13 Nm (98-115 inch lbs.).





72. 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.

Check overdrive servo travel. Install test spring from Overdrive Servo Rod Tool 307-162 (T86P-70023-B) in case.





73. Install overdrive servo piston and overdrive servo rod into case.





74. Install Overdrive Servo Rod Tool 307-162 (T86P-70023-B) and secure using servo cover bolts. Tighten bolts to 9-12 Nm (80-106 inch lbs.). Install Dial Indicator With Bracketry 100-002 (TOOL-4201-C) or equivalent as shown.
75. Tighten center screw on tool to 1.13 Nm (10 inch lbs.). Zero dial indicator.

Overdrive Piston Rod Selection:

76. 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.

77. CAUTION: Test spring for overdrive servo tool is plain-colored. DO NOT assemble the transaxle using the test spring or transaxle may not operate properly.

If overdrive servo travel was incorrect, install new overdrive servo rod and repeat this procedure to verify amount of piston travel. If within specifications, remove tool and test spring.





78. Install overdrive servo cover, piston, rod and spring assembly. Tighten retaining bolts to 9-12 Nm (80-106 inch lbs.).





79. WARNING: WEAR SAFETY GLASSES WHILE PERFORMING THIS PROCEDURE TO PREVENT PERSONAL INJURY.

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. Cover the vent hole in the test plate with a clean, lint-free shop towel to prevent spray when air is applied. Plugging vent hole during testing will result in inaccurate results.

Transmission Test Plate:

Perform air pressure checks using Transmission Test Plate 307-312 (T94P-77001-EH) and Test Plate Mounting Screws 307-126 (T82P-7006-C). After pressure checks have been performed, remove tools.








80. CAUTION: Seals must be lapped correctly or internal leakage will occur.

Install four new Teflon pump shaft rear seals and pump shaft front seals on pump shaft. Install pump shaft.





81. NOTE: Crimped end of link goes through detent lever.

Connect manual control valve actuating rod link to manual valve detent lever.





82. Start pump and main control valve body over pump shaft and connect manual control valve actuating rod to manual control valve. Push main control valve body down until seated.

Pump and Main Control Valve Body Assembly Retaining Bolts:

83. Install 23 main control valve body bolts and tighten in sequence (tighten from center outward) to 9-12 Nm (80-106 inch lbs.).

Transaxle Electrical Connections:

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





85. Clean, inspect and reinstall original main control cover gasket if not damaged and main control cover.
86. Tighten main control cover bolts to 9-12 Nm (80-106 inch lbs.).





87. Use 6 mm Allen wrench to tighten reverse clutch locator to 10-12 Nm (89-106 inch lbs.). Use 19 mm socket to tighten locknut to 34-47 Nm (25-34 ft. lbs.).





88. Install new fluid filter and seal assembly.





89. Install clean ceramic case magnet in transaxle pan in correct location.





90. Clean, inspect and reinstall original pan gasket if not damaged. Tighten transaxle pan retaining bolts to 9-12 Nm (80-106 inch lbs.).





91. Install turbine shaft speed sensor to case using an 8mm socket. Tighten retaining bolt to 10-14 Nm (89-123 inch lbs.).
92. Install transmission range sensor and loosely install two retaining bolts.





93. Use a 9 mm wrench on the manual shaft flats to rotate the shaft counterclockwise to the PARK detent.
94. Rotate two detent positions clockwise to the NEUTRAL detent position.
95. Align TR sensor slots using Digital TR Sensor Alignment Tool 307-351 (T97L-70010-A).





96. Tighten retaining bolts to 9-12 Nm (80-106 inch lbs.). Remove tool.





97. Install fluid filler tube grommet into case, then install fluid filler tube. Tighten bolt to 9-12 Nm (88-106 inch lbs.).





98. Install vehicle speed sensor (VSS). Tighten retaining bolt to 3.4-4.5 Nm (31-39 inch lbs.).





99. Install LH output shaft seal using Output Seal Replacer 307-157 (T86P-1177-B).





100. Install RH output shaft seal using Output Seal Replacer 307-157 (T86P-1177-B) and Output Shaft Seal Replacer Pilot 307-317 (T94P-77001-JH).





101. Install identification tag on case if removed.





102. Install torque converter using Torque Converter Handles 307-091 (T81P-7902-C). Remove torque converter handles.