Steps 1-50
Special Tools:
Assembly
1. Position case in horizontal position.
2. NOTE: Bolt holes are offset. Driven sprocket can only be aligned one way. Drain hole points downward.
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(R) bolts and tighten to 7-9 Nm (62-79 inch lbs.).
3. Clean filter with compressed air and install.
Converter Hub Seal Installation:
4. NOTE: After installation, verify presence of garter spring on seal.
Install converter impeller hub seal using Converter Hub Seal Replacer 307-186 (T87L-77837-AH) and dead blow (lead-filled) hammer.
5. Install RH differential seal using Output Seal Replacer 307-157 (T86P-1177-B) 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-D014 (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. NOTE: After completing end clearance check, back off screw on tool and leave tool in position for No.5 and No.8 selective thrust washer clearance check to be performed later.
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 inch lbs.).
^ 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.
Installing Remover/Replacer Tube:
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. 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.
Use the removal and installation tool to install the reverse clutch assembly and planetary assembly as one unit. Then remove the tool.
19. Start reverse anchor pin bolt and nut but do not tighten at this time.
20. 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.
Attach Front Clutch Loading Tool 307-171 (T86P-70389-A) to forward/intermediate/direct clutch assembly.
21. CAUTION: Make sure the assembly is fully seated before removing the tool.
Lower assembly into case, front sun shell gear splines into front planet.
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 inch lbs.).
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.)
Reading A:
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-D075 (D92P-4201-A) or equivalent on gauge bar and measure down to gauge tube. Do this on both sides of output shaft (180 degrees apart). Add both readings, divide by two to obtain reading A.
31. NOTE: Reading A and Dimension C from this chart will be used in selection of No. 5 thrust washer.
NO. 8 SELECTIVE THRUST WASHER:
Use reading A to select the correct No. 8 thrust washer from the chart below.
Reading B:
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 degrees apart). Add both readings, divide by two to obtain reading B. Remove gauge bar, depth micrometer and gauge tube from case.
33. 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.
Subtract Reading A from Reading B add difference between A and B to Dimension C. Record this as Reading D.
No.5 Thrust Washer Selection Chart:
34. Use Reading D to select the correct No. 5 thrust washer from the chart provided.
Installing No.5 Front Support Thrust Washer:
35. NOTE: Use petroleum jelly to hold washer in place for this step.
Install correct No. 5 driven sprocket support thrust washer on driven sprocket support.
No. 8 Thrust Washer And No. 9 Needle Bearing:
36. NOTE: No. 9 direct clutch hub thrust bearing may still be inside transaxle from No. 8 thrust washer selection procedure.
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.
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.
38. Remove End Play Tool 307-187 (T87P-70014-AH) and Step Plate Adapter 205-D014 (D80L-630-3) or equivalent from case.
39. NOTE: Make sure that the parking pawl engages the park gear and returns freely.
Install parking pawl, parking pawl return spring, parking pawl shaft and locator pin.
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. NOTE: Inspect the lube tubes for damage. If damaged or distorted, the lube tubes should be replaced.
NOTE: The reverse lube tube should be replaced whenever tube is removed.
NOTE: Any time the lube tubes are removed the lube tube seals must be replaced.
Install new lube tube seals. Install tubes in position and tap lightly until fully seated.
1 Of 2:
2 Of 2:
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.
Removing Manual Control Shaft:
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.
49. CAUTION: Be careful not to damage or bend tabs on exciter ring.
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.