Steps 54 - 107

54. Use Reading D to select the correct No. 5 thrust washer.

55. Note: Use petroleum jelly to hold the No. 5 thrust washer in place.





Install the No. 5 front support thrust washer.

56. CAUTION: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure. Use petroleum jelly to hold bearing and washer in place.

Install the correct bearing.





1 Install the correct No. 8 driven sprocket support thrust washer.
2 Install the No. 9 direct clutch needle bearing.





57. Install the driven sprocket support assembly.
58. Install the neutral/drive accumulator cover.





1 Install the neutral / drive accumulator piston.
2 Install the neutral / drive accumulator spring.
3 Install the neutral / drive accumulator cover.





59. Install the bolt.

60. Note: All the fluid supply tubes must have new O-rings installed.





Install the fluid supply tubes.





61. Install the brackets.





62. Using the special tool, install the manual control lever shaft seal.





63. Install the parking lever actuating rod.
- Push in on the park pawl.
- Slide down the parking lever actuating rod to fit in the park pawl.

64. Note: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.





Install the manual control lever shaft.

65. Note: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.





Install the roll pins.

66. Note: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.

Install the thrust washers.





1 Install the No. 2 drive sprocket thrust washer.
2 Install the No. 4 driven sprocket thrust washer.

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

Note: Lower the assembly into the sprocket supports simultaneously.





Install the drive chain and sprockets.

68. Install the shift accumulator springs.





1 Install the 1-2 accumulator outer spring.
2 Install the accumulator piston spring.
3 Install the reverse shift accumulator spring.
4 Install the accumulator spring.

69. Note: Make sure that the alignment pins are installed in case.





Install the new chain cover gasket.

70. CAUTION: Be extremely careful not to damage the cast iron sealing ring.

Note: Use petroleum jelly to hold thrust washers in place during assembly.





1 Install the No. 1 thrust washer.
2 Install the No. 2 thrust washer. Install the chain cover.

71. Note: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure.





Start two bolts.





72. Install the remaining bolts.





73. Install the bolts.

74. CAUTION: The test spring from the overdrive servo rod 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.

Inspect the spring height.





1 Test spring.
2 Original spring.

75. Overdrive servo travel check. Install the overdrive servo piston.





1 Install the test spring.
2 Install the overdrive servo piston.





76. Install the special tools.





77. Using the special tools, tighten the center screw and zero out the dial indicator.





78. Using the special tools, back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, see the overdrive specification chart and determine which overdrive servo rod to use.





79. If the overdrive servo travel was incorrect, install a new overdrive servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring.

80. CAUTION: Do not assemble the transaxle using the test spring.

Install the overdrive servo.





1 Install the overdrive servo spring.
2 Install the overdrive servo.
Install the overdrive servo cover and bolts.





81. Install the transmission test plate.

82. WARNING: Wear safety glasses while carrying out 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 the clutch or band applies.

Note: Plugging the vent hole during the test will provide an inaccurate result.








Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate clutch ports.

83. CAUTION: The seals must be lapped correctly or internal leakage will occur.





Install the new Teflon seals on the pump shaft.





84. Install the pump shaft.





85. Install the manual valve detent lever.





86. Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.

87. CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.





Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolt and tighten in sequence.





88. Connect the connectors.

89. Note: The main control cover gasket is reusable if not torn or damaged.





Install the main control cover, gasket and bolts.

90. Note: The transaxle side cover gasket is reusable if not torn or ripped.





For vehicles equipped with a structural side pan, remove the gasket. Clean and inspect the gasket, reinstall into the pan.





91. For vehicles equipped with a structural side pan, install the pan.





92. For vehicles equipped with a structural side pan, install the mount.
93. Tighten the reverse clutch anchor bolt.





1 Tighten the anchor bolt.
2 Tighten the locknut.





94. Install the new seal and gasket kit and seal assembly.





95. Install the oil pan magnet.

96. Note: The gasket is reusable if not damaged or torn.





Install the transmission fluid pan and gasket.
97. Install the Turbine Shaft Speed (TSS) sensor.





1 Install the sensor.
2 Install the bolt.

98. Verify that the shift selector lever is in NEUTRAL.





99. Install the digital TR sensor and loosely install the bolts.





100. Using the special tool, align the digital TR sensor and tighten the bolts.





101. Install the fluid filler tube with a new grommet.





102. Using the special tool install the LH output shaft seal.





103. Using the special tool install the RH output shaft seal.





104. Install the Output Shaft Speed (OSS) sensor and reconnect the harness.





105. Install the Output Shaft Speed (OSS) sensor cover.





106. Install the identification tag, if removed.





107. Using the special tools, install the torque converter.