Steps 1 - 43

Special Tools:

Special Tools:

Special Tools:

1. Using the special tools, install the drive sprocket bearing, if it was removed.

2. Note: The bolt holes are offset and the drive sprocket can only be aligned one way.





Install the driven sprocket support.





3. Install bolts.





4. Using the special tool, install the converter impeller hub seal.





5. Using the special tools, install the right hand output shaft seal.





6. Install the special tool.





7. Install the No. 19 thrust bearing.





8. Install the final drive ring gear.





9. Install the final drive differential assembly and snap ring. Align the opening of the snap ring with the lube transfer tube passages.





10. Install the special tool.





11. Using the special tools installed, carry out the end clearance check.
- Pry up on the bottom of the final drive assembly.
- Back out the screw on the End Plate Gauge until it no longer contacts the output shaft.
- Zero out the dial indicator.
- Tighten the screw on the bottom of the End Plate Gauge to 5 Nm (44 inch lbs.).
- Record the reading on the dial indicator.

1 The clearance should be within specification; if it is not within specification a selective thrust washer is available. Refer to the No. 18 selective thrust washer chart.





No. 18 Selective Thrust Washers





12. Install the low and intermediate band. Align the anchor pin pocket with the anchor pin.





13. Install the No. 15 rear sun gear thrust bearing and race, and the rear sun gear and drum.





14. Install the reverse clutch onto the planet assembly.





15. Assemble the special tools onto the planet assembly.





16. Using the special tools, install the planet and reverse clutch assembly.





17. Loosely install the reverse anchor pin and bolt.





18. Install the special tools onto the front sun and shell assembly.





19. Install the front sun shell assembly.





20. Install the overdrive band.





21. Install the plastic overdrive retainer.
22. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.





1 Remove the No. 9 bearing and race.
2 Remove the No. 8 sprocket support.





23. Install only the No. 9 needle bearing with the outer lip up.





24. Install the special tool.





25. Using the special tools, record the measurement. Take a measurement on both sides of the output shaft (180 degrees apart). Add both readings and divide by two to obtain reading A.

26. Note: Reading A and dimension C from this chart will be used in the selection of the No. 5 thrust washer.

Use reading A to select the correct No. 8 thrust washer from the No. 8 selective thrust washer chart.





No. 8 Selective Thrust Washer Chart





27. Remove the special tools.





28. Using the special tools, record the measurement. Take a measurement on both sides of the No.5 thrust washer mating surface of the overdrive drum (180 degrees apart). Add both readings, divide by two to obtain reading B.

29. Note: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.





Subtract reading A from reading B add the difference between A and B to dimension C. Record this reading as D.
30. Use Reading D to select the correct No. 5 thrust washer.








No. 5 Support Thrust Washer Chart

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





Install the No. 5 front support thrust washer.

32. CAUTION: The No. 9 direct hub needle bearing Inky 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.





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





33. Remove the special tools.





34. Install the driven sprocket support assembly.
35. Install the park pawl abutment.





1 Install the parking pawl and the return spring.
2 Install the parking pawl shaft.
3 Install the park pawl abutment.
4 Install the bolts.





36. Install the parking lever actuating rod.

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





Install the fluid supply tubes and brackets.





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

39. Note: Prior to installing the roll pins be sure that the manual control valve detent lever is pointing toward the driven sprocket support.

Install the manual control lever shaft.





1 Install the manual control lever shaft.
2 Install the manual valve detent lever.
3 Install the parking lever actuating rod.
4 Install the new roll pins.

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





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

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

Note: Lower the assembly into the sprocket supports simultaneously.





Install the drive chain and sprockets as an assembly.
42. Install the shift accumulator springs.





1 Install the drive shift accumulator spring.
2 Install the 3-4 accumulator spring.
3 Install the 1-2 accumulator spring.





43. Install the new chain cover gasket.