71 -109

Transaxle Con't

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 springs

Inspect the spring height.
1. Test spring.
. 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.

Overdrive Piston Rod Selection Chart

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.
3. Install the overdrive servo cover and bolts.

81. Install the transmission test plate.

82. WARNING: Wear safety glasses while caring out this procedure to prevent personal input.

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.

Clean and inspect the gasket.

90. NOTE: The main control cover gasket is reusable if not torn or damaged.

Install the main control cover gasket onto the pan.

91. NOTE: The main control cover gasket is reusable if not torn or damaged.

Install the main control cover.

92. 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.

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

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

95. Tighten the reverse clutch anchor bolt.
1. Tighten the anchor bolt.
2. Tighten the locknut.

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

97. Install the fluid pan magnet.

98. NOTE: The gasket is reusable if not damaged or torn. Install the transmission fluid pan and gasket.

99. Install the turbine shaft speed (TSS) sensor.
1. Install the sensor.
2. Install the bolt.
100. Verify that the shift selector lever is in NEUTRAL.