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Transaxle Con't31. Use Reading D to select the correct No. 5 thrust washer.
No. 5 Support Thrust Washer Chart
32. NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
Install the No. 5 front support thrust washer.
33. 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.
1. Install the correct No. 8 driven sprocket support thrust washer.
2. Install the No. 9 direct clutch needle bearing.
34. Remove the special tools.
35. Install the driven sprocket support assembly.
36. 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.
37. Install the parking lever actuating rod.
38. NOTE: All the fluid supply tubes must have new O-rings installed. Install the fluid supply tubes and brackets.
39. Using the special tool, install the manual control lever shaft seal.
40. 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.
41. 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.
42. 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.
43. Install the shift accumulator springs.
1. Install the drive shift accumulator spring (green).
2. Install the 3-4 accumulator springs.
^ The outer spring is yellow.
^ The inner spring is white.
3. Install the 1-2 accumulator springs (no color).
44. Install the new chain cover gasket.
45. CAUTION: Be extremely careful not to damage the cast iron sealing ring.
NOTE: Make sure that the alignment pins are installed in the case.
NOTE: Use petroleum jelly to hold thrust washers in place during assembly.
Install the chain cover with the No. 3 and No. 1 thrust washers installed.
46. 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.
47. Tighten the bolts in the sequence shown.
48. Using the special tool, install the seal.
49. Install the bolts.
50. Tighten the reverse clutch anchor bolt.
1. Tighten the anchor bolt.
2. Tighten the locknut.
51. Install the filter.
52. Install the magnet.
53. NOTE: The fluid pan gasket is reusable if not damaged.
Install the fluid pan and gasket.
54. CAUTION: The test spring from the overdrive servo rod tool is plain in color and teas 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.
55. Overdrive servo travel check. Install the overdrive servo piston.
^ Using the special tool, install the overdrive servo piston.
56. Install the special tools.
57. Tighten the center screw and zero out the dial indicator.
58. 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, refer to the overdrive specification chart and determine which overdrive servo rod to use.
59. If the overdrive servo travel was incorrect, install a new overdrive servo piston and rod assembly. 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 and Rod Assembly Selection Chart
60. CAUTION: The test spring from the low/intermediate servo is plain in color and has a thinner wire diameter than the original spring. Extreme care must be used not to assemble the tensile using the test spring.
Install the low and intermediate servo spring retainer on the test spring. Install the test spring into the transaxle case.
1. Test spring.
2. Original spring.