Part 1 of 2

Transaxle








Special Tool(s)





1. Install the parking pawl assembly.
1 Install the parking pawl and return spring.
2 Install the parking pawl shaft.





2. Install the park pawl roll pin.





3. Using the special tool, install the cup plug.





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

Install the stator support.





5. Install the stator support bolts.





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





7. Install the differential carrier thrust bearing.
1 Install the differential carrier thrust washer.
2 Install the differential carrier thrust bearing and race (tabs down).





8. Install the final drive ring gear.





9. Install the rear planet support spacer.





10. Install the final drive differential assembly.





11. Align the rear lube tube holes in the case window.








12. NOTE: The retaining ring must be correctly installed.

Using the special tool install the beveled retaining ring.





13. CAUTION: If support is not visible on inside diameter of the retaining ring the low/intermediate piston could be damaged.

Make sure that the beveled retaining ring seats correctly in case groove with the bevel down and final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall.





14. Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove.





15. Install the special tools.





16. Remove the No. 15 needle bearing.





17. NOTE: The dial indicator extension rod must set on the No. 15 bearing surface.

Install the special tools.





18. Install the special tools and zero the dial indicator.





19. Tighten the bolt.





20. Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification the next larger beveled ring retainer will need to be used.








21. Select the correct beveled retaining ring.





22. NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer.

Install the No. 15 thrust bearing.





23. Check the clearance for the No. 16 thrust washer. Mount the Dial Indicator with the stylus on the end of the output shaft. Zero the dial indicator.





24. Tighten the bolt. Read and record the dial indicator reading.





25. NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.

If the clearance is not within specification a thicker or thinner washer will need to be added.





No. 16 Thrust Race (Washer)





26. Install the low-intermediate one-way clutch assembly.





27. NOTE: The friction plate internal splines will center the one-way clutch.

Install the low-intermediate clutch pressure plate.
1 Install the low-intermediate clutch wave spring.
2 Install the low-intermediate clutch pack.
3 Install the low-intermediate clutch pressure plate.





28. CAUTION: Make sure that the retaining ring is seated in the case groove.

Install the low-intermediate clutch retaining ring.





29. WARNING: To prevent injury, wear eye protection when using pressurized air.

NOTE: Be sure the pressurized air is dry and regulated at 276 kPa (40 psi).

Apply regulated air pressure to the low-intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal.





30. Measure the clearance between the clutch pressure plate and the low-intermediate clutch retainer. If the clearance is not within specification a thicker or thinner retainer may be needed.







Selective Retaining Rings





31. Install the coast band.
1 Install the coast band.
2 Align the anchor pin pocket with the anchor pin in the case.





32. Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.





33. Install the park rod abutment and make sure that the park pawl moves freely.





34. Install the coast band piston cover.
1 Install the coast band servo piston spring.
2 Install the coast band servo piston.
3 Install the coast band servo piston cover.





35. Using the special tool, install the coast servo cover retaining ring.





36. Using the special tools, install the front planetary/reverse clutch assembly.





37. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.





38. Loosely install the reverse clutch anchor pin.





39. Using the special tool install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.





40. Install the overdrive band.





41. NOTE: The foot of the overdrive retainer goes down against the band.

Install the overdrive band anchor strut with the cross hairs facing up.





42. 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.





43. Install only the No. 9 needle bearing with the outer lip UP.





44. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.





45. Install the special tool to make the measurements.





46. When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by two to obtain reading A.





47. NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.

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






48. Remove the special tools.





49. Install the special tools to make the measurements.





50. Measure down to the No. 5 thrust washer mating surface of the overdrive drum. Take another reading on the other side of the drum 180 degrees from the first one. Add both readings and divide by two to obtain reading B.





51. Remove the special tools.





52. 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 and add the difference between A and B to dimension C. Record this reading as D.

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




No. 5 Support Thrust Washer Chart





54. NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.

Install the No. 5 front support thrust washer.





55. 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.