Part 2 Of 2

41. NOTE: The new clutch plates must be installed in the following order. Do not install the wave spring at this time.

Install a steel plate, a friction plate, a second steel plate, a second friction plate, a third friction plate, a third steel plate and the pressure plate.







42. Install the forward clutch snap ring.







43. Install the special tool. Zero out the special tool.







44. Lift up on the clutch plates by inserting a screwdriver in the clutch pack and record the measurement. Enter this measurement in the following table on the line labeled A.

45. NOTE: The specification for the clearance between the bottom of the snap ring and the top of the steel clutch plate is 1.39-1.68 mm (0.055-0.066 inch).

Selecting selective snap ring.

Forward Clutch Selective Snap Ring:

- Add line A to B, then subtract line C and enter this total on line D.
- Line D is the actual clearance with the snap ring used during this measurement.
- If the final measurement (D) is not within the specification, install a new selective snap ring (either thicker or thinner) until the clearance specification is achieved.







46. Remove the forward clutch pack snap ring.







47. Remove the forward clutch plates: steel and friction.







48. Install the forward clutch wave spring.







49. Install the forward clutch plates: steel and friction, alternating between steel and friction, starting with a steel plate.







50. Install the forward clutch pressure plate.







51. Install the forward clutch pack snap ring.







52. Install the forward clutch roller cage bearing.







53. NOTE: This is a selective fit washer for the input shaft set up.

Install the forward clutch upper bearing washer.







54. Install the forward clutch upper roller bearing.







55. Install the new O-ring seals.







56. Install the input shaft and a new planet carrier thrust washer.







57. Install the differential assembly in the case.







58. Install the bearing race onto the differential assembly.







59. Compress the special tool and hand-tighten the bolt.







60. Install the special tools onto the case.







61. Position the case onto the special tools and install the bolts.
- Tighten to 8 Nm (71 lb-in).







62. Loosen the top bolt of the special tool. Using feeler gauge measure the opening.

Differential Bearing Race Selective Shim (Part 1):

Differential Bearing Race Selective Shim (Part 2):

63. Measure the thickness of the bearing shim that came out when the race was removed. The thickness of the bearing shim should match the measured opening of the special tool. If the measurements do not match use a new selective bearing race shim.







64. Install the selective bearing race shim into the housing.







65. Position the new bearing race in place.







66. Install the special tools.







67. Install the special tools. Using the special tools, install the bearing race.







68. Install a new converter housing gasket.







69. NOTE: This is not a final torque. For this step only you can reuse the old bolts that were removed.

Position the converter housing in place. Install only 8 bolts evenly around the case to do the input shaft end play. It may be necessary to remove the install the correct shim. Tighten the bolts in a crisscross sequence.
- Tighten bolts to 8 Nm (71 lb-in).







70. Install the special tool to measure the input shaft end play.
- Tighten the wing nut.







71. Install the remaining special tool.
- Push down on the special tool and zero out the dial indicator.
- Lift up on the special tool and record the measurement 0.22-0.53 mm (0.008-0.021 inch) If the measurement is not within specification install a new input shaft bearing spacer.







72. NOTE: Once the input shaft end play is complete and it is within specification, install new bolts.

Position the converter housing in place. Install new converter housing bolts and tighten in 2 stages. Tighten the bolts in a crisscross sequence.
- Stage 1: Tighten bolts to 8 Nm (71 lb-in).
- Stage 2: Tighten bolts 90 degrees.







73. Install the side shaft gear assembly.
- Tighten to 23 Nm (17 lb-ft).







74. Position the output shaft seal in place.







75. Using the special tool, install the output shaft seal.







76. Position the output shaft seal in place.







77. Using the special tool, install the output shaft seal.







78. Install new O-ring seals on the feed tubes.
1 Install new O-ring seals on the inside and outside clutch (manual valve) supply feed tube.
2 Install new O-ring seals on the primary pressure feed tube.
3 Install new O-ring seals on the secondary pressure feed tube.
4 Install new O-ring seals on the main (pump) pressure feed tube (smaller tube).







79. CAUTION: Lubricate all of the O-ring seals with clean CVT automatic transmission fluid. Be careful not to nick, cut or damage the O-ring seals when installing the mechatronic assembly or internal damage to the transaxle will occur.

NOTE: Note the location of the 5 feed tubes.

Lubricate the seals with clean transmission fluid and install all of the feed tubes into the case.
1 Align the inner tube and install the clutch (manual valve) supply feed tube.
2 Install the primary pressure feed tube.
3 Install the secondary pressure feed tube.
4 Install the main (pump) pressure feed tube (smaller tube).
5 Install a new torque converter clutch pressure feed tube.







80. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

NOTE: The transmission control module (TCM) is integrated into the mechatronic assembly. If installing a new transaxle or a mechatronic assembly, the TCM will need to be checked and recalibrated (reflashed) to the latest level calibration available.

Position the mechatronic unit onto the case.







81. Tighten the mechatronic bolts in 2 stages.
- Stage 1: Tighten the bolts in the sequence shown to 5 Nm (44 lb-in).
- Stage 2: Tighten the bolts in the sequence shown 40 degrees (1/8 turn).







82. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Install the electrical connector into the case.







83. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

Rotate the outer shell connector in place and install the bolt.
- Tighten to 6 Nm (53 lb-in).







84. CAUTION: The output shaft speed (OSS) sensor has a spacer under the sensor for the bolt. This is used for keeping a specific distance from the differential gears.

Install the OSS sensor spacer, sensor and bolt.
- Tighten to 8 Nm (71 lb-in).







85. Connect the electrical connectors.







86. CAUTION:
- Make sure that the fluid filter pickup tube seal has been removed from the bore when the filter was removed. Failure to remove the seal prior to installing the new filter will result in transaxle failure.
- Make sure that the transmission fluid filter is fully seated into the bore. If the filter is not correctly installed, internal transaxle damage will occur.

Install a new fluid filter.







87. Make sure that the filter is seated over one of the mechatronic bolts.







88. Install a new transaxle fluid pan gasket.







89. Make sure that the magnets in the pan are in the correct location prior to installing the transmission fluid pan.







90. Install the transaxle fluid pan. Tighten the bolts in the sequence indicated.
- Tighten to 12 Nm (9 lb-ft).







91. CAUTION: Do not set the torque converter in the pump housing and rotate the torque converter to get it to fall into place or damage to the torque converter seal will occur.

Note the location of the index slot in the pump for the correct installation of the torque converter. The tab on the torque converter must correctly line up with the slot on the pump.







92. Making sure that you have the tab on the torque converter lined up with the slot on the pump, use the special tool to install the torque converter.







93. Using 4 new retainers, install the transaxle insulator.







94. Install a new fluid tube indicator grommet.







95. Install the fluid level indicator and tube.
- Tighten to 10 Nm (89 lb-in).

96. Clean the roll restrictor bolts using a wire brush and apply new Threadlocker to the threads.







97. Position the transaxle mount in place and install the upper retaining bolts.
- Tighten to 55 Nm (41 lb-ft).