End Clutch Seal Replacement Procedure

1. Raise the vehicle on a hoist using the proper lift points. Refer to the appropriate service manual for lift point locations.

2. Remove the right front wheel.

Note:
Be sure to mark the position of the valve stem on the hub so the wheel can be reinstalled on the hub in the same position as removed.

3. To gain access to transaxle's end clutch, remove passenger side (right) engine room (wheel well) side cover.





4. Remove the four bolts securing the end clutch cover.





5. Carefully remove the end clutch cover.

Note:
Take care not to damage the 0-ring seal. Check seal carefully for cleanliness, nicks or cuts. Position a drip pan under the end clutch area to contain fluid spillage.

6. Swing the end clutch cover out of the way using a hook made from a coat hanger. It may be necessary to release the pulse generator wire harness from the wire clips.

CAUTION:
Do not let the end clutch cover hang by the pulse generator harness.





7. Remove the end clutch assembly.

CAUTION:
Do not wipe the transaxle or components with cotton or other lint producing fabric. Premature failure of the transaxle is possible due to contamination.





8. Remove the thrust washer.





9. Remove the end clutch hub.

10. Remove the thrust bearing.

Note:
The thrust bearing may stick to the backside of the end clutch hub when removed.





11. Remove the end clutch oil seal by pushing the seal from the back of the end clutch assembly through the opening in the front. Using a flat bladed screwdriver, tap on the seal to remove it.





12. Fabricate an installation tool to insert the new seal into the end clutch assembly.

Tool: M10 bolt, M10 flange nuts (2). Assemble as shown.

CAUTION:
Threads must be below the end of the flange nut. Exposed threads will damage the end clutch seal lip and possibly cause extensive transaxle damage.





13. On a clean table, place a block under the center boss of the end clutch assembly. Approximate size of the block should be 90 mm wide and more than 8 mm thick. The block should be able to support the center section of the end clutch assembly.





14. Lubricate the seal with ATF. Place the new oil seal into position. The face with the shoulder should be facing up.





15. Gently but firmly install the new seal into position by tapping all around the special tool with a hammer. Work the seal into place gradually, keeping it straight. If the seal is allowed to cock to one side, the seal may fail later.





16. The seal is fully installed when the bottom of the oil seal seats against the end clutch inner ledge.


17. Place the thrust washer onto the end clutch. Be sure to align the tangs with the grooves.





18. Install the end clutch hub into the end clutch assembly.

Note:
Make certain the hub is fully installed into the clutch.





19. Place the thrust bearing on the end of the clutch hub with the rolled edge facing the clutch hub. If necessary, the bearing may be retained by using a small "dab" of petrolatum.

CAUTION:
The thrust bearing is fragile. Handle carefully.





20. Install the end clutch assembly onto the input shaft.








21. Measure the distance from the transaxle case to the outer edge of the end clutch assembly. Make certain that the end clutch protrudes no further than is specified in the table.





22. Check the end clutch cover O-ring for damage, position and cleanliness. Be certain the O-ring is fully seated in the groove along the edge of the cover.





23. Install the end clutch cover onto the transaxle. Be sure to properly torque the four bolts. Be sure to tighten the bolts evenly to prevent damage to the O-ring. DO NOT OVER-TIGHTEN!

Torque specifications:
F4A21, F4A22, and F4A23 =
7 N-m or 5 ft.lbs.

F4A32, F4A33, W4A31, W4A32, and
W4A33 = 11 N-m or 8 ft.lbs.

Note:
Uneven or over-tightening may cause O-ring failure.

24. If the pulse generator wire harness clips were released to gain clearance for the end clutch removal, be sure to reclip the harness into the clips.

25. Reinstall the engine room side cover.

26. Reinstall the right front wheel and tighten the lug nuts to the proper torque.

Note:
Be sure to align the valve stem with the mark on the hub.

27. Check transaxle fluid level.

28. Road test the vehicle to ensure proper operation of the transaxle. Check for signs of transaxle fluid leaks around 0-ring seal and on the ground under the vehicle.





29. Using a permanent marker, place a black mark on the transmission case at the location indicated on the diagram.