Steps 1-30
MAJOR COMPONENT ASSEMBLY- Tools Required
- KM 674 Oil Seal Installer
Assembly Procedure
1. Clean components using a clean, high-quality parts cleaning solvent and use compressed air to dry all parts. Inspect all parts for damage or wear.
Notice: Apply TOTAL FLUID HX to the seal ring.
Notice: Do not spread the seal ring ends more than necessary.
2. Install a new seal ring on the transaxle housing.
Notice: Press the bearing until it touches the housing.
3. Using a suitable press, install the bearing in the transaxle housing.
4. Install the magnets on the oil reserver plate.
5. Install the oil reserver plate.
- Tighten the bolts to 35 - 62 inch lbs. (4 - 7 mm).
Caution: Do not bend or damage the tube.
6. Install the lubricant apply tube.
- Using a plastic hammer, tap the tube into place.
7. Install the apply tube clamp and bolt.
Notice: Apply TOTAL FLUID HX to the O-rings and the piston bore.
8. Install new O-rings on the underdrive brake accumulator cover and the underdrive brake accumulator piston.
9. Install the accumulator piston spring, the underdrive brake accumulator piston and the underdrive brake accumulator cover.
10. Install the underdrive brake accumulator bracket, the spring guide sleeve, the spring and the two bracket bolts.
- Tighten the bolts to 71 - 106 inch lbs. (8 - 12 Nm).
Notice: Apply TOTAL FLUID HX to the seal rings.
Notice: Do not spread the seal ring ends more than necessary.
11. Install new seal rings of the underdrive clutch drum.
12. Install the underdrive one-way clutch.
13. Install the underdrive one-way clutch outer race retainer as shown.
14. Install the snap ring.
Notice: Align the brake band with the position of the anchor bolt.
15. Install the underdrive brake band.
Notice: Apply TOTAL FLUID HX to the O-ring.
16. Install a new O-ring on the anchor bolt. Install the anchor bolt.
- Tighten the bolt to 98 - 147 ft. lbs. (133 - 200 Nm).
Notice: Apply TOTAL FLUID HX fluid to the O-rings.
17. Install new O-rings on the underdrive brake piston and the underdrive brake piston cover.
Notice: Set the piston rod in the brake band depression.
18. Install the spring and underdrive brake piston.
19. Install the underdrive brake piston cover and the snap ring.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR INJURY MAY RESULT.
20. Inspect the underdrive brake piston stroke.
- Measure the brake piston stroke by applying compressed air into the passage shown. The piston stroke should be 5.48 - 7.02 mm. If the stroke is not within specifications, replace the piston rod with a longer one.
21. Install the counter drive gear into the transaxle case.
22. Install the snap ring.
Notice: Apply Transjel Assembly Lubricant J-36850 or equivalent to the thrust washer before installing.
23. Install the thrust washer and the underdrive clutch.
- Make sure the underdrive clutch turns freely counterclockwise and locks clockwise.
Notice: Apply Transjel Assembly Lubricant J-36850 or equivalent to the thrust washer before installing.
24. Install the thrust washer.
Notice: Apply Transjel Assembly Lubricant J-36850 or equivalent to the thrust washer before installing.
25. Install the thrust bearing to the rear side of the underdrive planetary gear. Install the planetary gear.
- Make sure the counterdrive and counterdriven gear rotate smoothly.
- Align the teeth of the clutch friction plates before installing the planetary gear.
Notice: Apply Transjel Assembly Lubricant J-36850 or equivalent to the thrust washer before installing.
Notice: Make sure the roller bearings are facing up.
26. Install the thrust washer and bearing.
Caution: Do not bend or damage the tube.
27. Install the lubricant apply tube.
- Using a plastic hammer, tap the tube into place.
28. Install the oil reserver plate.
- Tighten the bolts to 35 - 62 inch lbs. (4 - 7 Nm).
29. Install the oil finer.
- Tighten the bolt to 35 - 62 inch lbs. (4 - 7 Nm).
30. Install the transaxle case plate.
- Tighten the bolt to 35 - 62 inch lbs. (4 - 7 Nm).
Notice: Apply TOTAL FLUID HX to the seal and seal bore.