Steps 51-104

51. Remove the Gauge Bar and the Depth Micrometer.





52. Remove the Gauge Tube.





53. Install the Gauge Bar and Depth Micrometer to make the measurements.





54. 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.





55. Remove the Gauge Bar and the Depth Micrometer.





56. 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 add the difference between A and B to dimension C. Record this reading as D.
57. Use Reading D to select the correct No. 5 thrust washer.





No. 5 support Thrust Washer Chart





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

Install the No. 5 front support thrust washer.





59. 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 No. 8 driven sprocket support thrust washer and the No. 9 direct clutch needle bearing.





60. Install the driven sprocket support assembly.





61. Install the neutral/drive accumulator cover.
1 Install the neutral/drive accumulator piston.
2 Install the neutral/drive accumulator spring.
3 Install the neutral/drive accumulator cover.





62. Install the bolt.





63. NOTE: All the fluid supply tubes must have new O-rings installed.

Install the fluid supply tubes.





64. Install the brackets.





65. Install the manual control lever shaft seal using the Pinion Bearing Replacer.





66. Install the parking lever actuating rod.
^ Push in on the park pawl.
^ Slide down the parking lever actuating rod to fit in the park pawl.





67. Install the manual control lever shaft.
1 Install the manual control lever.
2 Install the manual valve detent lever.
3 Install the parking lever actuating rod.
4 Install the new roll pins.





68. 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.





69. CAUTION: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate properly if the tabs are bent.

NOTE: Lower the assembly into the sprocket supports simultaneously.

Install the drive chain and sprockets.





70. Lnstall the shift accumulator springs.
1 Install the 1-2 accumulator outer spring.
2 Install the accumulator piston spring.
3 Install the reverse shift accumulator spring.
4 Install the accumulator spring.





71. NOTE: Make sure that the alignment pins are installed in case.

Install the new chain cover gasket.





72. CAUTION: Be extremely careful not to damage the cast iron sealing ring.

NOTE: Use petroleum jelly to hold thrust washers in place during assembly.

1 Install the No. 1 thrust washer.
2 Install the No. 2 thrust washer.
3 Install the chain cover.





73. 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.





74. Install the remaining bolts.





75. Install the bolts.





76. CAUTION: The test spring from the overdrive servo rod tool is plain in color and has 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.





77. Overdrive servo travel check. Install the overdrive servo piston.
1 Install the test spring.
2 Install the overdrive servo piston.





78. Install the overdrive servo rod tool and the Dial Indicator with Bracketry.





79. Tighten the center screw and zero out the dial indicator.





80. 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.

Overdrive Piston Rod Selection Chart:

81. If the overdrive servo travel was incorrect install new overdrive servo rod. Zero dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove tool and test spring.





82. CAUTION: Do not assemble the transaxle using the test spring. Install the overdrive servo.

1 Install the overdrive servo spring.
2 Install the overdrive servo.
3 Install the overdrive servo cover and bolts.





83. Install the transmission test plate.








84. WARNING: Wear safety glasses while performing this procedure to prevent personal injury.

NOTE: When applying regulated 276 kPa (40 psi) air pressure to the appropriate passage, a dull should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies.

NOTE: Plugging the vent hole during the test will provide in inaccurate results.

Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate





85. CAUTION: The seals must be lapped correctly or internal leakage will occur.

Install the new Teflon seals on the pump shaft.





86. Install the pump shaft.





87. Install the manual valve detent lever.





88. Install the main control valve body over the pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover.





89. CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.

Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolt and tighten in sequence.





90. Connect the connectors.





91. NOTE: The main control cover gasket is reusable if not torn or damaged.

Install the main control cover, gasket and bolts.





92. Tighten the reverse clutch anchor bolt.
1 Tighten the anchor bolt.
2 Tighten the locknut.





93. Install the new seal and gasket kit and seal assembly.





94. Install the oil pan magnet.





95. NOTE: The gasket is reusable if not damaged or torn.

Install the transmission fluid pan and gasket.





96. Install the Turbine Shaft Speed (TSS) sensor.
1 Install the sensor.
2 Install the bolt.
97. Verify that the shift selector lever is in NEUTRAL.





98. Install the digital TR sensor and loosely install the bolts.





99. Align the digital Transmission Range (TR) sensor.
1 Align the digital transmission range sensor with the digital transmission (TR) range sensor tool.
2 Tighten the bolts.





100. Install the fluid filler tube.
1 Install the fluid filler tube grommet.
2 Install the filler tube.
3 Install the bolt.





101. Install the LH output shaft seal using the Output Seal Replacer.





102. Install the RH output shaft seal using the Output Shaft Seal Replacer Pilot and the Output Seal Replacer.





103. Install the identification tag, if removed.





104. Install the torque converter using the Torque Converter Handles.