Transaxle-Assembly (1 - 34)
TRANSAXLE-ASSEMBLYAssembly Note
1. Prepare the transaxle for assembly by proceeding with the following steps:
1. Clean all parts (except the friction plates, seals, and intermediate/overdrive band) in solvent.
2. Dry all parts with moisture-free regulated compressed air (do not use shop towels).
3. Lubricate all internal parts (including friction plates) with MERCON - Automatic Transaxle Fluid (ATF).
4. Make sure the complete assortment of selective thickness parts are on hand for adjustments during assembly:
1. Drive sprocket thrust washers.
2. Driven sprocket thrust bearing shims.
3. Differential case thrust bearing shims.
4. Low/reverse clutch pressure plates.
5. During assembly, use petroleum jelly to hold the parts in place (do not use grease).
6. Lightly coat bolt and nut threads with automatic transaxle fluid for correct installation torque specifications.
2. Install intermediate and overdrive band assembly into the transaxle case.
3. Install the No.1 pump support thrust bearing.
1. Lubricate the seal rings with MERCON - Automatic Transaxle Fluid (ATF).
Note:
^ Apply a thin coat of petroleum jelly to the pump support seals and to the pump bore in the transaxle.
4. Install pump assembly into the case.
Note:
^ Tighten the bolts in the indicated sequence.
5. Install the pump assembly bolts.
6. Using the special tools, install the low/reverse clutch piston.
1. Lubricate seals and piston bore with clean MERCON - Automatic Transaxle Fluid (ATF).
7. Install the low/reverse clutch return spring assembly.
8. Install the low/reverse clutch return spring retaining ring.
Caution:
^ The low/reverse clutch wave spring is fitted in this position for measurement purposes only.
9. Install the low/reverse clutch wave spring.
10. Install the low/reverse clutch plates.
1. Install the low/reverse clutch external spline (steel) clutch plates.
2. Install the low/reverse clutch internal spline (friction) clutch plates.
3. Install the low/reverse clutch pressure plate.
Caution:
^ The low one-way clutch thrust plate is fitted in the position for measurement purposes only.
11. Install the low one-way clutch thrust plate.
12. Measure the clearance between the low/reverse clutch pressure plate and the low one-way clutch thrust plate.
1. Take a second measurement on the opposite side.
2. Average the two measurements to get the clearance.
3. If the clearance is not within specification, select and fit the correct thickness pressure plate to obtain the specified clearance.
4. Pressure plate sizes:
1. 2.57-2.46 mm (0.101-0.097 inch)
2. 2.36-2.26 mm (0.092-0.089 inch)
3. 2.16-2.06 mm (0.085-0.081 inch)
Note:
^ One tooth of the low/reverse clutch pressure plate is notched for identification.
13. Remove the low one-way clutch thrust plate, the low/reverse clutch pressure plate, the low/reverse clutch external spline clutch plates (steel), the low/reverse clutch wave spring, and the low/reverse clutch internal spline clutch plates (friction).
1. Low one-way clutch thrust plate.
2. Low/reverse clutch pressure plate.
3. Low/reverse clutch external spline clutch plates (Steel),
4. Low/reverse clutch wave spring.
5. Low/reverse clutch internal spline clutch plates (friction).
14. Install the No. 1 pump support thrust bearing assembly.
Note:
^ Remove the seal sizer from forward/coast/direct clutch cylinder.
15. Install the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly.
16. Install the turbine shaft.
17. Install the No. 4 turbine shaft thrust bearing.
18. Install the forward one-way clutch and low/intermediate sun gear assembly.
19. Install the No. 5 low/intermediate sun gear thrust bearing.
20. Install the low/intermediate carrier assembly.
21. Install the No. 6 low/intermediate carrier thrust bearing.
22. Install the low/intermediate ring gear assembly.
23. Install the No. 7 reverse/overdrive sun gear thrust bearing.
24. Install the reverse/overdrive sun gear and shell assembly.
25. Install the reverse/overdrive carrier assembly with the captured No. 8 thrust bearing.
26. Install the low/reverse clutch plates (model dependent).
1. Install the low/reverse clutch external spline (steel) clutch plates.
2. Install the low/reverse clutch internal spline (friction) clutch plates.
3. Install the low/reverse clutch pressure plate previously selected.
27. Install the low/reverse clutch wave spring.
28. Install the low one-way clutch assembly with the identification ring on the inner ring facing upward.
29. Install the low one-way clutch thrust plate.
Note:
^ Make sure to position the low one-way clutch retaining ring as shown.
30. Install the low one-way clutch retaining ring.
31. Install the manual valve detent lever actuating rod assembly.
1. Install the parking cam actuator lever.
32. Install the manual valve detent lever.
33. Install the special tools.
34. Install the special tool with short spacers.