Transaxle-Assembly (35 - 70)
TRANSAXLE-ASSEMBLYAssembly Note
35. Using the special tools, measure the distance from the top of special tool to the No. 12 driven sprocket bearing surface area.
1. Record this dimension.
2. This dimension is designated with A.
36. Using the special tools, measure the distance from the top of special tool to the bearing surface on the reverse/overdrive carrier assembly on one side of the turbine shaft.
1. Repeat this measurement on the other side of the turbine shaft 180 degrees from the first measurement.
2. The average of these two dimensions is dimension B.
3. Remove the special tools.
37. Subtract dimension B from dimension A to get dimension C.
33. Use the third dimension to select the correct No. 11 driven sprocket shim.
1. Select a shim from the driven sprocket shim chart.
Driven Sprocket Alignment Shim No.11
39. Install and lubricate the following:
1. Lubricate the needles and seals in the No. 18 driven sprocket bearing
2. Install the selected No. 11 driven sprocket shim.
3. Install the No. 12 driven sprocket bearing.
40. Install the No. 9 reverse/overdrive ring gear thrust bearing.
Note:
^ Installation of the reverse/overdrive ring gear assembly at this time is for measurement purposes only.
41. Install the reverse/overdrive ring gear assembly.
42. Install the special tools.
43. Install the special tool with short spacers.
44. Using the special tools, measure the distance from the top of special tool to the face of the reverse/over drive ring gear assembly surface area.
1. Repeat this measurement 180 degrees from the first measurement.
2. The average of these two dimensions is dimension A.
3. Remove the special tools.
45. Add 25.4 mm (1.01 inch) (thickness of special tool) and thickness of short spacers.
1. This is the dimension B.
46. Subtract dimension A from dimension B.
1. This is dimension C.
47. Select No. 10 thrust washer from the drive sprocket thrust washer chart.
1. Use the third dimension to select the No. 10 drive sprocket thrust washer.
Drive Sprocket Alignment No.10 Thrust Washer
48. Use petroleum jelly and install the selected No. 10 drive sprocket thrust washer on the torque converter housing.
49. Remove the reverse/overdrive ring gear assembly.
50. Install the filter and seal assembly.
51. Install the special tool in the filter eyelet and transaxle hole.
Note:
^ Lubricate the filter recirculating regulator exhaust seal before installation.
52. Using the special tool, install the filter recirculating regulator exhaust seal.
53. Install the chain pan in the transaxle case.
54. Assemble and install the drive chain assembly.
1. Drive chain (copper colored link facing upward).
2. Driven sprocket assembly.
3. Reverse/overdrive ring gear assembly.
4. Verify that the driven sprocket assembly and reverse/overdrive ring gear assembly are seated.
55. Install the chain pan cover by snapping it into place.
56. Install the No. 13 driven sprocket thrust bearing.
57. Install the final drive carrier and differential assembly.
Note:
^ Plastic washers should be placed between bolt heads and special tool.
58. Install the special tools.
1. Install the special tool.
2. Install the special tool and bolts.
59. Using the special tools, measure the distance from the top of special tool to the shim surface area of the final drive carrier and the differential assembly on one side of the hub.
1. Repeat this measurement 180 degrees from the first measurement.
2. The average of these two dimensions is dimension B.
60. Use combined thickness of the special tool with long spacers 177.8 mm (7.11 inch) as dimension A.
61. Subtract dimension B from dimension A. This is dimension C.
62. Use dimension C to select the correct No. 14 differential bearing shim from the differential bearing shim chart.
Differential End Play No.14 Shim
63. Install the differential bearing assembly
1. Install the No. 14 differential bearing shim (selective fit).
2. Install the No. 15 differential bearing.
Note:
^ Check for correct alignment of the lube tube on the converter housing.
64. Install the torque converter housing onto the transaxle case.
1. Position and install the split flange gasket.
Note:
^ Tighten the bolts in the indicated sequence.
65. Install the torque converter housing-to-transaxle case bolts.
Note:
^ Note the number of grooves on the intermediate and overdrive servo apply rod.
66. Lubricate the assembly with clean MERCON - Automatic Transaxle Fluid (ATF).
1. Install the intermediate and overdrive servo return spring assembly onto the servo piston assembly.
2. Install the intermediate and overdrive servo apply rod and piston assembly.
3. Install the overdrive servo apply rod spring.
67. Install the special tool.
Note:
^ Struts on the special tool fit into the servo cover retaining ring groove.
68. Assemble the special tool.
1. Install struts.
2. Install bar.
3. Install bolts. (4). Install the center bolt.
69. Using the special tool, measure the distance to the bar of special tool.
1. Record this as dimension A.
70. Back off the center bolt of special tool until the piston movement stops.