Automatic Transaxle Overhaul: Assembly: Transaxle

Fig 1: Special Tool(s)

Fig 2: Special Tool(s)

Fig 3: Special Tool(s)

Fig 4: Special Tool(s)

Fig 5: Special Tool(s)

Fig 6: Special Tool(s)

1. Install the parking pawl assembly.
   1. Install the parking pawl and return spring.
   2. Install the parking pawl shaft.
      Fig 7: Installing Parking Pawl Assembly

      
2. Install the park pawl roll pin.
   Fig 8: Installing Park Pawl Roll Pin

   
3. Using the special tool, install the cup plug.
   Fig 9: Installing Cup Plug

   
4. Using the special tool, install the new drive sprocket bearing, if it was removed.
   Fig 10: Installing New Drive Sprocket Bearing

   
NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way.
Fig 11: Installing Driven Sprocket Support

5. Install the driven sprocket support.
6. Install the bolts.
   Fig 12: Installing Bolts

   
7. Using the special tool, install the converter impeller hub seal.
   Fig 13: Installing Converter Impeller Hub Seal

   
8. Install the differential carrier thrust bearing.
   1. Install the differential carrier thrust washer.
   2. Install the differential carrier thrust bearing and race (tabs down).
      Fig 14: Installing Differential Carrier Thrust Bearing

      
9. Install the final drive ring gear.
   Fig 15: Installing Final Drive Ring Gear

   
10. Install the rear planet support spacer.
    Fig 16: Installing Rear Planet Support Spacer

    
11. Install the final drive differential assembly.
    Fig 17: Installing Final Drive Differential Assembly

    
12. Align the rear lube tube holes in the case window.
    Fig 18: Aligning Rear Lube Tube Holes In Case Window

    
NOTE: The retaining ring must be properly installed.
Fig 19: Installing Beveled Retaining Ring

Fig 20: Seating Beveled Retaining Ring

13. Using the special tool, install the beveled retaining ring.
CAUTION: If support is not visible on inside diameter of the retaining ring the low/intermediate piston could be damaged.
Fig 21: Verifying Beveled Retaining Ring Installation

14. Make sure that the beveled retaining ring seats properly in case groove with the bevel down. The final drive support must be visible on the inside diameter of the retaining ring, but must not seat against the case wall.
15. Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove.
    Fig 22: Prying Up On Retaining Ring

    
16. Install the special tool.
    Fig 23: Installing Special Tool

    
17. Remove the No. 15 needle bearing.
    Fig 24: Removing No. 15 Needle Bearing

    
NOTE: The Gauge Shim Depth must set on the No. 15 bearing surface.
Fig 25: Installing Special Tools

18. Install the special tools.
19. Install the special tools. Zero the dial indicator.
    Fig 26: Installing Special Tools

    
20. Tighten the bolt.
    Fig 27: Tightening Bolt

    
21. Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification the next larger beveled ring retainer will need to be used.
    Fig 28: Recording Dial Indicator Reading

    
22. Select the correct beveled retaining ring.
    Fig 29: Identifying Beveled Retaining Rings

    
    Fig 30: Beveled Retaining Rings Specification

    
NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer.
Fig 31: Installing No. 15 Thrust Bearing

23. Install the No. 15 thrust bearing.
24. Check the clearance for the No. 16 thrust washer. Mount the special tool with the styles on the end of the output shaft. Zero the dial indicator.
    Fig 32: Checking Clearance For No. 16 Thrust Washer

    
25. Tighten the bolt. Read and record the dial indicator reading.
    Fig 33: Tightening Bolt

    
    Fig 34: Recording Dial Indicator Reading

    
NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race.
Fig 35: No. 16 Thrust Race (Washer) Specification

26. If the clearance is not within specification, a thicker or thinner washer will need to be added.
27. Install the low-intermediate one-way clutch assembly.
    Fig 36: Installing Low-Intermediate One-Way Clutch Assembly

    
NOTE: The friction plate internal splines will center the one-way clutch.
28. Install the low-intermediate clutch pressure plate.
    1. Install the low-intermediate clutch wave spring.
    2. Install the low-intermediate clutch pack.
    3. Install the low-intermediate clutch pressure plate.
       Fig 37: Installing Low-Intermediate Clutch Pressure Plate

       
CAUTION: Make sure that the retaining ring is seated in the case groove.
Fig 38: Installing Low-Intermediate Clutch Retaining Ring

29. Install the low-intermediate clutch retaining ring.
WARNING: To prevent injury, wear eye protection when using pressurized air.
NOTE: Be sure the pressurized air is dry and regulated at 276 kPa (40 psi).
Fig 39: Applying Regulated Air Pressure To Low-Intermediate Apply Port

30. Apply regulated air pressure to the low-intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal.
31. Measure the clearance between the clutch pressure plate and the low-intermediate clutch retainer. If the clearance is not within specification a thicker or thinner retainer may be needed.
    Fig 40: Measuring Clearance Between Clutch Pressure Plate & Low-Intermediate Clutch Retainer

    
    Fig 41: Selective Retaining Rings Specification

    
32. Install the coast band.
    1. Install the coast band.
    2. Align the anchor pin pocket with the anchor pin in the case.
       Fig 42: Installing Coast Band

       
33. Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.
    Fig 43: Installing Low-Intermediate Drum

    
34. Install the park rod abutment and make sure that the park pawl moves freely.
    Fig 44: Installing Park Rod Abutment

    
35. Install the coast band piston cover.
    1. Install the coast band servo piston spring.
    2. Install the coast band servo piston.
    3. Install the coast band servo piston cover.
    Fig 45: Installing Coast Band Piston Cover

    
36. Using the special tool, install the coast servo cover retaining ring.
    Fig 46: Installing Coast Servo Cover Retaining Ring

    
37. Using the special tools, install the front planetary/reverse clutch assembly.
    Fig 47: Installing Front Planetary/Reverse Clutch Assembly

    
38. Make sure that the reverse clutch cylinder apply tube hole is aligned with the case hole. Remove the tool.
    Fig 48: Checking Reverse Clutch Cylinder Apply Tube Hole Is Aligned With Case Hole

    
39. Loosely install the reverse clutch anchor pin.
    Fig 49: Loosely Installing Reverse Clutch Anchor Pin

    
40. Using the special tools, install the forward/intermediate clutch assembly. Align the shell and sun gear into the front planet.
    Fig 50: Installing Forward/Intermediate Clutch Assembly

    
41. Install the overdrive band.
    Fig 51: Installing Overdrive Band

    
NOTE: The foot of the overdrive retainer goes down against the band.
Fig 52: Installing Overdrive Band Anchor Strut

42. Install the overdrive band anchor strut with the cross hairs facing up.
43. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support.
    1. Remove the No. 9 bearing and race.
    2. Remove the No. 8 sprocket support.
       Fig 53: Removing No. 8 Sprocket Thrust Washer & No. 9 Bearing And Race

       
44. Install only the No. 9 needle bearing with the outer lip up.
    Fig 54: Installing Only No. 9 Needle Bearing

    
45. Install the special tool over the output shaft until it is fully seated on to the No. 9 needle bearing.
    Fig 55: Installing Special Tool Over The Output Shaft

    
46. Install the special tools to make the measurements.
    Fig 56: Installing Special Tools To Make Measurements

    
47. When taking the measurement, record reading on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by two to obtain reading A.
    Fig 57: Taking Measurement

    
NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer.
Fig 58: No. 8 Thrust Washer Selection Chart

48. Use the reading A to select the correct No. 8 thrust washer from the chart.
49. Remove the special tools.
    Fig 59: Removing Special Tools

    
50. Install the special tools to make the measurements.
    Fig 60: Install Special Tools To Make Measurements

    
51. 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.
    Fig 61: Measuring Down To No. 5 Thrust Washer Mating Surface

    
52. Remove the special tools.
    Fig 62: Removing Special Tools

    
NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart.
Fig 63: Calculating Reading

53. Subtract reading A from Reading B add the difference between A and B to dimension C. Record this reading as D.
54. Use Reading D to select the correct No. 5 thrust washer.
    Fig 64: No. 5 Support Thrust Washer Chart

    
NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place.
Fig 65: Installing No. 5 Front Support Thrust Washer

55. Install the No. 5 front support thrust washer.
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.
56. Install the correct No. 8 driven sprocket support thrust washer and the No. 9 direct clutch needle bearing.
    1. Install the No. 8 sprocket support thrust washer.
    2. Install the No. 9 needle bearing.
       Fig 66: Installing No. 8 Driven Sprocket Support Thrust Washer & No. 9 Direct Clutch Needle Bearing

       
57. Install the driven sprocket support assembly.
    Fig 67: Installing Driven Sprocket Support Assembly

    
58. 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.
       Fig 68: Installing Neutral/Drive Accumulator Cover

       
59. Install the bolt.
    Fig 69: Installing Bolt

    
NOTE: All the fluid supply tubes must have new O-rings installed.
Fig 70: Installing Fluid Supply Tubes

60. Install the fluid supply tubes.
61. Install the brackets.
    Fig 71: Installing Brackets

    
62. Using the special tool, install the manual control lever shaft seal.
    Fig 72: Installing Manual Control Lever Shaft Seal

    
63. 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.
      Fig 73: Installing Parking Lever Actuating Rod

      
NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support.
Fig 74: Installing Manual Control Lever Shaft

64. Install the manual control lever shaft.
NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support.
Fig 75: Installing Roll Pins

65. Install the roll pins.
NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place.
66. Install the thrust washers.
    1. Install the No. 2 drive sprocket thrust washer.
    2. Install the No. 4 driven sprocket thrust washer.
       Fig 76: Installing Thrust Washers

       
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.
Fig 77: Installing Drive Chain And Sprockets

67. Install the drive chain and sprockets.
68. Install 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.
       Fig 78: Installing Shift Accumulator Springs

       
NOTE: Make sure that the alignment pins are installed in the case.
Fig 79: Installing New Chain Cover Gasket

69. Install the new chain cover gasket.
CAUTION: Be extremely careful not to damage the cast iron sealing ring.
NOTE: Use petroleum jelly to hold thrust washers in place during assembly.
70. 1. Install the No. 1 thrust washer.
    2. Install the No. 2 thrust washer.
    3. Install the chain cover.
       Fig 80: Installing Thrust Washers & Chain Cover

       
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.
Fig 81: Starting Two Bolts

71. Start two bolts.
72. Install the remaining bolts.
    Fig 82: Installing Remaining Bolts

    
73. Install the bolts.
    Fig 83: Installing Bolts

    
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.
74. Inspect the spring height.
    1. Test spring.
    2. Original spring.
       Fig 84: Inspecting Spring Height

       
75. Overdrive servo travel check. Install the overdrive servo piston.
    1. Install the test spring.
    2. Install the overdrive servo piston.
       Fig 85: Checking Overdrive Servo Travel

       
76. Using the special tools, install the overdrive servo.
    Fig 86: Installing Overdrive Servo With Special Tools

    
77. Tighten the bolt and zero out the dial indicator.
    Fig 87: Tightening Bolt And Zeroing Out Dial Indicator

    
78. Back off the center bolt 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 Fig 89 and determine which overdrive servo rod to use.
    Fig 88: Reading Dial Indicator

    
79. 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.
    Fig 89: Overdrive Specification Chart

    
CAUTION: Do not assemble the transaxle using the test spring.
80. Install the overdrive servo.
    1. Install the overdrive servo spring.
    2. Install the overdrive servo.
    3. Install the overdrive servo cover and bolts.
       Fig 90: Installing Overdrive Servo

       
81. Install the special tools.
    Fig 91: Installing Special Tools

    
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 thud 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 inaccurate results.
Fig 92: Identifying Clutch Ports (1 Of 2)

Fig 93: Identifying Clutch Ports (2 Of 2)

82. 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 clutch ports.
CAUTION: The seals must be lapped correctly or internal leakage will occur.
Fig 94: Installing New Teflon(R) Seals On Pump Shaft

83. Install the new Teflon(R) seals on the pump shaft.
84. Install the pump shaft.
    Fig 95: Installing Pump Shaft

    
85. Install the manual valve detent lever.
    Fig 96: Installing Manual Valve Detent Lever

    
86. 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.
    Fig 97: Installing Main Control Valve Body

    
CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur.
Fig 98: Installing Pump Assembly And Main Control Valve Body

87. Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolt and tighten in sequence.
88. Connect the connectors.
    Fig 99: Connecting Electrical Connectors.

    
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 100: Inspecting Gasket

89. Inspect the gasket for nicks or tears.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 101: Installing Gasket Onto Pan

90. Install the gasket onto the pan.
91. Install the main control cover, gasket and bolts.
    Fig 102: Installing Main Control Cover, Gasket & Bolts

    
92. Tighten the reverse clutch anchor bolt.
    1. Tighten the anchor bolt.
    2. Tighten the locknut.
       Fig 103: Tightening Reverse Clutch Anchor Bolt

       
93. Install the new filter and seal assembly.
    Fig 104: Installing New Filter And Seal Assembly

    
94. Install the oil pan magnet.
    Fig 105: Installing Oil Pan Magnet

    
NOTE: The gasket is reusable if not damaged or torn.
Fig 106: Installing Transmission Fluid Pan & Gasket

95. Install the transmission fluid pan and gasket.
96. Install the turbine shaft speed (TSS) sensor.
    1. Install the sensor.
    2. Install the bolt.
       Fig 107: Installing TSS Sensor

       
97. Verify that the shift selector lever is in NEUTRAL.
98. Install the digital TR sensor and loosely install the bolts.
    Fig 108: Installing Digital TR Sensor & Loosely Install Bolts

    
99. Using the special tool align the digital transmission range (TR) sensor.
    1. Install the special tool.
    2. Tighten the bolts.
       Fig 109: Aligning Digital TR Sensor

       
100. Install the fluid filler tube.
     1. Install the fluid filler tube grommet.
     2. Install the filler tube.
     3. Install the bolt.
        Fig 110: Installing Fluid Filler Tube

        
101. Using the special tool, install the LH output shaft seal.
     Fig 111: Installing LH Output Shaft Seal

     
102. Using the special tool, install the RH output shaft seal.
     Fig 112: Installing RH Output Shaft Seal

     
103. Install the identification tag, if removed.
     Fig 113: Installing Identification Tag

     
104. Using the special tool, install the torque converter.
     Fig 114: Installing Torque Converter