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Transaxle Case Section

  1. Install oil seal using plastic hammer. Install parking support to back of transaxle case and tighten bolts to 17-20 ft. lbs. (23-27 N.m). Install inhibitor switch and detent spring. Tighten detent spring bolt to 44-62 INCH lbs. (5-7 N.m). Install range select lever, and tighten bolt to 44-62 INCH lbs. (5-7 N.m). Install manual plate, parking rod and insert spring pin through select lever and manual plate.
  2. Install low and reverse brake piston, return spring and retainer into rear of transaxle case. See Figure . DO NOT damage seal lip or tilt piston when installing. Using Installer (398497701), install needle bearing into one-way clutch inner race. Install 2 NEW seal rings, and apply petroleum jelly to grooves of one-way clutch inner race and to seal rings so seal ring won't expand. Carefully lower one-way clutch inner race into transaxle case. One-way clutch inner race should be inserted through retainer, return spring and low and reverse brake piston. Install 8 transaxle case-to-one-way clutch inner race bolts and tighten evenly to 17-20 ft. lbs. (23-27 N.m).
    3. NOTE: Low and reverse brake has 5 drive and driven plates on 2.2L, and 6 drive and driven plates on 2.5L.
  3. Place transaxle case vertically on wooden blocks with rear of case facing downward. Install low and reverse brake dish plate in same direction as noted during transaxle disassembly. Install driven plates, drive plates, retaining plate and snap ring. Intermittently apply compressed air to low and reverse brake pressure port to check brake operation. See Figure .
  4. Measure clearance between low and reverse brake snap ring and retaining plate. Standard clearance is .028-.047" (.70-1.20 mm) with an allowable limit of .087" (2.20 mm). If clearance is not within specification, install appropriate retaining plate. See SELECTIVE LOW & REVERSE BRAKE RETAINING PLATE  table.
  5. Install leaf spring in between case and low and reverse brake assembly. Ensure direction and position of leaf spring is correct. Install lathe cut seal rings onto 2-4 brake piston and coat seals with petroleum jelly. Install 2-4 brake piston into 2-4 brake piston retainer. See Figure . Align pressure feed hole in 2-4 brake retainer with 2-4 brake seal bore in transaxle case and install 2-4 brake retainer into transaxle case.
    6. NOTE: 2-4 brake has 3 drive and driven plates on both 2.2L and 2.5L.
  6. Install 2-4 brake return spring into transaxle case. Using Compressor (498677100), install 2-4 brake return spring snap ring. Install planetary gear and low clutch assembly into transaxle case. Rotate planetary and clutch assembly slowly, ensuring not to damage lathe cut seal rings on one-way clutch inner race. Install 2-4 brake rear pressure plate, drive plates, driven plates, retaining plate and snap ring.
  7. Install 2-4 brake seal into bore in transaxle case. Intermittently apply compressed air to 2-4 brake pressure port in transaxle case to check brake operation. Measure clearance between 2-4 brake snap ring and retaining plate. Standard clearance is .031-.047" (.80-1.20 mm) with a maximum allowable limit of .059" (1.50 mm). If clearance is not within specification, install appropriate retaining plate. See SELECTIVE 2-4 BRAKE RETAINING PLATE  table.
  8. Install 2-4 brake leaf spring. Ensure direction and position of leaf spring is correct. See Figure . Installation is complete when snap ring top surface of forward clutch drum is receded approximately .138" (3.50 mm) into rear internal gear.
  9. Install front sun gear and thrust needle bearing. Apply petroleum jelly to thrust needle bearing and install onto high clutch hub. Install high clutch hub by correctly engaging splines of front planetary carrier. Install high clutch assembly and engage high clutch hub with high clutch drive plate splines. Ensure high clutch assembly is fully seated onto high clutch hub.
  10. Adjust total end play. Measure distance from transaxle case mating surface to recessed portion of high clutch drum and subtract thickness of gauge block ("t"). This will be measurement ("L"). Refer to STEP 1 in illustration. See Figure .
    11. NOTE: Measurement "T" includes thrust needle bearing thickness.
  11. Measure distance from oil pump mating surface to top surface of thrust needle bearing on oil pump support and subtract thickness of gauge block ("t"). This will be measurement ("T"). Refer to STEP 2 in illustration. See Figure . Gasket thickness is .011" (.28 mm). This will be measurement ("G"). Calculate clearance between high clutch drum and pump support. Use the following equation: Clearance = (L + G) - T  .
  12. Select appropriate bearing that will provide total end play of .010-.022" (.25-.55 mm) clearance. See SELECTIVE TOTAL END PLAY THRUST NEEDLE BEARING  table.
  13. Install selected bearing race into recess of high clutch drum. Attach thrust needle bearing to oil pump cover with petroleum jelly. Install gasket to case mating surface. Align dowel pins and install oil pump housing to case. Ensure there is no clearance between mating surfaces. Clearance between mating surfaces indicates a damaged seal ring or misaligned thrust needle bearing. Install 2 oil pump housing nuts and tighten to 28-32 ft. lbs. (38-44 N.m).
SELECTIVE LOW & REVERSE BRAKE RETAINING PLATE

Part No. Thickness - In. (mm)
31667AA320 .165 (4.20)
31667AA330 .177 (4.50)
31667AA340 .189 (4.80)
31667AA350 .201 (5.10)
31667AA360 .213 (5.40)
31667AA370 .224 (5.70)
31667AA380 .236 (6.00)
SELECTIVE 2-4 BRAKE RETAINING PLATE

Part No. Thickness - In. (mm)
31567AA610 .220 (5.60)
31567AA620 .228 (5.80)
31567AA630 .236 (6.00)
31567AA640 .244 (6.20)
31567AA650 .252 (6.40)
31567AA660 .260 (6.60)
SELECTIVE TOTAL END PLAY THRUST NEEDLE BEARING

Part No. Thickness - In. (mm)
806528050 .161 (4.10)
806528060 .169 (4.30)
806528070 .177 (4.50)
806528080 .185 (4.70)
806528090 .193 (4.90)
806528100 .201 (5.10)
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