Transaxle Reassembly: Notes
- Place case in horizontal position. Install drive sprocket support. Drive sprocket support bolt holes are offset. Sprocket support can only be aligned one way. Install and tighten 6 Torx (T-30), bolts to specifications.
- Install converter oil seal using Seal Replacer (T86P-70401-A). Install right-hand output shaft seal using Seal Replacer (T86P-1177-B). After installation, ensure garter springs are present.
- Install Crossblock (T81P-78103-A), Step Plate (D80L-630-3) and Screw (D80L-515-S), over right-hand output shaft opening. See Fig 1 . This tool will be used later to perform selective thrust washer checks.
- Place transaxle in vertical position. Install No. 19 needle bearing over case boss with flat side facing up, outer lip facing down. Install final drive ring with external splines up. Lightly tap ring gear to fully seat in case splines.
- Reassemble governor drive gear, differential assembly, final drive sun gear, parking gear, No. 16 needle bearing, rear planetary support, No. 15 needle bearing and No. 18 thrust washer. See Fig 2 .
- Lower final drive assembly into case. Install snap ring and align snap ring with low-intermediate band anchor pin. Mount a dial indicator with stylus on end of output shaft. See Fig 3 .
- Back out Screw (D80L-515-S), of step 3), until it no longer touches shaft. Zero dial indicator. Tighten screw to 35-44 INCH lbs. (4-5 N.m). Ensure end clearance is .004-.025" (.1-.65 mm).
- If not within specification, replace No. 18 selective thrust washer with proper thicknesses. Available thicknesses are: .045-.049" (1.15-1.25 mm) Orange, .055-.059" (1.40-1.50 mm) Purple and .064-.069" (1.65-1.75 mm) Yellow.
- After installing correct thrust washer, recheck clearance. With end clearance within specifications, back off screw on tool and leave in position for No. 5 and No. 8 selective thrust washer clearance check.
- Install park pawl, return spring, park pawl shaft and locator pin. Ensure park pawl engages park gear and returns freely. Install park rod actuating lever and park rod in case. Install park rod abutment and start abutment bolts. Push in park pawl and locate rod between pawl and abutment.
- Using a 3/8" drift, gently install lube tube seal flush against rear case support. Install low-intermediate band and align anchor pin pocket with anchor pin. Install low-intermediate drum and sun gear assembly.
- Reassemble ring gear and shell assembly, rear planetary, No. 13 needle bearing, front planetary and snap ring. See Figure . Carefully slide planetary assembly over output shaft.
- Lower reverse clutch into case and start clutch plate engagement. Align clutch cylinder anchor pin pocket with anchor pin case hole. Use intermediate clutch hub to complete clutch plate engagement and fully seat reverse clutch. Rotate planet with hub to engage splines.
- Start reverse anchor pin bolt, but DO NOT tighten. Reassemble forward, direct and intermediate clutch assembly. Using Clutch Pack Holder (T86P-70389-A), lower assembly into case. Align shell and sun gear splines into forward planetary. Ensure assembly is fully seated before removing tool.
- Install overdrive band into case. Install plastic retainer with crosshairs facing up. Check drive sprocket end clearance for No. 5 and No. 8 thrust washer.
- Tighten screw on tool used in step 7) to 10 ft. lbs. (13.5 N.m). Install No. 9 needle bearing over output shaft, with outer lip facing up. Install No. 8 selective thrust washer. Install driven sprocket support and driven sprocket. Remove No. 5 thrust washer from sprocket support, if attached.
- To measure No. 8 thrust washer clearance, it must first be determined if machined bolt hole surfaces on driven sprocket support are above or below case machined surface. See Fig 4 .
- Above case machined surface, place depth micrometer on machined bolt hole surface and measure distance to case machined surface. Below case machined surface, place depth micrometer on case machined surface and measure distance to machined bolt hole surface. See Fig 4 .
- Measure at both bolt hole surfaces and take an average of both readings. If average reading for above case exceeds .008" (.21 mm), or .018" (.46 mm), for below case, use different NO. 8 thrust washer. See NO. 8 THRUST WASHER SELECTION
. Install correct thrust washer. Recheck measurement and record reading.NO. 8 THRUST WASHER SELECTION
Thickness Color .056-.060" (1.43-1.53 mm) Natural .066-.070" (1.68-1.78 mm) Dark Green .075-.079" (1.92-2.02 mm) Light Blue .085-.089" (2.17-2.27 mm) Red - Remove driven sprocket support, No. 8 thrust washer and No. 9 needle bearing. Apply grease to No. 5 thrust washer and install on driven sprocket support. Align washer tab with mating slot in support. Install driven sprocket support without No. 8 thrust washer and No. 9 needle bearing.
- Position depth micrometer on machined case surface and measure distance between machined bolt hole surface and case surface. Measure at both bolt hole surfaces and take an average of both readings.
- The difference between this reading and the reading for the No. 8 thrust washer recorded in step 18) must be greater than zero but less than .033" (.85 mm). If measurement exceeds specification, use different NO. 5 thrust washer. See NO. 5 THRUST WASHER SELECTION
.NO. 5 THRUST WASHER SELECTION
Thickness Color .086-.090" (2.18-2.28 mm) Green .095-.099" (2.43-2.53 mm) Black .105-.109" (2.67-2.77 mm) Natural .115-.118" (2.92-3.02 mm) Red - Remove driven sprocket support and install No. 9 needle bearing and correct No. 8 thrust washer. Install 5 Teflon seals on driven sprocket support. Install correct No. 5 thrust washer. Install driven sprocket support.
- Tap manual shaft seal into case. Start manual shaft through seal, and slide manual detent lever onto shaft. Slide shaft through park rod actuating lever and tap into case hole. Install new lock pin through case hole, aligning with groove in shaft. Install new roll pins.
- Align tabs on No. 2 and No. 4 thrust washers and install on drive and driven sprocket supports. Lubricate and install cast iron sealing ring on input shaft. Install chain on drive and driven sprockets. Lower assembly into sprocket supports, rotating to ensure they are fully seated.
- Install No. 1 and No. 3 thrust washers on chain cover, aligning tabs with slots in chain cover. Install new chain cover gasket. Install marked accumulator springs to correct position. Carefully align chain cover input shaft bore with input shaft. Gently apply downward pressure, to overcome accumulator spring pressure and start 2 chain cover bolts 180 degrees apart.CAUTION: Be extremely careful not to damage input shaft cast iron sealing ring when installing chain cover.
- Start remaining chain cover bolts and tighten in sequence to specification. See Fig 5 . Input shaft should have little end play and rotate freely. If it does not rotate freely, remove chain cover and check for damaged cast iron seal.
- Tighten park rod abutment bolts, reverse anchor pin bolt and lock nut to specifications. Clean and lightly tap tubes into position until fully seated. Apply Threadlock (262) around tube-to-case surface. Install tube retaining brackets.
- Install 2 "O" rings onto oil filter and press filter into case. Install reverse apply tube/oil filter bracket and bolt. Install oil pan with new gasket. Tighten to specifications. Install 4 new Teflon seals on pump drive shaft and install shaft.
- Install T.V. bracket with T.V. link through hole in case. Tighten throttle valve bracket bolts to specification. Connect manual valve link to detent lever.
- Start oil pump and valve body assembly over pump shaft and connect manual valve link to manual valve. Hold T.V. plunger in to clear TV bracket. Install oil pump and valve body assembly. See OIL PUMP & VALVE BODY ASSEMBLY under SERVICE (IN VEHICLE) in this article.
- Install bulkhead connector and 4 electrical connectors. Install neutral start switch. With manual shaft in Neutral, align switch using a .089" drill bit. Tighten switch to specification.
- Install valve body cover with new self-adhesive gasket. Tighten bolts to specification. Install dipstick tube grommet and dipstick tube in case. Place transaxle in horizontal position. Proceed to SERVO TRAVEL CHECK .