Final Assembly
NOTE:
Ensure all bearing preloads are set and appropriate shims are installed. See ADJUSTMENTS
.
NOTE:
For location of thrust bearings and races, refer to illustration. See Fig 1
. For outer diameter identification of bearings and races, see THRUST BEARING & RACE SPECIFICATIONS
table.
THRUST BEARING & RACE SPECIFICATIONS
| Application | Outer Diameter - In. (mm) | |
|---|---|---|
| Bearing No. | ||
| 1 | 1.57 (40.0) | |
| 2 | 1.57 (40.0) | |
| 3 | 1.54 (39.0) | |
| 4 | 3.08 (78.2) | |
| 5 | 2.05 (52.0) | |
| 6 | 1.97 (50.0) | |
| Race No. | ||
| 1 | 1.58 (40.2) | |
- Mount transaxle case in appropriate holding fixture. Install oil pipe. Install all bearing races and seals in transaxle case as needed. Set primary gear in place. Install spacer and bearing from opposite end of case. See Figure . Install lock nut and hand tighten.
- Secure primary gear with Holding Tool (49 B019 019). Using lock nut Socket (49 B019 021), tighten lock nut. Lock nut is tightened until a turning torque of 8.9-12.4 INCH lbs. (1.0-1.4 N.m) is achieved. Stake lock nut. Install front internal gear and one-way clutch. Install front planetary gear with thrust bearing. See Figure .
- Install front sun gear with thrust bearing. Install rear planetary gear. Install snap ring. Install 2-4 brake band servo return spring and piston in transaxle case. Install servo retainer (cover) and tighten bolts to specification. See TORQUE SPECIFICATIONS .
- Install 2-4 brake drum with thrust bearing. Install brake band. Install an alternate bolt in place of brake band strut. Bolt must be 2.36-2.75" (60-70 mm) in length. Tighten bolt to 43 INCH lbs. (4.9 N.m). Measure and record distance between case and head of bolt (dimension "A"). See Fig 2 .
- Remove bolt. Measure and record total length of bolt (dimension "B"). Subtract dimension "B" from "A". Difference is preferred brake band strut length. Strut may be up to a maximum of .157-.185" (4.0-4.7 mm) shorter. Struts range in length of 1.417-1.535" (36.0-39.0 mm) in .20" (.5 mm) increments. Install selected strut and tighten to specification.
- Place .102" (2.6 mm) thrust bearing race (thickest) on end cover. Install end cover without gasket on 2-4 brake drum and case. Measure clearance between cover and transaxle case. See Fig 3 . If clearance is zero, remove .102" (2.6 mm) thrust bearing race and place 2 .071" (1.8 mm) races on end cover. Install end cover and measure clearance.
- Subtract measured clearance from thickness of bearing race(s) used to determine end play amount. Select proper bearing race and install on end cover. See Fig 3 . Ensure tab on bearing race is installed in correct location. See Fig 4 . Install "O" rings in transaxle case. Install end cover using silicone sealer. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
- Install parking pawl spring, parking pawl and shaft to transaxle case. See Figure . Install support plate. Install actuator plate. Install secondary gear, and output gear and differential. Install forward clutch assembly. Apply light coating of silicone sealant to transaxle case and converter case. Install converter housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
- Install differential side gear Holders (49 G030 455) into differential side gears. Install oil pump. Install parking rod lever assembly. Install "O" ring on manual shaft. Install manual shaft to manual plate and detent bracket. Install roll pin. Install accumulators. See ACCUMULATORS under COMPONENT DISASSEMBLY & REASSEMBLY for identification.
- Install internal solenoid harness. Install valve body. Install valve body bolts in correct location. See Figure
. All bolts are same length except bolts with no markings. Tighten bolts in crisscross pattern to specification. Connect harness connectors to solenoids. See SOLENOID HARNESS CONNECTOR IDENTIFICATION
table.SOLENOID HARNESS CONNECTOR IDENTIFICATION
Shift Solenoid Connector Color A White B Blue C Green D White E Black Pressure Control Black - Install oil pan. Install oil pipe. Install vehicle speed and input/turbine speed sensors. Fully rotate manual shaft toward converter housing, then return 2 notches to Neutral position. Align notches in TR switch shaft hole with mark on switch housing. Install TR switch. Install manual lever.
- Install oil filler tube and dipstick. Install torque converter and check installed depth. See Fig 5 . Installed depth should be .609" (15.5 mm) for 1.6L models, and .846" (21.5 mm) for 1.8L models.