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Assembly Note

NOTE: The identification dot on the pump driven gear must face downward.
  1. Install the pump driven gear.
    Fig 1: Installing Pump Driven Gear
    G01163543
  2. Install the pump drive gear assembly.
    1. Install the pump drive gear.
    2. Install the pump drive gear insert.
    Fig 2: Installing Pump Drive Gear Assembly
    G01163544
  3. Using the special tool, measure the clearance between each gear and the pump body face.
    Fig 3: Measuring Clearance Between Gears And Pump Body
    G01163545
    1. If the clearance exceeds specification, install a new pump assembly.
  4. Install the special tool.
    Fig 4: Installing Special Tool
    G01163546
  5. Align the pump support assembly. Fill the pump gear cavity with MERCON(R) Multi-Purpose (ATF) Transaxle Fluid to the top of the gears. Align the pump guide screws.
    Fig 5: Installing Pump Body
    G01163547
    1. Install the pump body.
    2. Install the pump body separator plate.
    3. Install the pump body separator plate gasket onto the pump body.
    4. Install the pump support.
    NOTE: Install the four pump support bolts in the pump support holes, and remove the special tool. Then install the last two bolts.
  6. Install the six pump support bolts.
    Fig 6: Installing Six Pump Support Bolts
    G01163548
    NOTE: Make sure that the white stripe on the pump seal is visible around the pump body circumference.
  7. Install the pump seal on the pump body.
    Fig 7: Installing Pump Seal On The Pump Body
    G01163549
    NOTE: Make sure the pump support seal rings are overlapped correctly.
  8. Install the seven pump support seal rings.
    Fig 8: Installing Seven Pump Support Seal Rings
    G01163550
  9. Measure the pump rotational torque.
    1. Install the pump drive shaft.
    2. Measure the pump rotational torque.
    3. Remove the pump drive shaft.
    4. If rotational torque exceeds the specification, disassemble and inspect the pump assembly for contamination or incorrect end clearance.
      5. Fig 9: Measuring Pump Rotational Torque
      G01163551
  10. Install the No. 1 pump support thrust bearing.
    Fig 10: Installing No. 1 Pump Support Thrust Bearing
    G01163552
    1. Lubricate the seal rings with MERCON(R) Multi-Purpose (ATF) Transaxle Fluid.
  11. Install the forward/coast/direct clutch cylinder and reverse clutch drum on the pump support.
    12. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
    NOTE: With each application of air, you should hear the clutch pack apply. A hissing or high pitched squeal indicates that a seal is damaged or torn. Inspect to find the source and repair as necessary.
    Fig 11: Checking Clutch Cylinder With Compressed Air
    G01163553
  12. Check the following passages of the forward/coast/direct clutch cylinder and reverse clutch drum with moisture-free compressed air, regulated to 276 kPa (40 psi).
    1. Reverse clutch passage.
    2. Forward clutch passage.
    3. Direct clutch passage.
    4. Coast clutch passage.
    5. Converter bypass (located on the bottom).
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