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Transaxle Reassembly

NOTE: If transaxle housing, torque converter housing, differential carrier, bearings, thrust shim, spacer or differential bearing outer races are replaced, differential assembly bearing preload must be checked. See DIFFERENTIAL ASSEMBLY  under COMPONENT DISASSEMBLY & REASSEMBLY.
NOTE: Coat all components with ATF before reassembly.
  1. Install the main separator plate and the three dowel pins on the torque converter housing. See Figure and Figure . Install the ATF pump gears and ATF pump driven gear shaft. Install the ATF pump driven gear with its grooved and chamfered side facing down. See Fig 1 .
  2. Install the main valve body with four bolts. Make sure the ATF pump drive gear rotates smoothly in the normal operating direction, and the ATF pump driven gear shaft moves smoothly in the axial and normal operating directions. See Fig 2 .
    CAUTION: Failure to align the ATF pump driven gear shaft correctly will result in a seized ATF pump drive gear or ATF pump driven gear shaft.
  3. If the ATF pump drive gear and ATF pump driven gear shaft do not move freely, loosen the main valve body bolts, realign the ATF pump driven gear shaft, and then retighten to the specified torque. See TORQUE SPECIFICATIONS  .
  4. Install the stator shaft and stop shaft.
  5. Install the two dowel pins, torque converter check valve and torque converter check valve spring in the main valve body.
  6. Install the regulator valve body with the bolt on the main valve body.
  7. Install the two dowel pins and separator plate on the regulator valve body, then install the throttle valve body (seven bolts).
  8. Install the secondary separator plate with two dowel pins on the main valve body.
  9. Install the control shaft in the housing with the control shaft and manual valve together. See Fig 3 .
    Fig 1: Installing Pump Gears
    G00323743Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 2: Checking Pump Gear Installation
    G00323744Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 3: Installing Control Shaft To Manual Valve
    G00323745Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Install the detent arm and arm shaft in the main valve body, then hook the detent arm spring to the detent arm.
  11. Install the secondary valve body, servo separator plate and servo body (6 bolts).
  12. Install the ATF feed pipe in the servo body, then install the 4th accumulator cover (3 bolts).
  13. Install the ATF strainer (2 bolts).
  14. Install the servo detent base (2 bolts).
  15. Install the 1st/2nd accumulator body (6 bolts).
  16. Install 2 ATF feed pipes in the main valve body and the ATF feed pipe in the servo body.
  17. Install the differential assembly, countershaft sub-assembly, mainshaft sub-assembly, and secondary shaft sub-assembly in the torque converter housing. See Figure and Figure .
  18. Install the splined washer, thrust needle bearing and needle bearings on the secondary shaft.
  19. Install the needle bearings, countershaft 4th gear, reverse selector hub, and reverse selector with the shift fork on the countershaft.
  20. Turn the shift fork shaft so the large chamfered hole is facing the fork bolt hole. Then install the shift fork and the lock bolt with a new lock washer, and torque the lock bolt. Bend the lock tab against the bolt head. See Fig 4 .
    Fig 4: Installing Shift Fork
    G00323746Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Install the secondary shaft 2nd gear on the secondary shaft and the countershaft reverse gear on the countershaft one at a time. Then install the countershaft 2nd gear on the countershaft, and install the thrust needle bearing and thrust washer on the secondary shaft.
  22. Install the reverse idler gear into the transmission housing, then slip it the direction as shown. See Figure .
  23. Align the spring pin of the control shaft with the transmission housing groove by turning the control shaft.
  24. Install three dowel pins and a new gasket on the torque converter housing.
  25. Place the transmission housing on the torque converter housing.
  26. Install the transmission housing bolts along with the transmission hanger, the throttle control cable bracket/ transmission hanger and the harness bracket. Tighten the bolts in two or more steps in the sequence shown. See Figure . See TORQUE SPECIFICATIONS  .
  27. Coat the reverse idler gear shaft, needle bearing and new "O" rings with lithium grease lightly. Assemble new "O" rings and needle bearing on the reverse idler gear shaft. Then install the reverse idler gear shaft in the reverse idler gear shaft holder. Align the "D" shaped cut out of the shaft with the "D" shaped area of the holder.
  28. Engage the reverse idler gear to the countershaft and mainshaft reverse gears, then install the reverse idler gear shaft/holder assembly on the transmission housing.
    NOTE: Do not tighten the lock bolt to the specified torque or bend the lock tab in step  29 .
  29. Install the parking brake lever on the control shaft, then install the lock bolt loosely with a new lock washer.
  30. Slip the holder onto the mainshaft. See Figure .
  31. Lubricate the following parts with ATF:
    • Splines and threads of each shaft.
    • Threads of the old locknuts.
    • Splines of the mainshaft and countershaft idler gears.
    • Splines of the parking gear.
  32. Install the mainshaft idler gear. See Figure and Figure .
    NOTE: The mainshaft locknut has left-hand threads.
  33. Install the old locknut on the mainshaft to seat the idler gear. Do not drive the idler gear on with a hammer. Do not use an impact wrench, always use a torque wrench to tighten the locknut.
  34. Install the secondary shaft idler gear on the secondary shaft.
  35. Install the thrust washer, the thrust needle bearing, the needle bearing, the countershaft idler gear and the parking gear on the countershaft.
  36. Install the old locknut on the secondary shaft. Tighten the old locknut to seat the secondary shaft idler gear while holding the countershaft idler gear. Do not drive the idler gear on with a hammer. Do not use an impact wrench, always use a torque wrench to tighten the locknut.
  37. Install the parking brake pawl shaft and spring in the transmission housing, then install the parking brake pawl.
  38. Place a 24-mm socket on the parking gear, and install a 10 x 1.25 mm bolt in the countershaft. Then engage the parking brake pawl with the parking gear by moving up the parking brake pawl. Keep all of the particles out of the transmission when installing a 10 x 1.25 mm bolt. See Fig 5 .
    Fig 5: Installing Parking Gear
    G00323747Courtesy of AMERICAN HONDA MOTOR CO., INC.
    NOTE: Do not drive the parking gear on with a hammer.
  39. Tighten the bolt and lightly seat the parking gear.
  40. Remove the bolt and socket.
  41. Use the old locknut to tighten the press fit parking gear to the specified torque, then loosen it. See TORQUE SPECIFICATIONS  . Do not use an impact wrench, always use a torque wrench to tighten the locknut.
    CAUTION: Install the conical spring washers in the correct direction. See Figure and Figure .
  42. Remove the old locknut, then install new conical spring washers and new locknuts on each shaft.
  43. Tighten the locknuts to specified torque. The mainshaft locknut has left-hand threads.
  44. Stake each locknut into its shaft using a 3.5 mm punch.
  45. Set the parking brake lever in the position, then verify that the parking brake pawl engages the parking gear.
  46. If the pawl does not engage fully, check the parking brake pawl stop clearance.
  47. Place parking brake lever in "P" position. Ensure parking pawl fully engages with parking gear. If parking pawl does not fully engage, measure parking brake stop distance between parking pawl shaft and pin on parking brake stop. See Fig 6 .
  48. Parking brake stop distance should be 2.54-2.58" (64.5-65.6 mm). If parking brake stop distance is not within specification, install different size parking brake stop.
  49. Parking brake stop is available in different sizes. See PARKING BRAKE STOP SPECIFICATIONS  table.
    PARKING BRAKE STOP SPECIFICATIONS (1)

    I.D. Part No. Distance "A" In. (mm) Distance "B" In. (mm)
    1 24537-PA9-003 .433 (11.00) .433 (11.00)
    2 24538-PA9-003 .425 (10.80) .419 (10.65)
    3 24539-PA9-003 .417 (10.60) .406 (10.30)
    (1) Distances "A" and "B" are measured from center of parking brake stop. See Fig 6 .
    Fig 6: Measuring Parking Brake Sop Distance & Parking Brake Stop
    G93J22359Courtesy of AMERICAN HONDA MOTOR CO., INC.
  50. Tighten the bolt, and bend the lock tab against the bolt head.
  51. Install the right side cover.
  52. Install the throttle control lever and the spring on the throttle control shaft.
  53. Install the ATF cooler lines with new sealing washers. Install the ATF dipstick.
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