Transaxle Reassembly
NOTE:
All selective snap ring and thrust washer measurements taken during disassembly must be rechecked at appropriate reassembly stage.
- Install and ensure sun gear shaft, forward band, 1-2 band, reaction sun gear and reverse reaction drum are in place. Ensure 1-2 band anchor pins engage band, and 1-2 band assembly stop is in place.
- Recheck final drive end play. See FINAL DRIVE CARRIER ASSEMBLY under COMPONENT DISASSEMBLY & REASSEMBLY. Install thrust washer onto input shaft and hold in position with petroleum jelly. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates.
- Install input clutch roller clutch and sprag assemblies into case using Final Drive/Clutch Installer (J-33381). DO NOT install 2nd clutch housing, thrust bearing or thrust washer at this time.
- Check input clutch housing end play. See INPUT & 2ND CLUTCH ASSEMBLIES under TRANSAXLE DISASSEMBLY. See Figure . Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be .0-.006" (.0-.152 mm). If clearance is not as specified, use different thrust washer. See INPUT CLUTCH THRUST WASHER IDENTIFICATION table.
- Install reverse reaction plate and thrust washer. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub, and clutch housing must engage reverse reaction drum splines.
- Install reverse band into case, locating band on anchor pins. Install thrust washer to driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case, ensuring support lube hole aligns with hole in bottom of case. Install output shaft into case. Install "C" ring onto output shaft through bottom of case. Push "C" ring onto output shaft.
- Coat seal installer with petroleum jelly, and place seal installer over turbine shaft. Slide oil ring seals into position. Using appropriate seal sizer, size seals by gently twisting sizer over seal.
- Install thrust washer onto drive sprocket, and hold washer in position with petroleum jelly. Install sprockets and drive link chain onto case. Ensure Bronze colored link faces direction of removal. If NEW drive link chain is installed, link direction must be up. Install chain scavenging scoop.
- Install thrust washer onto driven sprocket and retain with petroleum jelly. Insert 4th clutch hub and shaft through driven sprocket, and install clutch apply plate with machined side facing down. See Figure . Install 4th clutch plates starting with steel plate.
- If necessary, pry out axle seal, and tap NEW seal into place. Install 3-4 accumulator components into channel plate. Install 3-4 accumulator cup. Install channel plate gaskets. Install thrust washer onto channel plate. See Figure .
- Install channel plate onto case. Channel plate lugs must align with tangs on 4th clutch plates and apply plate. See Figure . Install and tighten channel plate bolts. See Figure . Install manual valve link, retainer spring and manual valve. Install oil dam and channel plate gaskets. Install 4 check balls in channel plate, using petroleum jelly to retain check balls. See Figure . Install TCC solenoid screen.
- Install NEW spacer plate-to-channel plate gasket onto channel plate using alignment pins. Install spacer plate onto gasket. Install NEW spacer plate-to-valve body gasket onto spacer plate. See Fig 1 .
- Install oil pump drive shaft. Install shift solenoid screens. Install 6 check balls into control valve assembly. Use petroleum jelly to retain check balls in place. See Fig 1 .
- Install control valve assembly onto channel plate using alignment pins. See Fig 1 . Install and tighten control valve assembly bolts. See Figure . Install oil pump onto control valve assembly. Install and tighten oil pump bolts. See Figure .
- Install wiring harness to harness clips. Connect wiring harness connectors to solenoids and temperature sensor. Install temperature sensor into channel plate and attach to clip. See Figure . Ensure connectors for solenoid "B" and TCC solenoid are connected correctly. To identify correct wire for TCC solenoid, look for diode in wiring harness under shrink wrap. If solenoid "B" and TCC solenoid wires are reversed, transaxle will shift into Reverse okay, but engine will stall immediately after transaxle is shifted into Drive.
- Install gaskets and seal onto case side cover and channel plate. Install case side cover. Install accumulator pins into case. Install accumulator springs and pistons into accumulator housing. Springs and pistons are transaxle model specific. Install accumulator spacer plate and gaskets. Install accumulator housing onto accumulator cover. Install and tighten accumulator housing bolts.
- Install lube oil hose onto lube oil pipe. Install hose clamps. Install lube pipe retainer clip onto pipe and washer assembly. Install pipe and washer assembly onto lube oil hose.
- Install servo pipes into accumulator cover and 2-1 manual servo cover. Ensure lube oil pipe and manual servo pipe are installed correctly. Manual servo pipe should be installed in accumulator housing center hole, and lube oil pipe should be installed in right side hole. See Figure . Forward servo pipe cannot be installed in wrong hole due to a larger pipe diameter.
- If pipes are installed incorrectly, lube oil will apply 2-1 manual servo and band as soon as engine is started. Vehicle will display a tie-up condition in Park and Reverse, and on a 2-3 upshift. Vehicle will move forward in Neutral if condition exists.
- Install 2-1 manual servo components into transaxle case. Install accumulator cover, pipes and retainer onto case as an assembly. See Figure . Install pipe and washer assembly into transaxle case. Ensure pipe and washer assembly is installed into final drive internal gear. Lock retainer into case. Tighten hose clamps.
- Install NEW oil filter seal, filter and gasket into case. Install oil pan. Install forward and reverse servo return springs into proper servo bore. Assemble each servo and then install into case. Install NEW oil seal ring onto each servo cover. Install forward and reverse servo covers into case. Install snap ring and cover bolts. See Figure .
- Install speed sensor. Install modulator valve into case. Install NEW "O" ring seal onto modulator. Install modulator into case. Install retainer and bolt. Hold torque converter in place for installation.
INPUT CLUTCH THRUST WASHER IDENTIFICATION
| Washer ID No. | Color | Thickness: In. (mm) |
|---|---|---|
| 1 | Orange/Green | .114-.118 (2.90-3.00) |
| 2 | Orange/Black | .120-.124 (3.05-3.15) |
| 3 | Orange | .126-.130 (3.20-3.30) |
| 4 | White | .132-.136 (3.35-3.45) |
| 5 | Blue | .138-.142 (3.51-3.61) |
| 6 | Pink | .144-.148 (3.66-3.76) |
| 7 | Brown | .150-.154 (3.81-3.91) |
| 8 | Green | .156-.159 (3.96-4.04) |
| 9 | Black | .161-.165 (4.09-4.19) |
| 10 | Purple | .167-.171 (4.24-4.34) |
| 11 | Purple/White | .173-.177 (4.39-4.50) |
| 12 | Purple/Blue | .179-.183 (4.55-4.65) |
| 13 | Purple/Pink | .185-.189 (4.70-4.80) |
| 14 | Purple/Brown | .191-.195 (4.85-4.95) |
| 15 | Purple/Green | .197-.200 (5.00-5.08) |