Transaxle Reassembly

1. Install servo piston into transmission housing. With mounting device, press piston cover slightly and install snap ring to secure servo piston. Turn transmission over and install brake band "C" into housing. Fit lugs of brake band into 2 pins. Ensure brake band seats into transmission housing shoulder.
2. Assemble and install brake "D" clutch discs into transmission housing and secure with snap ring. Install measuring bar and dial indicator. Manually lift complete set of clutch discs and read clearance of discs. Clearance for 6 pairs of clutches should be .08-.10" (2.0-2.5 mm). Remove brake "D" disc set and insert 1st one-way clutch into transmission housing. Ensure inner ring of one-way clutch does not fall out. Turn transmission over while holding free-wheel in place.
3. Set tab washer with locking lug into transmission housing. Install slotted nut and tighten to 37 ft. lbs. (50 N.m). Bend lock tab into nut seat. Ensure free-wheel turns freely in clockwise direction. Reinstall brake "D" disc set and secure with correct washers. Install spider bowl into one-way clutch inner ring. Press tapered roller bearing inner ring onto output shaft. Insert output shaft into hollow gear and secure with snap ring. See Fig 1 .
   Fig 1: Exploded View Of Planetary Gears & Clutch "B"

   Courtesy of ZF GETRIEBE GMBH SAARBRUCKEN
4. Install output shaft/hollow gear assembly into transmission case. Install needle bearing assembly along with flat washer and angle washer in output shaft assembly. Install planetary carrier into hollow gear. Install sun gear into planetary carrier. Fit sun gear drum onto teeth of sun gear.
5. Install needle bearing assembly along with flat washer and angle washer into sun gear drum. Insert sun gear shaft into sun gear drum. Ensure when rotated, sun gear drum rotates in opposite direction from sun gear shaft. Install needle bearing assembly along with flat washer and angle washer over the end of the intermediate shaft. Insert intermediate shaft into sun gear shaft.
6. Fit rectangular rings and thrust washer on engine shaft. Install assembled clutch "E" and engine shaft assembly into case. Ensure shoulder of cylinder "E" is flush with edge of disc carrier on sun gear shaft.
7. Assemble clutch "A" and install 2 rectangular rings onto turbine shaft and engage hook. Press turbine shaft into clutch "A" cylinder and engage locking ring with snap ring pliers. Pull on turbine shaft until it seats with snap ring, otherwise axial clearance will be incorrect. Insert assembled clutch "A", rotating until teeth of discs engage. Plastic thrust washer must be centered on engine shaft. If correctly installed, engine shaft will project approximately .8" (22 mm) over turbine shaft.
8. Assemble clutch "B" and install into case by turning until discs fully engage. Clutch "B" must engage in recesses of drum for a gap of .04" (1.0 mm) to be still visible.
9. Assemble pump housing and torque converter pressure relief valve, and install on intermediate plate. Insert compression spring into opening in pump, place intermediate plate onto pump housing and align. Bolt intermediate plate to pump housing; tighten bolts to 89 INCH lbs. (10 N.m). Inspect torque converter relief valve to ensure it operates freely. Ensure pump operates freely. Install 3 rectangular rings onto hub of intermediate plate.
10. Assemble 2nd one-way clutch by inserting cage of one-way clutch into collar with collar facing down. If not installed properly, clamping direction will not be correct. Install cover rings on one-way clutch collar. Insert one-way clutch inner race by turning it clockwise. One-way clutch inner race must rotate freely in clockwise direction with collar pointing out.
11. Install .04" (1.0 mm) selective adjusting washer and angle washer onto shaft. DO NOT  install 2nd one-way clutch during measurement process. Install assembled pump and intermediate plate. Rotate back and forth until fully engaged. Hold in place with 2 opposing bolts. Tighten bolts to 89 INCH lbs. (10 N.m). Install measuring tool onto turbine shaft and secure tightly.
12. Measuring tip of dial indicator must rest on impeller shaft. Pull on measuring device to obtain reading. Axial clearance should be .004-.012" (.10-.30 mm). If clearance is not as specified, select correct washer. Remove intermediate plate assembly. Install angle washer and adjusting washer onto hub of intermediate plate.
13. Install 2nd one-way clutch into lined discs of brake "C" with inner teeth seated on washer. Ensure all lined discs mesh with one-way clutch inner race. Do this by rotating outer race; lined discs must also turn.
14. Tighten adjusting washer of brake band in order to secure cylinder "B" in place. Insert assembled pump, intermediate plate and 2nd gear one-way clutch into transmission. Rotate back and forth to seat unit. When inserting unit, hold one-way clutch to avoid discs slipping out. When properly installed, plate springs seat into transmission housing when pressure is applied against pump housing.
15. Install 8 bolts into intermediate plate and tighten bolts to 89 INCH lbs. (10 N.m). Loosen brake band and check axial clearance. Assemble governor housing on governor hub. Tighten retaining bolts to 89 INCH lbs. (10 N.m). Install rectangular ring on end groove of governor hub and snap hook. Insert 2 rubber rings into middle and rear groove. DO NOT  stretch rings unnecessarily.
16. Coat rubber rings and rectangular ring with petroleum jelly. Carefully insert assembled governor unit into transmission housing. Use care installing rubber rings into annular groove. Install tapered roller bearing inner race onto countershaft. Insert countershaft into engaging gears of governor flange while rotating shaft and holding flange in position to prevent it from falling out.
17. Install retaining tool to hold countershaft in place while turning transmission over. Slip spacer sleeve over countershaft on governor unit. Install outer race of tapered roller bearing with plastic hammer until seated. Outer ring must be seated with no clearance to ensure correct adjustment.
18. Press tapered roller bearing inner race onto spur gear. Install .07" (1.9 mm) washer and spur gear onto countershaft and snugly tighten bolt. Drive the 3 tension pins of adjusting ring until they protrude. Install adjusting ring onto tapered roller bearing inner race of output shaft with tension pins facing up and install on spur gear.
19. Engage parking pawl. Tighten countershaft nut to 44 INCH lbs. (5 N.m) to ensure tapered roller bearings are seated. Release parking interlock, rotate spur gears several times, tighten countershaft nut to 44 INCH lbs. (5 N.m) and rotate again.
20. Loosen nut, remove spur gear and use micrometer to measure thickness of washer at 3 tension pins of adjusting sleeve. Average 3 readings and install correct washer.
21. Insert correct washer and spur gear onto countershaft. Tighten countershaft bolt to 110 ft. lbs. (150 N.m). Install Preloading Device (87 91 733) to transaxle case. Attach measuring tool with dial indicator.
22. Turn adjusting screw down for gauge pointer to move. While rotating spur gears several times, set gauge scale to zero. If pointer deflects to end of scale, record readings to determine average reading. Loosen pretensioning device on bottom of transmission. Tighten adjusting screw one turn.
23. Rotate spur gears several times until pointer of dial indicator has settled. Record readings and obtain an average. Use following formula to obtain correct washer thickness:
    • S = .07" X + .03" 
    • S = Specific thickness of washer
    • .07 = Selected shim thickness when measured
    • X = Reading on dial indicator
      NOTE: If it is necessary to install a washer of different thickness, it is recommended to repeat measurement steps. Countershaft bolt must be tightened to 110 ft. lbs. (150 N.m).
24. Install spur gears and washer, and tighten bolt to 110 ft. lbs.(150 N.m). Install differential and torque converter housing. DO NOT  install end cover and gasket at this time; differential housing must be rotated over countershaft to seat bearings. This step must be repeated for subsequent adjusting of preload.
25. Install shaft seal into converter bellhousing and coat seal with petroleum jelly. Turn over converter bellhousing and install bearing race until it is seated. Press roller bearing onto right axle shaft and secure with snap ring.
26. Install new shaft seal and assembled right axle shaft. Secure assembled right axle shaft with snap ring. Slip new "O" ring on shaft and install axle seal. Install "O" ring on speedometer sleeve. Insert speedometer pinion into speedometer sleeve and install sleeve.
27. Insert assembled speedometer drive into converter housing ensuring speedometer seats properly into speedometer bore. Install new retaining ring. Install converter housing gasket and converter housing. Tighten bolts to 17 ft. lbs. (23 N.m).
28. Press left axle shaft bearing into bearing housing. Press axle shaft seal into other end of bearing housing. Using Differential Preload Tool (81 91 279), press left axle shaft into bearing housing and secure axle shaft with locking ring. See Fig 2 . Install differential bearing race into transmission housing. If necessary, preheat housing with heat gun.
29. Measure shoulder of axle shaft bearing housing and record, this is distance "B". Measure distance "A" between machined surface of converter housing (where axle bearing housing mates) and differential bearing race. Use following formula to determine washer thickness:
    • Clearance = "A" - "B" + .004" (.1 mm) 

Install determined washer thickness and reassemble.

30) Apply a light coat of ATF to cylinder "B". Tighten brake band bolt to 89 INCH lbs. (10 N.m). Turn cylinder "B" during tightening operation to ensure brake band is not twisted. Loosen adjusting bolt 2 turns. Mark adjusting bolt and housing to ensure screw does not turn. Tighten lock nut to 59 ft. lbs. (80 N.m).

31) Insert oil tubes into mounting tool and install with plastic hammer until seated. Install dipstick tube into transmission housing and secure with a clamp. Tighten clamp bolt to 44 INCH lbs. (5 N.m). Turn transmission on side to prevent bolt from falling into housing. Set gear selector to "1" position.

32) Pull accelerator cam, with accelerator cable, far enough to prevent accelerator cam from jamming with throttle piston. Set selector valve (push in) in valve body to "1" position. Install valve body, with accelerator cable pulled out, ensuring selector valve is inserted in pin of stop plate. Tighten all bolts to 89 INCH lbs. (10 N.m).

1. Pull out accelerator cable, with sleeve extended, to point of kickdown (noticeable resistance). Clamp lead seal 1.51-1.55" (38.5-39.5 mm) from end of sleeve. Check operation of accelerator cable and selector mechanism.
2. Install new oil pan gasket and oil pan. Tighten bolts to 53 INCH lbs. (6 N.m). Install oil pan drain plug and tighten plug to 59 ft. lbs. (80 N.m). Install "O" ring and oil filter onto transmission housing.
3. Install filter cover, with magnet. Install bolt and tighten to 71 INCH lbs. (8 N.m). Install torque converter and secure with retaining clamp. Install new "O" ring on dipstick and install dipstick.