Transaxle Reassembly

NOTE: Handle all parts carefully to avoid damaging bearing and mating surfaces. Lubricate all components with automatic transmission fluid prior to reassembly. Gaskets and thrust washers may be held in place by using petroleum jelly. Use all NEW gaskets and oil seals, and tighten bolts evenly. See Fig 1 for thrust washer and thrust bearing locations.

Fig 1: Cross Sectional View of Transmission Housing

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If only transmission section and differential section were separated: Place final drive housing with converter housing facing downward. Install guide on spline portion of drive pinion rear end and join differential section with transmission section. Install transfer drive shaft at this time also (4WD transmissions only).
Ensure that parking rod and parking actuator engages properly and sealing lip is not damaged. Install valve body, vacuum diaphragm assembly and downshift solenoid. Install servo apply and servo release tubes and install oil pan.
Place transmission on oil pan and install turbine shaft and oil pump drive shaft with single oil supply port positioned toward oil pump. Install torque converter onto stator shaft, turbine shaft and pump drive shaft taking care not to damage oil seal in converter housing. See Fig 2 .

Fig 2: Positioning Oil Port
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If complete transmission was disassembled: Install parking pawl and parking pawl shaft. Install parking rod support plate, parking pawl return spring and parking pawl in housing and retain with spring after inserting shaft from front side. Connect parking rod, parking lever and retain with clip.
Install parking rod on notched portion of parking shaft support plate with cam portion positioned at back of parking pawl. Install parking lever to parking lever pin and retain with clip. See Fig 3 .

Fig 3: Installing Parking Pawl Assembly
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Install drive pinion seal guide to splines of drive pinion rear end and connect transmission housing and final drive housing using 8 (8 mm) nuts being careful not to damage oil seal.
Engage planetary gear unit with center support assembly and check operation of one-way clutch. Check that one-way clutch in planetary gear unit rotates clockwise only, then separate assemblies.
Place center support and low-reverse brake assembly in base and select a retaining plate so that dimension "H" is 2.89-2.92" (73-74 mm). See Fig 4 .

Fig 4: Selecting Retaining Plate
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If clearance is not within specifications, correct by installing a retaining plate of different thickness. Center support and low-reverse brake assembly retaining plates are available in thicknesses of .268" (6.8 mm) to .283" (7.2 mm) in .008" (0.2 mm) increments.
Install snap ring, retaining plate, drive plates, driven plates, center support assembly and snap ring into transmission housing. When installing center support, install (6 mm) bolts in support while turning support gradually being careful not to damage one-way clutch or bushing.
After assembly, measure clearance between piston and driven plate. Clearance should be be .020-.047" (0.50-1.2 mm). With clearance correctly set, apply compressed air to oil hole in center support and check operation of low-reverse brake piston. See Fig 5 and Fig 6 .

Fig 5: Measuring Piston & Low-Reverse Driven Plate Clearance
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Fig 6: Checking Operation Of Low-Reverse Brake Piston
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Install connecting shell and and clutch hub as an assembly to spline of reverse sun gear and forward sun gear. Install forward clutch assembly and reverse clutch assembly. Ensure that thickness of washer installed between forward clutch and clutch hub is .047" (1.2 mm).
Match projected portions of brake band with notches in transmission housing and install brake band. Using depth gauge block and gauge, check transmission total end play with thrust bearing removed.
Place gauge block on rear face of transmission housing, then using depth gauge, measure distance "L" (from forward clutch to top of gauge block). See Fig 7 . Place gauge block on top of oil pump carrier (with thrust bearing installed.)

Fig 7: Measuring Distance "L" For End Play Adjustment
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Measure distance "I" (from rear cover mounting surface to top of gauge block). See Fig 8 . Note both values just obtained for future reference. Add .016" (0.4 mm) to distance "L", then subtract allowable transmission end play of .01-.02" (.25-.50 mm).

Fig 8: Measuring Distance "I" For End Play Adjustment
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Subtract distance "I" from value just obtained. Final value is thickness of washer to be installed. End play washers are available in thicknesses of .039" (1.0 mm) to .087" (2.2 mm) in increments of .008" (0.2 mm).
Using depth gauge block (498147001) and gauge (398643600), check reverse clutch end play. Place gauge on rear face of transmission housing and measure distance "M" (from rear face of reverse clutch drum to top of gauge block). See Fig 9 .

Fig 9: Measuring Distance "M" For Reverse Clutch End
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Place gauge block on oil pump face and measure distance "m" (from rear cover mounting surface to top of gauge block). Add .016" (0.4 mm) to distance "M", then subtract allowable end play of .020-.030" (0.5-0.8 mm). Subtract distance "m" from value just obtained. See Fig 10 .

Fig 10: Measuring Distance "m" For Reverse Clutch End Play Adjustment
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Final value is thickness of reverse clutch drum thrust washer to be installed. Reverse clutch drum thrust washers are available in thicknesses of .039" (1.0 mm) to .087" (2.2 mm) in increments of .008" (0.2 mm).
Install transfer drive shaft. Secure transfer coupling to transfer drive shaft with a NEW spring pin and engage shaft with drive pinion splines. Install thrust bearing on on forward clutch. Apply petroleum jelly to washers which have been selected and place them on oil pump carrier.
Before installing oil pump assembly ensure that mating surfaces of transmission cover (intermediate houing on 4WD transmissions) and transmission housing are free from oil. Install oil pump assembly being careful not to drop washers.
Install servo return spring on servo piston. Install band servo piston and piston cover into transmission housing by using piston rod as a guide. Ensure that "O" ring is not damaged. Secure piston with snap ring.
Install brake band apply strut and tighten band adjusting screw to 78 INCH lbs. (9 N.m), then back screw off 2 complete turns and tighten lock nut to 20 ft. lbs. (27 N.m.). Using shims, adjust clearance between manual plate and spacer to .012" (0.3 mm) and tighten nut to 25-33 ft. lbs. (33-44 N.m). See Fig 11 .

Fig 11: Adjusting Manual Plate-To-Spacer Clearance
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Install valve body into transmission housing, making sure that groove in manual valve engages pin in manual plate. Tighten valve body bolts to 50-70 INCH lbs. (6-8 N.m). With valve body installed fully compress vacuum throttle valve and measure distance from end of valve where modulator rod will seat to outside of transmission housing.
Resulting measurement will determine length of modulator rod to be installed. Select a rod from those listed in modulator rod selection table. Install "O" ring on vacuum diaphragm and install selected rod together with vacuum diaphragm. See Fig 12 and Fig 13 .

Fig 12: Measuring Throttle Valve Depth for Modulator Rod Selection
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Fig 13: Modulator Rod Selection Table
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Install NEW servo apply and servo release tubes by lightly tapping them into position. Ensure that tube installed height does not exceed 1.61 (41 mm), as measured from transmission housing oil pan mating surface. Install oil pan. Place transmission on oil pan and install turbine shaft and oil pump drive shaft with single oil port toward oil pump.
On 4WD transmissions: Using installers, install bearing and transfer clutch (drum) assembly to rear shaft. Install rear pressure plate, plates and front pressure plate. Apply compressed air to oil hole located at end of rear shaft to ensure that piston moves freely.
On 4WD transmissions: Check clearance between retaining plate and clutch assembly snap ring using a feeler gauge. Clearance should be .016-.031" (0.4-0.8 mm) If clearance is not within specifications, correct by installing a retaining plate of different thickness.
On 4WD transmissions: Transfer clutch assembly retaining plates are available in thicknesses of .185 (4.7 mm) to .232" (5.9 mm) in 0.3" (0.17 mm) increments.
On 4WD transmissions: Install washer, bearing, transfer drive gear, washer, bearing and seal ring onto rear drive shaft. Install rear shaft assembly in extension housing, being careful not to damage bushing or seal at end of drive shaft.
On 4WD transmissions: Place gauge block on rear face of intermediate housing, then using depth gauge, measure distance "N" (from housing bearing bore to top of gauge block). See Fig 14 . Note value obtained for future reference.

Fig 14: Measuring Distance "N" For Transfer Shaft End Play
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On 4WD transmissions: Place gauge block on top of bearing, then using depth gauge, measure distance "n" (from extension housing to top of gauge block). See Fig 15 . Add .008" (0.2 mm) to distance "N", then subtract allowable end play of .012" (0.3 mm) from this value.

Fig 15: Measuring Distance "n" For Transfer Shaft End
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On 4WD transmissions: Subtract distance "n" from value just obtained. Resulting value is thickness of rear shaft thrust washers to be installed. Rear shaft thrust washers are available in thicknesses of .008" (0.2 mm) and .020" (0.5 mm). DO NOT install more than 3 thrust washers.
On 4WD transmissions: Install rear drive gear thrust plate and transfer drive gear in intermediate case. Ensure that thrust plate notch aligns with with mounting bolt. Install selected washer in intermediate housing. Install extension assembly and tighten bolts to 18 ft. lbs. (24 N.m).
NOTE: Be sure to install transfer solenoid wire harness clip and seal ring.
Install "O" ring to bore in extension housing. Install transfer solenoid and tighten (hand tight). Install temperature switch and gasket. Tighten to 13 ft. lbs. (18 N.m). Fasten wire harnesses with clips and install rear engine mount.