Steps 41 - 95

41. NOTE: The roll pin does not need to sit flush with the shifter assembly.

Install a new manual lever shaft roll pin.





42. Loosely install the transmission range (TR) sensor.





43. Check accumulator bores and pistons for steps and install the accumulator pistons in their respective bores.





44. NOTE: The neutral drive accumulator springs are thinner than the 1-2 accumulator springs.

Install the thinner and longer neutral drive accumulator springs.





45. Install the neutral drive accumulator piston.





46. Install the 1-2 accumulator springs.





47. Install the 1-2 accumulator piston.





48. Inspect the seals. Lubricate and install the transaxle internal harness electrical connector.





49. NOTE: Make sure that the manual valve is in the manual control valve shift lever.

NOTE: Do not fully tighten the bolts at this stage.

Install the main control valve body.





50. Tighten the main control valve body retaining bolts.
- Tighten the bolts in the sequence shown.





51. NOTE: It is necessary to connect the connectors in the same positions as noted in disassembly. Connector color letters are cast in the solenoid body.

Install the main control wiring harness, connect the electrical connectors and install the ground wire bolt.
1. Solenoid SSC; Color N (Neutral/White).
2. Solenoid SSE; Color G (Green).
3. Solenoid SSD; Color L (Blue).
4. Solenoid EPC; Color B (Black).
5. Solenoid SSA; Color N (Neutral).
6. Solenoid SSB; Color B (Black).





52. Install the fluid filter.





53. Connect the transmission fluid temperature (TFT) sensor.





54. Apply a bead 1.5 mm diameter of Loctite 5699 to the transaxle fluid pan.





55. Install the transaxle fluid pan.
56. Rotate the transaxle 180 degrees.





57. Install the low/reverse clutch piston.





58. Install the low/reverse clutch return spring.





59. Install the bevel ring with the outer edge of the beveled ring up towards the top of the case.





60. Inspect the position of the bevel ring.
1. Make sure the low/reverse clutch piston is seated.
2. Make sure the bevel ring is installed with the inside edge facing down.





61. Install the low one-way clutch inner race.





62. NOTE: The opening of the retaining ring must be at the ten o'clock position.

Install the low one-way clutch retaining ring.





63. Install the low/reverse plates and pressure plate.





64. Install the low reverse clutch plate selective retaining ring.
- Check the clutch clearance.





65. NOTE: Make sure that the snap ring is installed before installing the planet assembly.

Install the planet assembly.





66. CAUTION: The edge of the planet assembly must fit flush with the transaxle case.

Inspect the planet assembly installation.





67. CAUTION: The planet assembly must only rotate counterclockwise.

Check to make sure that the one way clutch is correctly installed.
- Rotate the planet assembly clockwise and counterclockwise.





68. Install the intermediate/overdrive drum assembly.





69. Install the intermediate/overdrive band.





70. Install the direct clutch cylinder thrust bearing with the rollers facing up.





71. Install new end cover-to-case seals.





72. Install new end cover seals.





73. Install the direct clutch hub bearing shim and an additional shim to increase the total shim thickness to specification shown.





74. Measure the gap between the transaxle end cover and the transaxle assembly.
1. Position the transaxle end cover on the transaxle assembly.
2. Measure the gap between the transaxle end cover and the transaxle assembly.





75. Remove the transaxle end cover.





76. NOTE: The clearance for the direct clutch bearing shim is 0.05-0.50 mm.

Choose and install the correct direct clutch hub bearing shim:
- Line 1: total amount of shim thickness used during transaxle end cover mock up.
- Line 2: measure the gap between transaxle end cover and transaxle case.
- Line 3: subtract Line 2 from Line 1 to obtain the actual clearance.
- Line 4: subtract 0.05 mm (0.002 inch) from Line 3 for maximum shim thickness.
Subtract 0.50 mm (0.020 inch) from line 3 for the minimum thickness shim.





77. CAUTION: Applying too much sealer in the area of the fluid return holes may cause the fluid return holes to become blocked and cause a transmission failure.

Apply a 1 mm (0.04 inch) bead of sealer to the transaxle end cover.





78. Install the transaxle end cover.





79. Using the special tool, collapse the intermediate/overdrive band to specification, then back out three and a half turns.





80. Holding the special tool, lightly seat the nut against the transaxle case, then remove the special tool without changing the relationship of the nut on the bolt.





81. Using the special tool, select an intermediate/overdrive band bolt that measures from the end of the bolt to the face of the nut as shown.





82. NOTE: Apply thread sealer to the bolt.

Install the intermediate/overdrive band anchor bolt.
83. Rotate the transaxle 180 degrees.





84. Install the forward clutch hub.





85. Install the forward clutch assembly.





86. Install the forward clutch thrust washer.





87. Lubricate and install new fluid pump seals.





88. Install the fluid pump (do not force the pump down at this time).





89. Install the fluid pump bolts.
- Use the bolts to seat the fluid pump.
- Tighten bolts in an alternating sequence.





90. Install the output shaft speed (OSS) sensor.





91. NOTE: Apply thread sealer to the bolt.

Install the turbine shaft speed (TSS) sensor.





92. Using the special tool, align the TR sensor and tighten the bolts.





93. CAUTION: Do not use air tools on this bolt. Hold the manual control lever while tightening the manual control lever bolt.

Install the manual control lever.





94. Install the torque converter.





95. Using the special tool, secure the torque converter