Steps 1 - 40

Part 1:

Part 2:

Part 3:

Special Tool(s)





Material

Assembly





1. Using the special tool, install the final drive input gear bearing.
1. Install the final drive input gear bearing.
2. Install the special tool.





2. Using an arbor press and the special tools, seat the final drive input gear bearing.





3. Install a new collapsible spacer.





4. Using the special tool, position the final drive input gear.

5. CAUTION: Hold the final drive input gear while installing the final drive input gear bearing to prevent it from falling out of the transaxle case.

Rotate the transaxle 180 degrees.





6. Using the special tools, install the final drive input Bear bearing.
7. Rotate the transaxle 180 degrees.





8. Using the special tool, lock the final drive input gear.
9. Rotate the transaxle 180 degrees.





10. NOTE: A high tightening torque specification between 400-450 Nm (295-332 ft. lbs.) is necessary to crush the collapsible spacer for correct bearing preload.

NOTE: If the preload is too high, a new collapsible spacer must be installed.

Using the special tools, tighten the nut to achieve the preload specification.
11. Rotate the transaxle 180 degrees.





12. NOTE: Make sure that the final drive rotates.

Unlock the special tool.
13. Rotate the transaxle 180 degrees.





14. CAUTION: Make sure the bearing preload is within specification.

NOTE: Rotate the gear 10 times to make sure that the bearings are correctly seated.

Using the special tools, measure the rotating torque.





15. After achieving the correct torque, remove the special tools and stake the nut to prevent movement.
16. Rotate the transaxle 180 degrees.





17. Position the transfer shaft gears in the transaxle case.





18. Install the parking pawl return spring.





19. Connect the spring.
1. Install the parking pawl abutment.
2. Install the lever.
3. Install the pin.
4. Connect the spring.





20. Install the parking pawl assembly cover and bolts.





21. Install the differential case assembly.





22. Position the bearing cups.





23. Install the special tools.





24. NOTE: The converter housing cover must be installed evenly or an incorrect reading will result.

Using the special tools, assemble the transaxle for end play measurement.
1. Position the converter housing.
2. Install the long bolts and seat the case cover flat.
3. Install the short bolts.





25. Remove the converter housing.
1. Remove bolts.
2. Remove the converter housing.





26. Remove the special tools.





27. Remove the bearing cups.





28. NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct transfer shaft shim, measure the depth of the plunger on the special tool and select the correct transfer shaft shim.





29. NOTE: If the plunger is above the contact surface, the reading will be incorrect.

To determine the correct differential shaft shim, measure the depth of the plunger on the special tool and select the correct differential shaft shim.





30. Using the special tool, install the correct transfer shaft shim and bearing cup in to the converter housing.





31. Using the special tool, install the correct differential shaft shim and differential case bearing cup into the converter housing.





32. Apply a one millimeter thick bead of Loctite 5699.





33. Position the converter housing on the transaxle case and install the bolts.





34. Install the intermediate/overdrive band servo piston return spring.





35. Install the intermediate/overdrive servo piston.





36. Install the O-ring seal.





37. NOTE: The three bolts must be loosely installed, then tightened in sequence to compress the intermediate/overdrive spring evenly.

Install the intermediate/overdrive band servo piston cover.





38. Install the shifter assembly and bolt.





39. NOTE: Lubricate the O-ring prior to assembly.

Install the new O-rings on the manual lever shaft.





40. Install the manual lever shaft.