Steps 51-94

Transaxle





















Assembly

51. NOTICE: Tighten the spring retainer bolts by tightening them slightly in an alternating pattern or damage can occur to the clutch actuator levers.

NOTE: Make sure the spring retainer contour aligns with the actuator lever contour as shown.

NOTE: Make sure the serial number on the spring retainer matches the serial number on the actuator lever. If reusing the spring retainers and actuator levers use the marks made during removal for assembly.

Install the spring retainers and spring retainer bolts.

- Tighten to 26 Nm (19 lb-ft).





52. Remove the clutch actuator lever locks if installed.





53. Install the clutch motors. For additional information, refer to Clutch Motor - No. 1 Clutch Motor - No. 1 and Clutch Motor - No. 2 Clutch Motor - No. 2.

54. NOTE: The engagement system bearing unit should be installed easily.

Install the engagement system bearing unit.





55. NOTICE: Do not tilt transaxle after the Z-washers are installed, they may come off center and damage can occur.

Install the Z-washers onto the engagement system bearing unit and center them correctly.





56. If installing a new clutch go to step 19.

57. NOTE: Make sure the special tool washer is also installed.

Install the special tool in a vise.





58. Place the clutch on the special tool and align one clutch stud with the slotted hole on the special tool.





59. Install the special tool loosely on the clutch.





60. Install the special tool on the clutch making sure the legs are inserted in the slots.





61. Turn the special tool clockwise to the stops and hold.





62. NOTICE: Failure to rotate the self-adjuster to the stops before compressing the clutch, causes damage to the clutch.

Tighten the special tool until the 3 clutch 1 locks can be locked in place by hand.





63. Install the special tool loosely on the clutch.





64. Using the special tool, move the clutch self-adjuster counterclockwise to the stop and hold.





65. NOTE: An audible click can be heard when the clutch locks lock.

Using the special tool, compress the clutch to the stops on the clutch. The locks on clutch 2 lock at this time.





66. Remove the special tools.





67. NOTE: The minimum number of engaged clutch locks is 6. Make sure the 6 locked clutch fingers align with the clutch studs as shown. If not, reset the clutch 2 locks as necessary.

Visually check the locks to make sure they have locked. 3 locks shown, 12 total.





68. If installing a used clutch, verify the clutch is not worn or damaged. Perform the next 2 steps to check for clutch wear.

69. Check clutch 1 for wear by measuring the distance between the adjuster ring 1 long hole and lever 1 spring. Replace the clutch assembly if the measurement is 26 mm (1.023 in) or less.





70. Check clutch 2 for wear by measuring the distance between adjuster ring 2 and the cover. Replace the clutch assembly if the measurement is 15 mm (0.59 in) or less.





71. Apply a small amount of transmission fluid on the input shaft bearing surface.





72. Apply a small amount of DPS6 Grease on both input shaft splines.





73. Verify the Z-washers are installed correctly.





74. NOTICE: Verify the clutch locks are locked prior to installation or the transaxle may not operate correctly and damage can occur. If the clutch locks are not locked go to step 2 within this procedure.

Using the special tools, install the clutch in the transaxle.





75. Remove all the special tools.





76. Install the special tools onto the transaxle case.





77. NOTICE: Do not overtighten the special tool or damage can occur.

Using the special tools, push the clutch down with approximately 5 Nm (44 lb-in) of torque until seated on the input shaft bearing and the snap ring groove is visible.





78. NOTE: Make sure the hollow input shaft snap ring is fully seated.

Install the new hollow input shaft snap ring.





79. NOTE: Align the index marks on the clutch hub and clutch.

Install the clutch hub.





80. Install the new clutch hub snap ring in the position shown.





81. NOTICE: Do not turn the special tool more than 12 turns or damage to the clutch actuator engagement lever can occur.

Using the special tool, release the clutch 1 locks and then the clutch 2 locks by slowly turning the special tool counterclockwise. An audible click will be heard when the clutch locks are released.





82. Apply anti-seize to both clutch motor surfaces where indicated.





83. Apply anti-seize to the clutch actuator lever splines as shown.





84. Install the clutch motor 2 and the 4 clutch motor 2 bolts.
- Tighten to 5 Nm (44 lb-in).





85. Install the clutch motor 1 and the 4 clutch motor 1 bolts.
- Tighten to 5 Nm (44 lb-in).





86. NOTICE: Be sure to use the 3.2 mm (0.125 in) input shaft speed sensor 2 shim or damage can occur to the transaxle.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 2.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 2 O-ring for installation.

Install the input shaft speed sensor 2.

1. Install the input shaft speed sensor 2 shim.

2. Install the input shaft speed sensor 2.

3. Install the input shaft speed sensor 2 bolt.
- Tighten to 10 Nm (89 lb-in).





87. NOTICE: Be sure to use the 3.5 mm (0.137 in) input shaft speed sensor 1 shim on input shaft speed sensor 1 or damage can occur to the transaxle.

NOTE: Install a new O-ring if installing the existing input shaft speed sensor 1.

NOTE: Use a small amount of transmission fluid on the input shaft speed sensor 1 O-ring for installation.

Install the input shaft speed sensor 1.

1. Install the input shaft speed sensor 1 shim.

2. Install the input shaft speed sensor 1.

3. Install the input shaft speed sensor 1 bolt.
- Tighten to 10 Nm (89 lb-in).





88. NOTE: If installing the old OSS sensor, install a new O-ring.

Install the OSS sensor and the OSS sensor bolt.

- Tighten to 10 Nm (89 lb-in).





89. Install the TR sensor and the 2 TR sensor bolts.
- Tighten to 10 Nm (89 lb-in).





90. Carefully inspect the TCM and the transaxle bore for debris or damage. Clean and/or repair as needed.

91. NOTE: Use a small amount of transmission fluid on the new O-rings prior to installation.

Install new O-rings if the TCM is being reused.





92. NOTICE: Do not force the TCM onto the transaxle or damage may occur.

NOTICE: Make sure the TCM sits flush on the transaxle or damage can occur.

Install the TCM on the transaxle. Apply light pressure to seat the O-rings. If the TCM does not push in place with light pressure, remove the TCM and slightly turn the TCM gears and retry installing the TCM on the transaxle.





93. Install the 4 TCM bolts.
- Tighten to 27 Nm (20 lb-ft).





94. Install the transaxle wiring harness.