DISASSEMBLY AND ASSEMBLY

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1 Automatic Transaxle/Transmission DISASSEMBLY AND ASSEMBLY Transaxle Special Tool(s) Dial Indicator Gauge With Holding Fixture (TOOL-4201-C) Special Tool(s) Test Plate Screw Set, Transmission (T82P-7006-C) Step Plate 205-D014 (D80L-630-3) Air Test Plate, Transmission (T94P EH) Installer, Steering Gear Pinion Bearing (T90C-3504-DH) Gasket, Transmission Air Test Plate (T94P EH1) Depth Micrometer 303-D075 (D92P-4201-A) Installer, Halfshaft Output Fluid Seal (T86P-1177-B) Retaining Ring Pliers (T95P AHR) Gauge, Servo Rod (T86P B) Handle, Torque Converter (T81P-7902-C) Holding Fixture Transmission (T57L-500-B) (Continued) Lifting Fixture, Clutch Pack (T86P A) (Continued) Copyright 2004, Ford Motor Company Last updated: 6/4/2008

2 Automatic Transaxle/Transmission Special Tool(s) Installer, Torque Converter Fluid Seal (T87L AH) Special Tool(s) Aligner, Output Shaft Fluid Seal (T94P JH) End Play Gauge Shim Selection Gauge (T87P AH) (T94P MH) Remover/Installer, Servo Piston Shim Depth Gauge (T92P A) (T94P NH) Shim Selection Gauge Bar Alignment Gauge, TR Sensor (T94P Q) (T97L A) Remover, Reverse Clutch/Planet Remover/Installer Bearing Tube (T94P FH) (T75L-7025-C) Remover/Installer, Front Clutch Remover, Bearing Collet Sleeve (T94P HH) (T77F-7025-C) (Continued)

3 Automatic Transaxle/Transmission

4 Automatic Transaxle/Transmission

5 Automatic Transaxle/Transmission

6 Automatic Transaxle/Transmission

7 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 1 N S Pushpin 26 7A233 Gear parking 2 N S1036 Bolt M6-1.0 x 16.5 hex 27 7F405 Bearing and race assembly flange head (2 req d) final drive gear thrust No. 16 (attaches dust cover to case) 28 7F451 Race Final drive gear Cover lower converter thrust front No. 16 (select housing fit) Cover lower converter 29 7A130 Support assembly rear housing planetary Converter assembly 30 7G085 Seal assembly fluid 6 7F401 Seal assembly converter transfer tube (2 req d) impeller hub 31 7H290 Piston and seal assembly Seal assembly differential low/intermediate clutch (2 req d) 32 7H266 Washer support and spring 8 N S1036 Stud M x 60.5 assembly low/intermediate pilot clutch (bonded) Case assembly 33 7D483 Ring 56.3 mm (2.216 in) retainer type SU external 10 7G112 Bearing and race assembly differential carrier thrust No. 34 7G178 Bearing and race assembly 19 sun gear thrust No G103 Washer differential carrier 35 7D483 Ring 170 mm (6.692 in) thrust No degree bevel (retains rear support in case) (select 12 7F343 Gear final drive ring fit) 13 7C144 Rear support spacer 36 7D171 Race Low/intermediate 14 7F465 Gear and differential case one-way clutch outer assembly 37 7A089 Low/intermediate one-way 15 W S Ring 27 mm (1.062 in) clutch race and roller retaining external (retains assembly output shaft in differential 38 7E085 Spring low/intermediate case assembly) clutch cushion S Ring 77.3 mm (3.043 in) 39 7B164 Plate assembly retaining external (retains low/intermediate clutch pinion shaft in differential internal (5 req d) (friction) case) 40 7B442 Plate low/intermediate Washer rear axle clutch external (5 req d) differential pinion thrust (2 steel req d) 41 7B066 Plate low/intermediate Pinion front wheel drive clutch pressure differential (2 req d) 42 7D483 Retainer low/intermediate Washer differential side clutch (select fit) gear thrust (2 req d) 43 7A162 Band assembly coast Gear differential side (2 req d) 44 7A626 Gear/drum/race assembly rear sun S Pin coiled spring (retains differential pinion shaft ) 45 7A153 Gear rear ring Shaft differential pinion 46 7D006 Gear assembly rear planetary Shaft differential output 47 7G177 Bearing and race assembly 24 N S Circle clip output shaft planetary thrust center No. 13 retaining 48 7A398 Gear assembly front 25 7F342 Gear and deflector assembly planetary final drive sun (Continued) (Continued)

8 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 49 7D483 Ring front planetary 72 7E005 Piston assembly retaining intermediate clutch 50 7D483 Ring mm (6.059 in) 73 7F225 Seal intermediate clutch internal retaining (select fit) piston inner 51 7B066 Plate reverse clutch 74 7G120 Cylinder and hub assembly pressure direct/intermediate clutch 52 7B164 Plate assembly reverse 75 7G102 Seal intermediate/direct clutch internal (4 req d) clutch hub (2 req d) (friction) 76 7F225 Seal direct clutch piston 53 7B442 Plate reverse clutch inner external (4 req d) (steel) 77 7A262 Piston assembly direct 54 7E085 Spring reverse clutch clutch piston 78 7G448 Ring direct clutch apply 55 N S Ring 67.0 mm (2.637 in) 79 7F235 Support and spring assembly retaining type SU eternal direct clutch (retains support and spring assembly in reverse clutch 80 7C122 Ring 77.0 mm (3.031 in) cylinder) retaining style SU external (retains direct clutch support 56 7G335 Support and spring assembly and spring assembly to reverse clutch cylinder) 57 7D402 Piston reverse clutch 81 7B066 Plate direct clutch 58 7D403 Seal reverse clutch piston pressure outer 82 7F369 Washer direct one-way 59 7D404 Seal reverse clutch piston clutch thrust No. 7 inner 83 7D171 Race direct one-way 60 7F341 Cylinder reverse clutch clutch outer 61 7D064 Gear and shell assembly 84 7A089 Clutch assembly direct front sun one-way 62 7C096 Bearing and race assembly 85 7G156 Race and bushing assembly forward sun gear thrust No. direct one-way clutch 10 and 11 inner 63 7B067 Hub intermediate clutch 86 7A360 Cylinder and valve assembly 64 7D483 Ring mm (5.994 forward clutch in) retainer style internal 87 7A548 Seal forward clutch piston (select fit) inner 65 7B066 Plate intermediate clutch 88 7A262 Piston assembly forward pressure clutch 66 7B164 Plate assembly 89 7G299 Support and spring assembly intermediate/direct clutch forward clutch internal (friction) 90 N S Ring 85.0 mm (3.346 in) 67 7B442 Plate intermediate/direct retaining type style SU clutch external (steel) external (retains forward 68 7E085 Intermediate clutch cushion clutch support and spring spring assembly in cylinder) 69 7C122 Ring 72.0 mm (2.834 in) 91 7B164 Plate assembly forward retaining style SU external clutch internal (4 req d) (friction) 70 7H185 Piston assembly intermediate clutch balance 92 7B442 Plate forward clutch external (4 req d) (steel) 71 7F222 Support and spring assembly intermediate clutch 93 7B066 Plate forward clutch pressure (Continued) (Continued)

9 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 94 7A166 Washer forward clutch 120 7G092 Seal front pump shaft (2 thrust No. 6 req d) 95 7D171 Race low one-way clutch 121 7G089 Collar fluid level outer thermostatic retaining (2 96 7A089 Clutch assembly low req d) one-way 122 7G191 Element fluid level 97 7L669 Drum assembly overdrive thermostatic 98 7F240 Bearing and race assembly 123 7G190 Plate fluid level direct clutch hub No. 9 thermostatic valve 99 7G273 Washer driven sprocket 124 N S Pin 4 mm (0.157 in) x 22 support thrust No. 8 (select coiled (3 req d) (retains fluid fit) level thermostatic valve plate and fluid) 100 7F196 Band assembly overdrive 125 7G249 Chain assembly drive 101 7D430 Retainer overdrive band 126 7G096 Washer chain cover thrust 102 7D019 Seal forward clutch No. 3 cylinder (5 req d) 127 N S1000 Bolt M6-1.0 x 16.5 hex 103 7D014 Washer support thrust flange head (attaches detent front No. 5 (select fit) spring assembly to chain 104 7G166 Support assembly driven cover) sprocket 128 7E332 Spring assembly manual 105 7G247 Bearing assembly driven valve detent sprocket 129 7G276 Bulkhead assembly wiring 106 7G115 Washer driven sprocket connector thrust No G303 Gasket chain cover 107 7G132 Sprocket and race assembly 131 7G188 Cover assembly chain driven Vent assembly case 108 7H150 Wheel driven sprocket speed sensor 133 7L282 Vent cap 109 7A108 Support assembly stator 134 7Z465 Retainer clip transaxle (part of 7N825 support cooler tube (2 req d) assembly) 135 7D273 Connector assembly cooler 110 7G233 Bearing assembly drive 3/8 (2 req d) sprocket S100 Plug 1/8-27 mm hex head Seal turbine shaft O-ring special pilot (2 req d) (pressure tap plugs for chain 112 7G091 Seal turbine shaft rear cover) 113 7F213 Shaft turbine 137 N S Screw M6-1.0 x 17 pan 114 7G099 Washer drive sprocket head pilot (attaches separator thrust No. 1 and 2 plate to valve body) 115 7G129 Sprocket assembly drive 138 7G308 Screen assembly bypass 116 N S Ring mm (1.037 in) clutch solenoid (2 req d) retaining style SU external 139 N S Pin 6 mm (0.236 in) x 20 (retains turbine shaft to drive spring coiled (part of 7A100) sprocket) 140 7A100 Control assembly main 117 7G090 Seal turbine shaft front 141 7A136 Gasket pump assembly to 118 7G093 Seal pump shaft rear (2 valve body req d) 142 7A142 Plate pump body separator 119 7B328 Shaft assembly pump 143 7G331 Gasket pump body to drive separator plate (Continued) (Continued)

10 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 144 7A104 Body, bearing and seal 165 7G284 Support pump bore ring assembly pump radial seal 145 7Z144 Seal x 1.78 O-ring 166 7H141 Sensor assembly outer (small) transmission fluid temperature 146 7Z144 Seal x 1.78 O-ring (TFT) inner (large) 167 7F396 Gasket main control cover 147 7G383 Solenoid assembly 168 N S437 Bolt M6-1.0 x 16.5 hex electronic pressure control flange pilot (19-attaches (EPC) bottom pan to case) 148 N S Bolt M6-1.0 x 30 hex 169 N S1427 Bolt M6-1.0 x 27.5 hex head (3-attaches pump flange pilot (4-attaches main assembly to main control) control cover to chain cover) 149 7Z484 Seal 6.07 x 1.78 O-ring 170 N S437 Bolt M x 38 hex outer (small) (1 on solenoid flange pilot (11-attaches main assembly (EPC) 1 on control cover to chain cover 150 7Z484 solenoid assembly (TCC) 171 7G004 Cover main control 3 on solenoid assembly shift) 172 7G484 Solenoid valve shift (3 req d) Seal 15.6 x 1.78 O-ring inner (large) (1 on 173 N S1000 Bolt M6-1.0 x 60 hex solenoid assembly (EPC) 1 flange head (15 attaches on solenoid assembly (TCC) pump body and main control 3 on solenoid assembly to chain cover shift) 174 N S1000 Bolt M6-1.0 x 40 hex 151 7G136 Solenoid assembly torque flange head (4-attaches valve converter clutch (TCC) body to chain cover) 152 N S Bolt M6-1.0 x 16 large 175 7Z490 Plate assembly control hex flange head (attaches valve body separator (bonded) torque converter solenoid and 176 7A100 Pump and control assembly pressure control solenoid to 177 N S Pin 5 mm (0.196 in) x 14 pump body) spring coiled 153 7G285 Spring pump bore ring 178 N S101 Stud M8 x x 154 N S Pin 8 mm (0.314 in) x 81.8 hex head shoulder 37.7 straight hardened (attaches chain cover 155 7G287 Ring pump valve support assembly to case assembly) (2 req d) 179 N S36 Bolt M6-1.0 x 50 hex 156 7A146 Rotor pump flange head (attaches chain cover to case) 157 7R194 Ring pump body 180 N S36 Bolt M6-1.0 x 14 hex 158 7G282 Support pump bore ring flange head (attaches turbine side gear shaft speed sensor to chain 159 7G281 Seal pump bore ring side cover assembly) 160 7G187 Cover and sleeve assembly 181 N S1000 Bolt M x 43 hex pump (attaches chain cover to 161 N S1100 Bolt M6-1.0 x 88.5 hex driven sprocket and support flange head pilot (4-attaches assembly) pump cover, pump body, 182 N S2 Bolt M x 45 hex valve body to chain cover) flange head (2- attaches chain 162 N S21 Bolt M6-1.0 x 22.5 hex cover to driven sprocket head (2-attaches pump cover support assembly) to pump body) 183 N S100 Seal 15.0x1.5 O-ring 163 7G286 Vane pump (7 req d) 184 7M101 Sensor turbine shaft speed 164 7G283 Seal pump bore ring radial (TSS) (Continued) (Continued)

11 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 185 N S1036 Bolt M x 35 hex 208 7N049 Rod manual control valve flange head (15-attaches chain actuating cover to case) 209 7G100 Pin shaft retainer (1 used 186 7A020 Indicator assembly fluid as park pawl shaft retainer, 3 level used as manual control shaft 187 N S1036 Bolt M6-1.0 x 22.5 hex pin) flange head (1-attaches filler 210 7A115 Lever assembly manual tube to case and 3-attaches valve detent (inner) O.D. servo cover to case) 211 7F251 Piston 1-2, 2-3 shift 188 7A228 Tube assembly filler upper accumulator 189 7H003 Tube assembly filler lower 212 7G095 Seal 1-2, 2-3 and N-D 190 7N243 Grommet filler tube shift accumulator piston 191 7D027 Cover overdrive servo 213 7G267 Spring 1-2 shift piston accumulator 192 7D024 Seal overdrive servo cover 214 7F284 Spring accumulator 1-2 and 2-3 assist 193 7H188 Piston assembly overdrive servo 215 7G094 Shaft shift accumulator piston (4 req d) 194 7F201 Spring overdrive servo piston return 216 7G257 Spring 2-3 shift accumulator S2 Nut 1/4 spring (attaches I.D. tag to case) 217 7F246 Piston reverse shift accumulator 196 7B148 Tag service identification 218 7F248 Seal reverse shift 197 N S101 Bolt M x 35 hex accumulator piston flange head (2-attaches case to chain cover) 219 7G266 Spring reverse shift accumulator 198 N S36 Screw M6-1.0 x 28 pan head (5 req d) (5-attaches 220 7G266 Spring 3-4 shift case to chain cover) accumulator 199 N S1000 Screw M6-1.0 x 20 pan 221 7H276 Shaft drive shift head (6-attaches stator accumulator support to converter housing) 222 7G274 Piston drive shift 200 N S103 Bolt M6-1.0 x 30 hex accumulator flange head (2-attaches 223 7G300 Spring drive shift transmission range sensor to accumulator (outer) case) 224 7G301 Spring drive shift 201 7F293 Sensor assembly accumulator (inner) transmission range (TR) 225 7H277 Seal drive shift 202 7C493 Shaft manual control lever accumulator cover 203 7H103 Sensor assembly 226 7H275 Cover drive shift transmission output shaft accumulator sensor (OSS) 227 N Bolt M6-1.0 x 60 hex 204 N S36 Bolt M6-1.0 x 16.5 hex flange head (attaches drive flange head (attaches the OSS shift accumulator cover to sensor) case) 205 7A434 Heat shield OSS 228 N S Screw M12 x 1.75 x F337 Seal assembly manual set hex socket (reverse clutch control shaft assembly locator bolt) 207 N S Pin mm (0.502 in) x 229 N S Nut M12 x 1.75 hex 25 dowel harden (2 req d) (reverse clutch assembly locator nut) (Continued) (Continued)

12 Automatic Transaxle/Transmission Item Part Number Description Item Part Number Description 230 7A256 Lever assembly manual 253 7Z302 Seal fluid filter control 254 7A089 Filter assembly fluid 231 7H291 Spring coast servo return 255 7L027 Magnet ceramic case 232 7H281 Piston and rod assembly 256 7A191 Gasket transaxle pan coast servo 257 7A194 Pan transaxle 233 7H284 Cover and seal assembly coast servo 258 Low/intermediate one-way clutch 234 7H285 Ring coast servo cover retainer 259 Low/intermediate clutch 235 7A232 Rod assembly parking 260 Reverse clutch pawl actuator 261 Intermediate clutch 236 7G101 Abutment parking pawl 262 Direct clutch actuator 263 Forward clutch 237 N S1000 Bolt M8 x 1.25 x 25 hex flange head (2-attaches 264 Direct one-way clutch abutment to case) 238 7D070 Spring parking pawl return 1. Install the parking pawl assembly D071 Shaft parking pawl 1 Install the parking pawl and return spring A441 Pawl parking brake 2 Install the parking pawl shaft. 241 N S Plug 13.9 mm (0.547 in) cup 242 7G199 Tube reverse fluid supply transfer 243 7G087 Tube servo apply fluid transfer 244 7G463 Tube low/intermediate clutch apply fluid transfer 245 7G084 Tube rear lube fluid transfer 246 N S100 Seal O-ring (used on rear lube fluid tube) 247 N S100 Seal O-ring (used on reverse fluid supply tube) 248 N S100 Seal O-ring (used on servo apply tube - reverse supply tube and low/intermediate clutch apply tube) 249 N S100 Seal O-ring (used on servo apply tube) 250 7G353 Bracket assembly tube support main 251 7G353 Bracket assembly tube support (reverse clutch and servo apply) 252 7G353 Bracket assembly tube support (rear lube and low/intermediate clutch) (Continued) 2. Install the park pawl roll pin.

13 Automatic Transaxle/Transmission Using the special tool, install the cup plug. 4. NOTE: The bolt holes are offset and the drive sprocket can only be aligned one way. Install the driven sprocket support. 7. Install the differential carrier thrust bearing. 1 Install the differential carrier thrust washer. 2 Install the differential carrier thrust bearing and race (tabs down). 5. Install the bolts. 8. Install the final drive ring gear. 6. Using the special tool, install the converter impeller hub seal.

14 Automatic Transaxle/Transmission Install the rear planet support spacer. 10. Install the final drive differential assembly. 11. Align the rear lube tube holes in the case window. 13. NOTICE: If the support is not visible on the inside diameter of the retaining ring, the low/intermediate piston could be damaged. Make sure that the beveled retaining ring seats correctly in the case groove with the bevel down. The final drive support must be visible on the inside diameter of the retaining ring but must not seat against the case wall. 12. NOTE: The retaining ring must be correctly installed. Using the special tool, install the beveled retaining ring.

15 Automatic Transaxle/Transmission Place a screwdriver into the differential case and pry up to make sure that the retaining ring is fully seated in the top of the case groove. 18. Install the special tool and zero the dial indicator. 15. Install the special tools. 16. Remove the No. 15 needle bearing. 19. Tighten the bolt. Tighten to 1.5 Nm (12 lb-in). 17. NOTE: The dial indicator extension rod must set on the No. 15 bearing surface. Install the special tools.

16 Automatic Transaxle/Transmission Read and record the dial indicator reading. If the dial indicator reading indicates movement more than the specification, the next larger beveled ring retainer will need to be used. 21. Select the correct beveled retaining ring. Item Part Number Thickness Style 1 F5DZ-TD483-E mm Style 5 ( inch) 2 F5DZ-TD483-D mm Style 4 ( inch) 3 F5DZ-TD483-C mm Style 3 ( inch) 4 F5DZ-TD483-B mm Style NOTE: Make sure the No. 15 needle bearing is on the rear planet support hub and the black plastic No. 15 thrust washer is in place on top of the low/intermediate clutch spring retainer. ( Install the No. 15 thrust bearing. inch) 5 F5DZ-TD483-A mm Style 1 ( inch)

17 Automatic Transaxle/Transmission Check the clearance for the No. 16 thrust No. 16 Thrust Race (Washer) (Continued) washer. Mount the Dial Indicator with the Thickness ID stylus on the end of the output shaft. Zero the mm Black (No. 3) dial indicator. ( in) mm White (No. 4) ( in) mm Brown (No. 5) ( in) mm( Gold (No. 6) in) 24. Tighten the bolt. Read and record the dial indicator reading. Tighten to 1.5 Nm (12 lb-in). 26. Install the low-intermediate one-way clutch assembly. 25. NOTE: The beveled retaining ring and the rear planet support must be removed to change the No. 16 thrust race. If the clearance is not within specification a thicker or thinner washer will need to be added. No. 16 Thrust Race (Washer) Thickness ID mm Green (No. 1) ( in) mm Blue (No. 2) ( in)

18 Automatic Transaxle/Transmission NOTE: The friction plate internal splines will center the one-way clutch. Install the low-intermediate clutch pressure plate. 1 Install the low-intermediate clutch wave spring. 2 Install the low-intermediate clutch pack. 3 Install the low-intermediate clutch pressure plate. 29. WARNING: To prevent injury, wear eye protection when using pressurized air. NOTE: Be sure the pressurized air is dry and regulated at 276 kpa (40 psi). Apply regulated air pressure to the low-intermediate apply port. Make sure that the piston moves and no air is leaking past the piston seal. 30. Measure the clearance between the clutch pressure plate and the low-intermediate clutch 28. NOTICE: Make sure that the retaining ring retainer. If the clearance is not within is seated in the case groove. Install the low-intermediate clutch retaining ring. specification a thicker or thinner retainer may be needed. Selective Retaining Rings Thickness mm ( inch) mm ( inch) mm ( inch)

19 Automatic Transaxle/Transmission Selective Retaining Rings (Continued) Thickness mm ( inch) mm ( inch) 33. Install the park rod abutment and make sure that the park pawl moves freely. 31. Install the coast band. 1 Install the coast band. 2 Align the anchor pin pocket with the anchor pin in the case. 34. Install the coast band piston cover. 1 Install the coast band servo piston spring. 2 Install the coast band servo piston. 3 Install the coast band servo piston cover. 32. Install the low-intermediate drum. Rotate the low-intermediate drum and sun gear into the low-intermediate one-way clutch.

20 Automatic Transaxle/Transmission Using the special tool, install the coast servo 38. Loosely install the reverse clutch anchor pin. cover retaining ring. 39. Using the special tool, install the 36. Using the special tools, install the front forward/intermediate clutch assembly. Align the planetary/reverse clutch assembly. shell and sun gear into the front planet. 37. Make sure that the reverse clutch cylinder apply 40. Install the overdrive band. tube hole is aligned with the case hole. Remove the tool.

21 Automatic Transaxle/Transmission NOTE: The foot of the overdrive retainer fits 44. Install the special tool over the output shaft against the band. until it is fully seated on to the No. 9 needle Install the overdrive band anchor strut with the bearing. cross hairs facing upward. 42. Remove the No. 8 sprocket thrust washer and the No. 9 bearing and race from the driven sprocket support. 1 Remove the No. 9 bearing and race. 2 Remove the No. 8 sprocket support. 45. Install the special tool to make the measurements. 46. When taking the measurement, record readings on both sides of the output shaft 180 degrees apart from each other. Add both readings and divide by two to obtain reading A. 43. Install only the No. 9 needle bearing with the outer lip upward.

22 Automatic Transaxle/Transmission NOTE: Reading A and Dimension C from the chart will be used in the selection of the No. 5 thrust washer. Use reading A to select the correct No. 8 thrust washer from the chart. No. 8 Thrust Washer Selection Chart Reading Washer Dimension A Thickness C Color/ID mm Natural mm mm (0.058 (No. 1) ( ( inch) inch) inch) mm Dark Green 50. Measure down to the No. 5 thrust washer mm mm (0.068 (No. 2) mating surface of the overdrive drum. Take ( ( inch) another reading on the other side of the drum inch) inch) 180 degrees from the first one. Add both mm Light Blue readings and divide by two to obtain reading B. mm mm (0.077 (No. 3) ( ( inch) inch) inch) mm Red (No. mm mm ( ) ( ( inch) inch) inch) mm Black (No. mm mm (0.094) 5) ( ( inch) inch) 48. Remove the special tools. 51. Remove the special tools. 49. Install the special tools to take the measurements.

23 Automatic Transaxle/Transmission NOTE: Reading A was obtained during No. 8 thrust washer selection. Dimension C is found on the No. 8 thrust washer selection chart. Subtract reading A from Reading B and add the difference between A and B to dimension C. Record this reading as D. Reading B: - Reading A: Difference: +Dimension C: Reading D: 53. Use Reading D to select the correct No. 5 thrust washer. No. 5 Support Thrust Washer Chart Washer Reading D Thickness Color/ID mm mm Green (No. 1) ( ( inch) inch) mm mm Black (No. 2) ( ( inch) inch) mm mm Natural (No. 3) ( ( inch) inch) mm mm Red (No. 4) ( ( inch) inch) mm mm Blue (No. 5) ( ( inch) inch) 54. NOTE: Use petroleum jelly to hold the No. 5 thrust washer in place. Install the No. 5 front support thrust washer. 55. NOTICE: The No. 9 direct hub needle bearing may still be inside the transaxle from the No. 8 driven sprocket support thrust washer selection procedure. Use petroleum jelly to hold bearing and washer in place. Install the correct bearing. 1 Install the correct No. 8 driven sprocket support thrust washer. 2 Install the No. 9 direct clutch needle bearing. 56. Install the driven sprocket support assembly.

24 Automatic Transaxle/Transmission Install the neutral/drive accumulator cover. 60. Install the brackets and bolts. 1 Install the neutral/drive accumulator piston. Tighten to 11 Nm (8 lb-ft). 2 Install the neutral/drive accumulator spring. X X The outer spring is yellow in color. The inner spring is grey in color. 3 Install the neutral/drive accumulator cover. 61. Using the special tool, install the manual control lever shaft seal. 58. Install the bolt. 59. NOTE: All the fluid supply tubes must have new O-rings installed. Install the fluid supply tubes. 62. Install the parking lever actuating rod. Push in on the park pawl. Slide the parking lever actuating rod down to fit in the park pawl.

25 Automatic Transaxle/Transmission NOTE: The manual control valve detent lever must be installed with the shoulder and roll pin hole pointing toward the driven sprocket support. Install the manual control lever shaft. 64. NOTE: Prior to installing the roll pins be sure that the manual control valve detent lever shoulder and roll pin hole is pointing toward the driven sprocket support. Install the roll pins. 66. NOTICE: Be careful not to damage or bend the exciter tabs on the driven sprocket speed sensor wheel. The TSS sensor will not operate correctly if the tabs are bent. NOTE: Lower the assembly into the sprocket supports simultaneously. Install the drive chain and sprockets. 65. NOTE: Apply petroleum jelly to the drive sprocket thrust washer and driven sprocket thrust washer to hold them in place. Install the thrust washers. 1 Install the No. 2 drive sprocket thrust washer. 2 Install the No. 4 driven sprocket thrust washer.

26 Automatic Transaxle/Transmission Install the shift accumulator springs. 1 Install the 1-2 shift accumulator piston spring (no color or brown). 2 Install the 2-3 shift accumulator piston spring (no color or brown). 3 Install the reverse shift accumulator piston spring (pink). 4 Install the 3-4 shift accumulator piston spring (pink). 70. NOTE: After installing the chain cover the input shaft should have some end play and should rotate freely. Apply gentle downward pressure on the chain cover to overcome spring pressure. Start the two bolts. 68. NOTE: Make sure that the alignment pins are installed in the case. Install the new chain cover gasket. 69. NOTICE: Be extremely careful not to damage the cast iron sealing ring. Use petroleum jelly to hold thrust washers in place during assembly. 1 Install the No. 1 thrust washer. 2 Install the No. 2 thrust washer. 3 Install the chain cover.

27 Automatic Transaxle/Transmission Install the remaining bolts. 73. NOTICE: The test spring from the overdrive Tighten No. 1 to 25 Nm (18 lb-ft). servo rod tool is plain in color and has a shorter free height than the operational Tighten No. 2 to 43 Nm (32 lb-ft). spring. Extreme care must be used not to Tighten No. 3 to 31 Nm (23 lb-ft). assemble the transaxle using the test spring. Tighten No. 4 to 11 Nm (8 lb-ft). Inspect the spring height. 1 Test spring. 2 Original spring. 74. Check overdrive servo travel. Install the overdrive servo piston. 1 Install the test spring. 2 Install the overdrive servo piston. 72. Install the bolts. Tighten No. 1 to 26 Nm (19 lb-ft). Tighten No. 2 to 12 Nm (9 lb-ft).

28 Automatic Transaxle/Transmission Install the special tools. 78. If the overdrive servo travel was incorrect, install a new overdrive servo rod. Zero the dial indicator and repeat the above step to verify the amount of piston travel. If within specification, remove the tool and test spring. Overdrive Piston Rod Selection Chart Overdrive Servo Rod Length No. of mm Inch Grooves a Using the special tools, tighten the center screw and zero out the dial indicator. a Grooves are at the tip. 79. NOTICE: Do not assemble the transaxle using the test spring. Install the overdrive servo. 1 Install the overdrive servo spring. 2 Install the overdrive servo. 3 Install the overdrive servo cover and bolts. 77. Using the special tools, back off the center screw until the piston movement stops and read the dial indicator. The reading should be within specification. If the reading does not match the specification, see the overdrive specification chart and determine which overdrive servo rod to use. 80. Install the transmission test plate.

29 Automatic Transaxle/Transmission WARNING: Wear safety glasses while carrying out this procedure to prevent personal injury. NOTE: When applying regulated 276 kpa (40 psi) air pressure to the appropriate passage, a dull thud should be heard when the clutch or band applies. There should be no hissing sound when the clutch or band applies. NOTE: Plugging the vent hole during the test will provide an inaccurate result. Cover the vent hole in the test plate with a clean lint free shop towel to prevent spray when air is applied. Apply air pressure to the appropriate clutch ports. Part Item Number Description 82. NOTICE: The seals must be lapped correctly or internal leakage will occur. Install the new Teflon seals on the pump shaft accumulator test passage 83. Install the pump shaft. 2 Overdrive servo test passage 3 Direct clutch test passage 4 Low/intermediate clutch and accumulator test passage 5 Coast band test passage 6 Reverse clutch test passage accumulator test passage 8 Neutral/reverse accumulator test passage 9 Vent hole 10 Forward clutch test passage 11 Intermediate clutch test passage accumulator test passage 84. Install the manual valve detent lever.

30 Automatic Transaxle/Transmission Install the main control valve body over the 87. Connect the connectors. pump shaft and connect the main control valve actuating rod while pushing down until it is seated on the chain cover. 86. NOTICE: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur. Use the valve body guide pins to install the pump assembly and main control valve body. Install the bolts and tighten in sequence. Tighten to 10 Nm (89 lb-in). 88. NOTE: The transaxle side cover gasket is reusable if not torn or ripped. Remove the gasket. Clean and inspect the gasket, and reinstall into the pan.

31 Automatic Transaxle/Transmission Install the M8 x 1.25 pan bolts. Tighten to 25 Nm (18 lb-ft). 90. Install the M6 x 1.00 pan bolts. Tighten to 12 Nm (9 lb-ft). 92. Tighten the reverse clutch anchor bolt. 1 Tighten the anchor bolt. X Tighten to 11 Nm (8 lb-ft). 2 Tighten the locknut. X Tighten to 43 Nm (32 lb-ft). 93. Install the new seal and gasket kit and seal assembly. 91. Install the mounting bracket and bolts. Tighten to 62 Nm (46 lb-ft).

32 Automatic Transaxle/Transmission Install the fluid pan magnet. 97. NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o clock position. Verify that the shift selector lever is in NEUTRAL. 98. Install the digital TR sensor and loosely install the bolts. 95. NOTE: The gasket is reusable if not damaged or torn. Install the transmission fluid pan and gasket. 99. Using the special tool, align the digital TR sensor and tighten the bolts. 96. Install the turbine shaft speed (TSS) sensor. 1 Install the sensor. 2 Install the bolt.

33 Automatic Transaxle/Transmission Install the fluid filler tube with a new 103. Install the output shaft speed (OSS) sensor and grommet. reconnect the harness. 1 Install the grommet. 2 Install the fluid filler tube. Tighten to 10 Nm (89 lb-in) Install the OSS sensor cover. 1 Install the OSS cover. 2 Install the bolt Using the special tool, install the LH output X Tighten to 11 Nm (8 lb-ft). shaft seal. 3 Connect the connector to the bracket Using the special tool, install the RH output 105. Install the identification tag, if removed. shaft seal.

34 Automatic Transaxle/Transmission NOTE: Locate and align the orange dot adjacent to the stud on the torque converter and place it in the 6 o clock position. Using the special tools, install the torque converter.

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