Transaxle Assembly
GENERAL ASSEMBLY NOTES1. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance.
2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least two hours.
3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their places.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transaxle, be sure to use new gaskets and O-rings.
7. Dry all parts by blowing with compressed air. Never use shop rags.
8. Be sure to install the thrust bearings and races in the correct direction and position.
INSTALL OR CONNECT
- Tools Required:
- J 35679 Band Apply Pin Gage
- J 35549 Second Coast Piston Brake Compressor
1. Parking pawl onto the case. Hook the spring ends to the case and pawl.
2. Pin into the hole of the case through the spring and the pawl.
3. Parking lock rod.
4. Parking lock pawl bracket.
5. Check operation of parking lock pawl. Make sure the counter driven gear is locked when the manual valve lever is in "P" range.
6. Intermediate shaft.
7. Transaxle rear cover over new gasket.
Tighten
- Transaxle rear cover bolts to 25 N.m (18 lb. ft.).
Inspect
- Intermediate shaft end play. If the thrust play is not within specifications, check the installation of intermediate shaft. Make sure that the intermediate shaft turns smoothly.
8. First and reverse brake in case. Install the inner flange, facing the flat end toward the oil pump side.
9. Five discs in the following order: disc-plate-disc-plate-disc-plate-disc-plate-disc.
10. Outer flange. Face the flat end toward the piston side.
11. Snap ring end gap into the groove.
Inspect
- Operation of first and reverse brake. Apply compressed air into the oil passage with the case and be sure that the piston moves.
12. No. 2 planetary carrier thrust washer. Coat thrust washer with the petroleum jelly and install it onto the planetary carrier.
Important
- Make sure that the different lug shapes match the openings on the carrier.
13. Ring gear into case.
14. Coat the races and bearing with petroleum jelly and install them onto the ring gear.
15. Align the flukes of the discs in the first and reverse brake.
16. Align the spline of the planetary carrier with the flukes of the discs and install the planetary gear into the first and reverse brake discs.
17. No. 2 one-way clutch into case with shiny side upward.
18. One-way clutch onto the inner race while turning the planetary gear clockwise.
19. Coat the thrust washer with petroleum jelly.
20. Thrust washer onto the planetary gear.
21. Turn the planetary carrier. The carrier should turn freely clockwise and should lock counterclockwise.
22. Snap ring. Check that end gap is installed into the groove.
23. Second coast brake band guide so that its tip touches the case.
24. Second brake into case. Install the flange, facing the flat end toward you.
25. Clutch assembly: Disc-plate-disc-plate-disc-plate.
26. Piston return spring assembly, so that each of the springs are over the protrusions in the case.
27. Second brake drum into case. Align the groove of the drum with the bolt and place it into the case.
28. Snap ring into the case so that the end gap is installed into the groove.
- While compressing the piston return springs over the drum with hammer handle, install the snap ring into the groove.
Inspect
- Operation of second brake. Apply compressed air into the oil passage of the case and be sure that the piston moves.
29. Second brake drum gasket until it makes contact with the 2nd brake drum.
30. No. 1 one-way clutch and second brake hub.
31. Align the flukes of the discs in the 2nd brake.
32. Align the spline of the hub with the flukes of the discs and install the hub to the 2nd brake discs.
33. Sun gear and sun gear input drum. While fuming the sun gear clockwise, install it into the one-way clutch.
34. Front planetary gear and ring.
35. Coat the race and bearing with petroleum jelly and install them onto the planetary gear.
36. Planetary gear into the case.
37. Race and bearing.
38. Intermediate shaft oil seal ring.
39. Ring gear.
Important
- If the planetary gear and the other parts are installed correctly into the case, the end of bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft.
40. Second coast brake band by installing the pin through the oil pump mounting bolt hole.
41. Forward clutch into case.
42. Coat the races and bearings with petroleum jelly and install them onto both sides of the clutch drum.
43. Align the flukes of the disc in the forward clutch. Hold the sun gear input drum and rotate the input shaft to mesh the hub with the clutch discs of the forward clutch.
44. Align the center of the input shaft and intermediate shaft and while pushing on the input shaft, rotate it to mesh the hub and disc.
Important
- If the flukes of the discs are meshed with the hub correctly, the protrusion of the input shaft drum will have entered deeper than the tip of the sun gear input drum.
45. Direct clutch into case.
46. Coat the clutch drum thrust washer with petroleum jelly.
47. Clutch drum thrust washer facing the oil groove upward onto the drum.
48. Align the flukes of discs in the direct clutch.
49. Hold the input shaft and put the direct clutch drum through in the 2nd coast brake band.
- Mesh the hub with the flukes of the direct clutch while turning the clutch drum.
Important
- If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the thrust bearing on the forward clutch.
50. Oil pump into case.
- After installing the oil pump, measure the input shaft thrust play.
- If the thrust play is in excess of standard, select and insert one of the two different size shims.
51. Coat the race with petroleum jelly.
52. Race onto stator shaft.
53. O-ring around the pump body and lightly coat with GM # 1050169 lube.
54. Oil pump with gasket through the input shaft and align the bolt holes of the pump body with the transaxle case.
55. Hold the input shaft and lightly press the oil pump body to the side oil seal rings on the stator shaft through the direct clutch drum.
NOTICE: Do not push excessively hard on the oil pump or the oil seal ring will stick to the direct clutch drum.
56. Pump retaining bolts.
Tighten
- Pump retaining bolts to 22 N.m (16 lb. ft.).
Measure
- Thrust play of input shaft.
- There are two different thickness of races for the end of the stator shaft. If necessary, select one of them:
0.8 mm (0.031-inch).
1.4 mm (0.055-inch).
Inspect
- Input shaft rotates freely
- Second coast brake piston stroke.
57. Brake piston, without the outer spring, into the bore and install the snap ring.
Measure
- Brake apply piston rod length.
- Install a J 35679 band apply pin gage. Observe the groove on the plunger of the tool. Firmly push button of tool. This action pushes the brake apply rod into the case. If the groove is visible, the piston stroke is to specifications: 1.5 mm to 3.0 mm (0.059 to 0.118 inch). If the stroke is more than specified, replace the piston rod with a longer one.
- Piston rod length.
72.9 mm (2.870 in.).
71.4 mm (2.811 in).
- Stroke. If it is still more than specified, replace the brake band.
58. Second coast brake piston.
A. Remove the installed parts from the bore.
B. Install the outer spring with the piston.
C. Place the cover into the bore.
D. Using a J 35549 second coast piston brake compressor, install the snap ring while pressing the cover.
59. Check operation of second coast brake. Apply compressed air into the hole with the case and make sure that the piston rod moves.
60. Accumulator pistons and springs.
A. Install the springs and pistons into the bore.
B. Place the cover with the gasket and tighten the bolts a little at a time in sequence. Each bolt length (mm) is indicated in the image.
61. Governor apply gasket.
62. Install governor oil strainer.
63. Throttle cable in case. Push the cable through the case, being careful not to damage the O-ring. Check for full seating.
64. Place valve body on transaxle.
A. While holding the cam down with your hand, slip the cable end into the slot.
B. Lower the valve body into place.
65. Fourteen bolts in valve body. refer to "Valve Body Assembly."
Tighten
- Valve body bolts to 10 N.m (89 lb. in.).
66. Manual valve on valve body. Refer to "Valve Body Assembly."
Tighten
- Manual bolts to 10 N.m (89 lb. in.).
67. Detent spring.
Tighten
- Detent spring bolt to 10 N.m (89 lb. in.).
68. Oil tubes.
NOTICE: Be careful not to bend or damage the tube
69. Tube retainer.
Tighten
- Tube retainer bolts to 10 N.m (89 lb. in.).
70. Oil strainer
Tighten
- Oil strainer bolts to 10 N.m (89 lb. in.).
71. Magnet in place.
Important
- Place magnet in a pan so that it does not interfere with tubes.
72. Oil pan with gasket.
Tighten
- Oil pan bolts to 5.0 N.m (44 lb. in.).
73. Governor body.
A. Install the governor body adapter.
B. Install the governor body with the plate washer.
C. Install the thrust washer onto the governor body.
D. Install the cover over a new O-ring.
E. Install the cover bracket with 2 bolts.
74. Throttle cable retaining plate.
75. Tube and filler gage.
76. PNP switch.
A. Install a new seal gasket, facing the lip inward.
B. Install lock washer and nut.
Tighten
- Nut to 7.0 N.m (62 lb. in.).
77. Stake nut with lock washer.
78. Manual shift lever
79. Adjust PNP switch
A. Connect an ohmmeter between the terminals.
B. Shift the lever into the "N" position.
C. Adjust the PNP switch to the point where there is continuity between the terminals.
D. Lock the PNP switch with 2 bolts.
Tighten
- PNP switch mounting bolts to 5.5 N.m (49 lb. in.).
80. Two oil cooler pipes.
A. Install the bracket onto the case.
B. Connect the pipes to the union.
C. Clamp the two pipes onto the bracket.
D. Tighten the union nuts.
Tighten
- Union nuts to 34 N.m (25 lb. ft.).