Transaxle Case

Special Tool(s)

Exploded View

Disassembly

1. Special Tool(s): Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C), Transfer Gear Bearing Race Remover 307-577

2. Punch a hole in the fluid dam. Center punch.

3. General Equipment: Dent Puller

4. Special Tool(s): Differential Bearing Cup Remover 307-586
   1. Position the Differential Bearing Cup Remover 307-586 in the transmission case with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the transmission case.
   2. Expand the Differential Bearing Cup Remover 307-586 by hand.
   3. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the transmission case, tighten the nut.

5. General Equipment: Shop Press

Assembly

1. Special Tool(s): Handle 205-153 (T80T-4000-W), Oil Dam Seal Installer 307-583

2. Special Tool(s): Handle 205-153 (T80T-4000-W), Oil Dam Seal Installer 307-583

3. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the transmission case. Visual check.

4. Special Tool(s): Bearing Cup Installer 307-576
   General Equipment: Shop Press

5. Special Tools(s): Bearing Cup Installer 307-689

6. Special Tool(s): Bearing Cup Installer 307-689, Installer, Transfer Gear Bearing 307-541, Drawbar 204-029

10. • Tighten to 12 Nm (106 lb-in).

11. Remove the torque converter housing differential and transfer shaft bearing races to select a new differential or transfer shaft shim. Refer to Torque Converter Housing.

Torque Converter Housing

Special Tool(s)

Exploded View

Disassembly

1. Special Tool(s): Remover/Installer, Front Wheel Hub 204-069, Transfer Gear Bearing Race Remover 307-577

3. Punch a hole in the fluid dam. Center punch.

4. General Equipment: Dent Puller

5. Special Tool(s): Differential Bearing Cup Remover 307-586
   1. Position the Differential Bearing Cup Remover 307-586 in the torque converter housing with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the torque converter housing.
   2. Expand the Differential Bearing Cup Remover 307-586 by hand.
   3. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the torque converter housing, tighten the nut.

6. General Equipment: Shop Press

Assembly

1. NOTE: Temporarily install the differential and the transfer shaft in the transmission case.

2. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591 (307-591/1 and 307-591/2)

3. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (studs)

4. NOTE: Make sure that the silicone has been cleaned off the machined surface of the transmission case and the torque converter housing before installing the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) or the preload measurement may be inaccurate.

   Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (4 spacers)

6. Special Tools(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (remaining 4 spacers, bolts and washers)
   • Tighten to 24 Nm (18 lb-ft).

7. Special Tools(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (4 nuts and washers)
   • Tighten to 24 Nm (18 lb-ft).

8. Rotate the transfer shaft and the differential several times to seat the bearing cups.

9. Measure and record the smallest and largest preload gap on the Shim Gauge, Differential/Transfer Gear Bearing 307-591/1. Average the 2 measurements to get the thickness of the differential bearing preload shim. Refer to Specifications in this section for the differential bearing preload shim part number.
   General Equipment: Feeler Gauge.

10. Measure and record the smallest and largest preload gap on Shim Gauge, Differential/Transfer Gear Bearing 307-591/2. Average the 2 measurements to get the thickness of the transfer shaft bearing preload shim. Refer to Specifications in this section for the transfer gear bearing preload shim part number.
    General Equipment: Feeler Gauge.

11. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (4 nuts, bolts and spacers and 8 washers)

12. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (4 spacers)

13. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/3 (4 studs)

14. Special Tool(s): Shim Gauge, Differential/Transfer Gear Bearing 307-591/1 and 307-591/2

16. Assemble the torque converter housing. Refer to Torque Converter Housing.

17. Special Tool(s): Handle 205-153 (T80T-4000-W), Oil Dam Seal Installer 307-583

18. NOTICE: Support the torque converter housing using blocks of wood, or damage to the torque converter housing may occur.

    Special Tool(s): Handle 205-153 (T80T-4000-W), Oil Dam Seal Installer 307-583

19. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the torque converter housing. Visual check.

21. Special Tool(s): Bearing Cup Installer 307-576
    General Equipment: Shop Press

23. Special Tool(s): Bearing Cup Installer 307-576

24. Special Tool(s): Bearing Cup Installer 307-576, Installer, Transfer Gear Bearing 307-541, Drawbar 204-029

Transfer Shaft and Gear

Special Tool(s)

Exploded View

Disassembly

1. Inspect the transfer shaft bearings for damage or excessive wear. Install new if necessary. Visual check.

2. Special Tool(s): Puller, Bearing 205-D064 (D84L-1123-A)
   General Equipment: Shop Press

3. Inspect the transfer shaft assembly for damage. Visual check.
   1. Inspect the park pawl wheel for damage and install new, if necessary.
   2. Inspect the transfer shaft and transfer shaft input gear for damage and install new, if necessary.

Assembly

2. Special Tool(s): Differential Bearing Installer and Guide 307-587 (307-587/2 and 307-587/3)
   General Equipment: Shop Press

3. Select a new transfer shaft shim. Refer to Torque Converter Housing.

Differential Gear Assembly

Special Tool(s)

Exploded View

Disassembly

1. NOTE: AWD shown, FWD similar.

   Inspect the differential bearings for damage or excessive wear. Install new bearings if necessary.

2. Special Tool(s): Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C), Puller, Bearing 205-D064 (D84L-1123-A), Step Plate 205-D019 (D80L-630-8) ( AWD ) or Step Plate 205-D015 (D80L-630-4) ( FWD ).

3. NOTE: AWD shown, FWD similar.

   Special Tool(s): Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C), Puller, Bearing 205-D064 (D84L-1123-A), Step Plate 205-D019 (D80L-630-8).

4. NOTE: If replacing the ring gear, it is also necessary to replace the transfer shaft.

   Check the differential assembly and the ring gear for damage. Visual check.

Assembly

1. NOTE: Do not torque the 4 ring gear bolts.

   Hand-start 4 new ring gear bolts to align the holes in the ring gear and the differential case. Evenly tighten the 4 bolts to seat the ring gear onto the differential case.

2. Install the remaining 12 new differential ring gear bolts and tighten in 2 stages.
   • Stage 1: Tighten to 33 Nm (24 lb-in).
   • Stage 2: Tighten an additional 60 degrees.

3. Special Tool(s): Differential Bearing Installer and Guide 307-587 (307-587/1 and 307-587/2)
   General Equipment: Shop Press

4. Select a new differential shim. Refer to Torque Converter Housing.