Service Procedure

1. Drive the vehicle between 60 and 70 MPH (light throttle application) with the overdrive switch ON (A/T in fourth gear), then turn the overdrive switch OFF (A/T in third gear).

A. If the whine noise exists after the overdrive switch is turned off, proceed with step 2.

B. If the whine noise does not exist after the overdrive switch is turned off, this bulletin does not apply.

2. Record radio station pre-sets.

3. Turn the ignition key to the OFF position.

4. Disconnect the negative cable from the battery.

5. Remove the left front tire/wheel assembly and the side plastic covers.

6. Remove the transaxle assembly from the vehicle. Refer to the transaxle removal procedure listed in the AT section of the applicable service manual.





7. Remove the speed sensor from the transaxle (see Figure 1).

8. Remove the torque converter from the transaxle.

9. Remove the converter housing from the transaxle assembly as follows:





A. Remove the bolts that secure the converter housing to the transaxle (see Figure 2).

NOTE:
Remove the converter housing bolts shown in black (see Figure 2).

B. Once the bolts are removed, gently tap on the converter housing to separate it from the transaxle.





10. Remove the differential gear assembly from the transaxle (see Figure 3).

11. Remove the oil pump from the transaxle as follows:





A. Remove the 0-ring from the input shaft (see Figure 4).

B. Remove the bolts that secure the oil pump assembly to the transaxle.





C. Remove the oil pump assembly, baffle plate and gasket from the transaxle (see Figure 5).





12. Remove the revolution sensor from the transaxle side cover (see Figure 6).





13. Remove the 14 bolts that secure the transaxle side cover (see Figure 7).

NOTE:
Four of the 14 bolts are self-sealing type (see Figure 7).

14. Remove the side cover.





15. Remove the output gear from the transaxle (see Figure 8).

16. Remove the output gear needle bearing from the transaxle (see Figure 8).





17. Remove the idler gear retaining nut (see Figure 9).





18. Remove the idler gear using Kent-Moore puller # J25726-B (see Figure 10).





19. Remove the idler gear bearing outer race from the transaxle case using Kent-Moore puller # J34286 (see Figure 11).





20. Install the new idler gear bearing outer race in the transaxle case using Kent-Moore tool # J25405 or # J34331 (see Figure 12).

21. Clean the new idler gear and output gear with a suitable cleaner to remove any dirt, oil residue, etc.





22. Press the new idler gear bearing onto the new idler gear (see Figure 13).





23. Press the new output gear bearing onto the new output gear (see Figure 14).





24. After packing the seal grooves with petroleum jelly, install new seal rings (P/N 31525-80X02) on the output gear shaft (see Figure 15).

25. Perform the "Reduction Pinion Gear Bearing Pre-load" procedure to determine the proper shim thickness of the reduction pinion gear bearing. Refer to the AT section of the applicable service manual.

26. Install the proper reduction pinion gear bearing shim onto the reduction pinion gear.

NOTE:
Part numbers for all reduction pinion gear bearing shims are listed under Service Data and Specifications (SDS) in the AT section of the applicable service manual.

27. Loosely install the new idler gear on the reduction pinion gear.





28. Place the transaxle assembly onto a hydraulic press stand so the reduction pinion gear is supported on the bottom and the idler gear is facing upwards (see Figure 16).

29. Press the idler gear onto the reduction pinion gear until the idler gear is fully seated against the pinion gear adjusting shim.

30. Remove the transaxle from the hydraulic press stand and place it on the work bench.

31. Engage the idler gear with the parking pawl and tighten the idler gear retaining nut to 294 - 324 N.m (30 - 33 Kg-m, 217 - 239 ft-lb).





32. Cinch the idler gear retaining nut (see Figure 17).

33. Install the new output gear needle bearing on the transaxle.

NOTE:
Make sure the smooth (solid) side of the needle bearing is placed against the transaxle.

34. Apply ATF to the output gear bearing.

35. Carefully install the output gear in the transaxle.

36. Measure the output gear end play to determine the proper adjusting shim thickness. Refer to the AT section of the applicable service manual for the output gear adjusting shim thickness procedure.





37. Install the proper adjusting shim in the side cover (see Figure 18).

NOTE:
Part numbers for all output gear end play adjusting shims are listed under Service Data and Specifications (SDS) in the AT section of the applicable service manual.

38. Clean the sealing surfaces of the transaxle and side cover.

39. Apply locking sealant (Loctite # 518 or equivalent) to the side cover sealing surface and install the side cover to the transaxle.

40. Re-install the side cover securing bolts and tighten them evenly in a criss-cross pattern to 26 - 30 N.m (2.7 - 3.1 Kg-m, 20 - 22 ft-lb).

NOTE:
Four of the 14 side cover securing bolts are self sealing and must be reinstalled in specific mounting holes (see Figure 7).

41. Re-install the differential gear in the transaxle.

42. Re-install the oil pump and tighten the mounting bolts evenly in a criss-cross pattern to 18 - 21 N.m (1.8 - 2.1 kg-m, 13 - 15 ft-lb).

43. Re-install the 0-ring in the oil pump input shaft.

44. Clean the sealing surfaces of the transaxle and the converter housing.

45. Apply locking sealant (Loctite # 518 or equivalent) to the converter housing sealing surface.

46. Re-install the converter housing and tighten the mounting bolts evenly in a criss-cross pattern to 43 - 47 N.m (4.4 - 4.8 kg-m, 32 - 35 ft-lb).

47. Re-install the torque converter making sure the converter is fully engaged into the oil pump.

48. Re-install the speed sensor and tighten the mounting bolt to 5 - 7 N.m (0.5 - 0.7 kg-m, 43 - 61 in-lb).

49. Re-install the revolution sensor and tighten the mounting bolt to 5-7 N.m (0.5-0.7 kg-m, 43-61 in-lb).

50. Re-install the transaxle assembly in the reverse order that it was removed.

51. Re-install the drivers side front wheel and tighten the wheel securing nuts to 98 - 118 N.m (10 12 Kg-m, 72 - 86 ft-lb).

52. Re-install the side plastic covers.

53. Check the ATF level with the engine warm and at idle speed and with the vehicle on a level surface. Add fluid accordingly.

CAUTION:
Be careful not to overfill the transaxle with ATF.

54. Road test the vehicle to check for noise. Also check for fluid leaks.

55. Re-program all radio pre-sets