Service Manual

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03C2T02168

0300 035H

09G

1004

1. Clean all transaxle case parts thoroughly and dry

with compressed air.

2. Inspect all case parts thoroughly and replace as

necessary.

3. Inspect the steel sleeve in the rear of case very

closely, as shown in Figure 90.

Note: This sleeve contains sealing rings for the

K2 clutch and sleeve is prone to "spinning" on

the case, creating cross-leaks.

There is a replacement sleeve available from

Sonnax® under part number 15759-01K with

improved retention and includes installation

instructions for 09G, 09K, 09M.

4. Install two new sealing rings into the grooves in

the steel sleeve at rear of case (See Figure 90)

and lube with small amount of Trans-Jel®.

5. Install tapered roller bearing and roller bearing

race as necessary, as shown in Figure 91.

Note: Shims under the tapered roller bearing

and the roller bearing race are used to set the

pre-load for final drive and transfer/pinion

gear shaft, which should be 4 to 6 inch pounds

of rotating torque.

6. Install new inner and outer "O" ring seals into

B2 clutch piston grooves, as shown in Figure 92,

and lube with small amount of Trans-Jel.

Figure 91

561

562

563

564

561 TAPERED ROLLER BEARING (FINAL DRIVE).

562 ROLLER BEARING SHIM (SETS FINAL DRIVE PRE-LOAD).

563 TAPERED ROLLER BEARING RACE (TRANSFER/PINION GEAR).

564 BEARING RACE SHIM (SETS TRANSFER/PINION PRE-LOAD).

Figure 90

COMPONENT REBUILD (CONT'D)

TRANSAXLE CASE ASSEMBLY

WARNING: At time of this printing, there are not

any new "hard parts" available from the

manufacturer for this unit. The only source will be

used aftermarket suppliers.

482

483

484

Figure 92

482 B2 CLUTCH APPLY PISTON.

483 B2 CLUTCH APPLY PISTON INNER "O" RING SEAL.

484 B2 CLUTCH APPLY PISTON OUTER "O" RING SEAL.

Continued on Page 64

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information