Disassembly
DISASSEMBLYBefore disassembling transaxle, move the shift lever clockwise as far as it will go. This should be one position past the L position. Then remove the shift lever.
NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as the unit might then fail.
Fig. 155:
Measuring input shaft end play before disassembly will usually indicate when a # 4 thrust plate change is required. The number 4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft (Fig. 155). Move input shaft in and out to obtain end play reading.
End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transaxle.
Fig. 156:
Remove both speed sensors from transaxle case (Fig. 156).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Fig. 157:
Fig. 158:
NOTE: For valve body recondition procedure, refer to Automatic Transmission/Transaxle, Service and Repair, Disassembly and Assembly.
Fig. 159:
Fig. 160:
Fig. 161:
Fig. 162:
Fig. 163:
Fig. 164:
Fig. 165:
Fig. 166:
Fig. 167:
CAUTION: Tag the springs for the Overdrive Accumulator so that they are not confused with the springs in the Low/Reverse Accumulator.
Fig. 168:
Fig. 169:
NOTE: Remove driveshaft retainer clips from driveshafts.
NOTE: To align oil pump during installation, use threaded dowels or Phillips screwdrivers.
Fig. 170:
Fig. 171:
Fig. 172:
Fig. 173:
OIL PUMP INSPECTION
When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage.
1. Remove the reaction shaft support bolts.
Fig. 174:
2. Remove reaction shaft support from pump housing (Fig. 174).
3. Remove the pump gears and check for wear and damage.
4. Install the gears and check clearances.
Fig. 175:
5. Measure the clearance between the outer gear and the pump pocket (Fig. 175). Clearance should be 0.045 - 0.141mm (0.0018 - 0.0056 inch)
6. Position an appropriate piece of Plastigage across both pump gears.
7. Align the Plastigage to a flat area on the reaction shaft support housing.
8. Install the reaction shaft to the pump housing. Tighten the bolts to 27 Nm (20 ft. lbs.)
9. Remove bolts and carefully separate the housings. Measure the Plastigage following the instructions supplied.
10. Clearance between outer gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.008 - 0.0018 inch). Clearance between inner gear side and the reaction shaft support should be 0.020 - 0.046mm (0.008 - 0.0018 inch).
Fig. 176:
CAUTION: By-pass valve must be replaced if transmission failure occurs.
Fig. 177:
Fig. 178:
Fig. 179:
Fig. 180:
Fig. 181:
Fig. 182:
Fig. 183:
Fig. 184:
The number seven needle bearing has three anti reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 183). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
Stand bans upright on bellhousing.
Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.
Fig. 185:
Fig. 186:
Fig. 187:
Fig. 188:
Fig. 189:
Fig. 190:
Fig. 191:
Fig. 192:
Fig. 193:
Fig. 194:
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
Fig. 195:
Fig. 196:
Fig. 197:
CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, removal or installation will be difficult. Overspreading of the chain sprockets will also make sprocket removal difficult.
Fig. 198:
Fig. 199:
Fig. 200:
Fig. 201:
Remove main sump baffle from transaxle case (Fig. 201).
CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.
WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
Fig. 202:
Fig. 203:
Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in (Fig. 202) and (Fig. 203). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
Fig. 204:
Using a small chisel, carefully open stakes on nut (Fig. 204).
Fig. 205:
6:
Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut (Fig. 205). Note that your breaker bar will turn clockwise to remove the nut and counter clockwise to install the nut.
Fig. 207:
Use special tool 6596 to remove front output shaft bearing cup (Fig. 207).
Fig. 208:
Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rearward (Fig. 208).
Fig. 209:
Fig. 210:
Fig. 211:
Fig. 212:
Fig. 213:
Fig. 214:
Fig. 215:
NOTE: Using a pin punch, drive out guide bracket pivot shaft.
Fig. 216:
Fig. 217:
Fig. 218:
Fig. 219:
Fig. 220:
Fig. 221:
At this point the Centerline of the transaxle has been removed. If the condition for disassembly did not pertain to the differential, its disassembly may not be required. Inspect the rear transfer shaft area and the transfer shaft seal area for contamination. If evidence of contamination is present, replace the rear transfer shaft bearing and/or the transfer shaft seal.