Steps 1 - 36

40TE AUTOMATIC TRANSAXLE

DISASSEMBLY STEPS 1 - 36

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the TCM Quick Learn Procedure. Testing and Inspection

NOTE: This procedure does not include final drive (differential) disassembly.

(1) Remove input and output speed sensors.
(2) Remove three solenoid/pressure switch assembly-to-case bolts.

Fig.11 Solenoid/Pressure Switch Assembly And Gasket:

(3) Remove solenoid/pressure switch assembly (1) (Fig. 11) and gasket (2).

Fig.12 Removal Oil Pan Bolts:

(4) Remove oil pan-to-case bolts (1) (Fig. 12).

Fig.13 Removal Oil Pan:

(5) Remove oil pan (1) (Fig. 13).

Fig.14 Remove Filter And O-Ring:

(6) Remove oil filter (1) (Fig. 14).
(7) Turn manual valve fully clock-wise to get park rod into position for removal.

Fig.15 Remove Valve Body-to-Case Bolts:

(8) Remove valve body-to-case bolts (1) (Fig. 15).

CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.

Fig.16 Push Park Rod Rollers From Guide Bracket:

(9) Using a screwdriver (2) (Fig. 16), push park rod rollers (1) away from guide bracket (3).

Fig.17 Valve Body Removal/Installation:

(10) Remove valve body assembly (1) (Fig. 17).

NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.

Fig.18 Underdrive And Overdrive Accumulators:

(11) Remove underdrive (2) (Fig. 18) and overdrive (4) accumulators.

Fig.19 Remove Low/Reverse Accumulator Snap Ring:

(12) Remove low/reverse accumulator snap ring (1) (Fig. 19).

Fig.20 Remove Low/Reverse Accumulator Plug:

(13) Remove low/reverse accumulator plug (2) (Fig. 20).

Fig.21 Low/Reverse Accumulator Piston:

(14) Remove low/reverse accumulator piston (1) (Fig. 21) using suitable pliers.

Fig.22 Low/Reverse Accumulator:

(15) Remove piston (1) and springs (3) (Fig. 22).

Fig.23 Measure Input Shaft End Play:

(16) Measure input shaft end play using End Play Socket Set 8266 (1) (Fig. 23) and C-3339 (3). Place transaxle so input shaft is vertical. Set up end play set and dial indicator. Input shaft end play should be within 0.13 - 0.64 mm (0.005 - 0.025 inch) If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.

Fig.24 Remove Oil Pump-to-Case Bolts:

(17) Remove oil pump-to-case bolts (1) (Fig. 24).

CAUTION: Be sure input speed sensor is removed before removing oil pump.

Fig.25 Install Tool C-3752:

(18) Install pullers Tool C-3752 (1) (Fig. 25).

Fig.26 Remove Oil Pump:

(19) Push in on input shaft while removing pump (1) (Fig. 26).

Fig.27 Oil Pump Removed:

(20) Remove oil pump assembly (1) (Fig. 27).

Fig.28 Remove Oil Pump Gasket:

(21) Remove oil pump gasket (1) (Fig. 28).

CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.

Fig.29 Remove Bypass Valve:

(22) Remove cooler bypass valve (1) (Fig. 29).

Fig.30 Remove No.1 Caged Needle Bearing:

(23) Remove #1 needle bearing (1) (Fig. 30).

Fig.31 Remove Input Clutch Assembly:

(24) Remove input clutch assembly (1) (Fig. 31).

Fig.32 No.4 Thrust Plate:

(25) Remove #4 thrust plate (2) (Fig. 32).

Fig.33 Remove Front Sun Gear Assembly:

(26) Remove front sun gear assembly (1) (Fig. 33) and #4 thrust washer (2).

Fig.34 Remove Front Carrier/Rear Annulus Assembly:

(27) Remove front carrier/rear annulus assembly (2) (Fig. 34) and #6 needle bearing (1).

Fig.35 Remove Rear Sun Gear:

(28) Remove rear sun gear (2) (Fig. 35).

Fig.36 Number 7 Bearing:

(29) Remove needle bearing (1) (Fig. 36).

NOTE: The number 7 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig.37 Remove 2/4 Clutch Retainer Snap Ring:

(30) Setup Compressor 5058 (1) (Fig. 37). Compress 2/4 clutch return spring (4) Oust enough to remove snap ring) and remove snap ring (3).

NOTE: Verify that Compressor 5058 is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.