Part 1

DISASSEMBLY





1. Remove the speed sensors (1, 2 and 3).




2. Remove bolts (1) at the oil filter pan (2).
3. Remove the oil filter pan (2).




4. Remove the bolts (1) at the oil filter (2).
5. Remove the oil filter (2).




6. Remove the oil filter seal (1) at the case.




7. Remove bolts (2) at the valve body oil pan (1).




8. Remove the pressure tap plug (2) at valve body pan.
9. Remove the valve body pan.




10. Remove the electrical connector (1) at the range sensor (4).
11. Remove the bolt (3) holding the detent spring.
12. Remove the detent spring (2).




13. Remove valve body bolts (1).




14. Remove valve body (1) from oil transfer tubes and manual valve (3) from rooster comb.




15. Remove oil transfer tubes (2) from the case.








16. Remove all six accumulators (1, 2, 3, 5, 6 and 7) from case along with the accumulator return springs.
17. Remove the 2/4 clutch oil supply seal (4) from the case.
18. Remove the manual lever, TRS and sealRemoval.




19. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up End Play Socket Set 8266A (1,2) and dial indicator (3). Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.) Record indicator reading for reference upon reassembly.




20. Remove the front pump bolts (1).




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

21. Install oil pump puller C-3752.(1) on oil pump.




22. Remove oil pump assembly (1).




23. Remove oil pump gasket (2).




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

24. Remove cooler bypass valve (2).




25. Remove number one needle bearing (1).




26. Remove input clutch assembly (1).




27. Remove number four thrust plate (2).




28. Remove front sun gear assembly (1) and number four thrust washer (2).




29. Remove front carrier/rear annulus assembly (2) and number six needle bearing (1).




30. Remove rear sun gear (2) and number seven needle bearing (1).




31.
NOTE: The number seven needle bearing (1) 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 (1).





32. Setup compressor 5058 (1), Compress 2/4 clutch return spring (4) (just 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.

33. Remove 2/4 clutch retainer (1).




34. Remove 2/4 clutch return spring (1).




35. Remove 2/4 clutch pack (1,2). Tag 2/4 clutch pack for reassembly identification.




36. Remove tapered snap ring (3).




37. Remove low/reverse reaction plate (1).




38. Remove one low/reverse clutch disc (1).




39. Remove low/reverse reaction plate snap ring (2).




40. Remove low/reverse clutch pack (1,2).




41. Remove transfer gear cover-to-case bolts (2).
42. Remove transfer gear cover (1).�




43. Remove the oil scavenger (2).




44. Bend back the locking tabs (2) at the output transfer gear retaining strap (3).
45. Remove the bolts (1) at the output transfer gear retaining strap (3).
46. Remove the output transfer gear retaining strap (3).