Part 2

Transaxle - Overhaul


















Disassembled Views









































All vehicles

51. Remove and discard the forward clutch piston.





52. NOTE: Note the location of the studbolts for assembly.
Remove the 19 torque converter housing bolts.






53. NOTICE: Carefully pry on the transaxle torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.

Carefully pry the torque converter housing off the transaxle case just enough to break the seal of the silicone and remove the torque converter housing from the transaxle case.






54. Remove the transaxle lube tube.





55. Remove the differential and ring gear assembly.





56. Remove the transfer shaft and gear assembly.





57. NOTICE: If a differential bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.

Inspect the differential for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the ring gear for damage. Install new bearings or a ring gear on the differential if damage or excessive wear is found. For additional information, refer to Differential Gear Assembly . If the differential bearings are replaced the bearing races in the transaxle case and the torque converter housing must also be replaced. For additional information, refer to Transaxle Case and Torque Converter Housing . If the differential ring gear is replaced, the transfer shaft must also be replaced. For additional information, refer to Transfer Shaft and Gear .





58. NOTICE: If a transfer shaft bearing is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.

Inspect the transfer shaft for damage or excessive wear. Inspect the bearings for excessive wear or damage and inspect the park pawl wheel, transfer shaft and transfer shaft input gear for damage. Install new bearings, park pawl wheel, transfer shaft or transfer shaft input gear if damage or excessive wear is found. For additional information, refer to Transfer Shaft and Gear . If the transfer shaft bearings are replaced the bearing races in the transaxle case and the torque converter housing case must also be replaced. For additional information, refer to Transaxle Case and Torque Converter Housing . If the transfer shaft is replaced, the differential ring gear must also be replaced. For additional information, refer to Differential Gear Assembly .
1. Bearings

2. Transfer shaft input gear

3. Transfer shaft

4. Park pawl wheel






59. Remove the pump-to-case seal.





60. Remove the 2 bolts and the oil reservoir.





61. Remove the reservoir O-ring seal.





62. NOTICE: Gently pry the pin out of the hole from under the head on each side or the pin may be broken off in the hole.

Remove and discard the TR (Transmission Range) sensor locking pin.






63. Remove the TR (Transmission Range) sensor.
1. Slide the TR (Transmission Range) sensor out of the transaxle case.

2. Rotate the TR (Transmission Range) sensor detent plate until it rests against the transaxle case.

3. Remove the park pawl actuator rod from the detent lever and remove the TR (Transmission Range) sensor.






64. Remove the park pawl actuator rod.





65. Remove the manual lever shaft seal.





66. NOTICE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.

Inspect the transaxle case side transfer shaft bearing cup for damage. If the transaxle case side transfer shaft bearing cup is damaged, install a new bearing cup. For additional information, refer to Transaxle Case . If a new bearing cup is installed in the transaxle case, install a new transfer shaft bearing cup in the torque converter housing. For additional information, refer to Torque Converter Housing . Install new bearings on the transfer shaft. For additional information, refer to Transfer Shaft and Gear .





67. Remove the halfshaft seal from the transaxle case.





68. NOTICE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transaxle failure can occur.

Inspect the transaxle case side differential bearing cup for damage. If the transaxle case side differential bearing cup is damaged, install a new bearing cup. For additional information, refer to Transaxle Case . If a new bearing cup is installed in the transaxle case, install a new differential bearing cup in the torque converter housing. For additional information, refer to Torque Converter Housing . If a new bearing cup was installed, the differential bearings must also be replaced. For additional information, refer to Differential Gear Assembly .





69. Remove the bolt and the fluid baffle from the torque converter housing.





70. Remove the 9 stator support assembly bolts.





71. Remove the stator support assembly.





72. Remove the 3 bolts and the fluid pump and filter assembly.





73. NOTE: Note the orientation of the fluid filter to the fluid pump.
Remove and discard the fluid filter.

1. Pull the filter out of the bore of the fluid pump. Discard the fluid filter.

2. If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.






74. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.

75. Remove the fluid pump sprocket and chain assembly.





76. Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.
- Check the drive chain for wear, damage, stretching or tightness of the chain links.

- Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.






77. Remove the fluid pump drive sprocket and driven sprocket thrust washers.





78. NOTICE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transaxle failure can occur.

Inspect the torque converter housing side transfer shaft bearing cup for damage. If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. For additional information, refer to Torque Converter Housing . If a new bearing cup is installed in the torque converter housing, install a new transfer shaft bearing cup in the transaxle case. For additional information, refer to Transaxle Case . Install new bearings on the transfer shaft. For additional information, refer to Transfer Shaft and Gear .





Front Wheel Drive (FWD) vehicles

79. Remove the halfshaft seal from the torque converter housing.





All vehicles

80. NOTICE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transaxle failure can occur.

Inspect the torque converter housing side differential bearing cup for damage. If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. For additional information, refer to Torque Converter Housing . If a new bearing cup is installed in the torque converter housing, install a new differential bearing cup in the transaxle case. For additional information, refer to Transaxle Case . If a new bearing cup was installed, the differential bearings must also be replaced. For additional information, refer to Differential Gear Assembly .