Disassembly

AUTOMATIC TRANSAXLE





COMPONENTS

DISASSEMBLY

CAUTION:
1. Because the automatic transmission is manufactured from high-precision parts, sufficient care must be taken not to scratch or damage these parts during disassembly and reassembly.
2. The working area should be covered with a rubber mat to keep it clean at all times.
3. Do not wear any cloth gloves and do not use any rags during disassembly. Use nylon cloth or paper towels if you need to use something.
4. Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent but they should be dried completely using compressed air.
5. Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF) so that they do not become dirty.
6. If the transmission body has been damaged, disassemble and clean the cooler system also.





1. Remove the torque converter and set aside.
2. Measure the input shaft end play.
3. Remove the left and right roll stopper brackets.
4. Remove the wiring harness bracket.
5. Remove the control cable support bracket.





6. Remove the dipstick.
7. Remove the oil cooler feed tube, gasket, and eye bolt.
8. Remove the input shaft speed sensor and the output shaft speed sensor.





9. Remove the manual control lever, then remove the transaxle range switch.





10. Remove the vehicle speed sensor.





11. Remove the valve body cover.





12. Remove the manual control shaft detent.





13. Disconnect the harness connectors of the valve body.

CAUTION: To prevent damage to transaxle components make sure that the manual control lever and the park/neutral switch have been removed before attempting to remove the valve body.

NOTE: The valve body mounting bolts are different lengths. Note the locations of the bolts to aid in assembly.





14. Remove 28 of the valve body mounting bolts. Do not remove the bolts shown in the illustration at this time.
15. Remove the oil temperature sensor.





16. Remove the valve body, gasket, and the 2 steel balls.

NOTE: Make sure not to lose the 2 steel balls.





17. Remove the solenoid valve wiring harness snap ring.
18. Remove the solenoid valve harness.





19. Remove the strainer.
20. Remove the second brake retainer oil seal.

CAUTION: The second brake retainer oil seal must be removed before removing the transaxle powertrain components from the case or damage to the seal will occur.








21. Remove the 4 accumulator pistons, the 4 large springs, and the 3 small springs.





22. Remove the manual control lever shaft pin (roller).
23. Remove the manual control lever shaft.
24. Remove the parking pawl rod.





25. Remove the torque converter housing and 18 mounting bolts. Tap the housing off with a non-metallic hammer.





26. Remove the 2 O-rings from the case.





27. Remove the differential.





28. Remove the main oil filter.





29. Remove oil pump mounting bolts.

CAUTION: The oil pump is not serviceable, it must be replaced as a pump assembly. Do not disassemble the pump as improper alignment during assembly will cause pump failure and could cause damage to the transaxle.





30. Install the special tool (09452-33100), as shown in the illustration.
31. Remove the oil pump by turning special tool screws clockwise.
32. Remove the oil pump gasket.





33. Remove thrust bearing #1.





34. Grasp the input shaft, then pull out the underdrive clutch and input shaft as an assembly.





35. Remove thrust bearing #2.





36. Remove the underdrive clutch hub.





37. Remove the rear cover and mounting bolts.
38. Remove the thrust race #8.
39. Remove the 4 seal rings.

NOTE: Do not remove the input shaft rear bearing unless directed to do so by the instructor. Once this bearing has been removed, it MUST be replaced.





40. Remove the 3 O-rings.





41. Remove thrust bearing #7.
42. Remove the reverse and overdrive clutch.





43. Remove thrust bearing #6.
44. Remove the overdrive clutch hub.





45. Remove thrust bearing #5.





46. Remove the planetary reverse sun gear.





47. Remove the second brake piston snap ring.





48. Remove the second brake piston and return spring.





49. Remove the second brake pressure plate, 3 brake discs, and 2





50. Remove the overdrive planetary carrier.





51. Remove thrust bearing #4.
52. Remove the output planetary carrier.





53. Remove the underdrive sun gear.
54. Remove thrust bearing #3.





55. Remove the low/reverse reaction plate snap ring.





56. Remove the low/reverse reaction plate and brake disc.





57. Remove the low/reverse brake snap ring.





58. Remove the low/reverse 6 brake discs, 5 brake plates, and brake pressure plate.





59. Remove the wave spring.





60. Remove the parking pawl shaft.
61. Remove the spacer.
62. Remove the parking pawl spring. Note the orientation of the spring to aid in reassembly.





63. Remove the 2 parking roller support shafts.
64. Remove the parking pawl case.
65. Remove the parking roller support.





66. Remove the snap ring.
67. Remove the spring retainer.
68. Remove the return spring.
69. Remove the low/reverse brake piston. Use compressed air directed into the valve body passage.





70. Remove the 7 transfer gear mounting bolts.





71. Remove the transfer drive gear.





72. Remove the plastic cap, if present.





73. Straighten the locking tab of the output shaft lock nut, if bent.

NOTE: The output shaft lock nut is left-hand thread.





74. Remove the output shaft lock nut.





75. Remove the output shaft bearing retainer mounting bolts.





76. Tap out the output shaft, tapered roller bearing, and the collar from the back side.





77. Tap out the bearing outer race and spacer using a suitable driver.
78. Remove the snap ring.
79. Remove the differential bearing outer race and spacer from the torque converter housing.
80. Remove the differential bearing outer race from the transaxle case.