Disassembly

1. Thoroughly clean the transaxle exterior and dry it with compressed air.





2. Install Bench Mounted Holding Fixture T57L-500-B and Transmission Mounting Bracket T94P-77000-F on the transaxle case. Position a drain pan under the transaxle.





3. Install Torque Converter Handles T81P-7902-C and remove the torque converter from the case. Drain the fluid from torque converter.





4. Use a 3/8 inch drive ratchet to remove the transaxle drain plug from the case. Allow the transaxle to drain completely.





5. Remove the pump drive shaft by pulling it from the end of the turbine shaft assembly.





6. Install Converter Seal Remover T94P-77000-B and Impact Slide Hammer T50T-100-A. Remove the converter impeller hub seal and discard.





7. Remove the RH and LH differential seals using Converter Seal Remover T94P-77000-B and Impact Slide Hammer T00L-100-A. Discard the differential seals.





8. Use an 8 mm socket to remove the turbine shaft speed sensor bolt.





9. Pull the turbine shaft speed sensor from the bore.





10. Remove and discard the turbine shaft speed sensor O-ring.





11. Remove the fluid filler tube bolt using an 8 mm





12. Pull the fluid filler tube from the bore.





13. Remove the fluid filler tube and discard the fluid filler tube grommet.





14. Remove-the speedometer driven gear bolt using an 8 mm socket.





15. Remove the speedometer-driven gear from the

NOTE: This transaxle uses a speedometer-driven gear assembly that can be taken apart.

16. Inspect the gear teeth for chips, nicks or concave teeth.
17. Remove the O-ring from the driven gear retainer. Discard the O-ring.





18. Use an 8 mm socket to remove the two transmission range (TR) sensor bolts.





19. Pull the TR sensor from the manual valve detent lever shaft.





20. Use an 8 mm socket to remove the 14 main control cover bolts.
21. Pull the main control cover assembly from the case.
22. Separate the main control cover assembly from the main control cover gasket. Discard the main control cover gasket.
23. Inspect the main control cover vent assembly and main control cover grommet.





24. Remove wiring harness clip from main control.





25. Remove the 12 main control bolts shown.





26. Pull the main control slightly away from the case. Disconnect the Z-link from the manual valve.

CAUTION: Do not allow loose manual valve to become damaged.





27. Squeeze the retainer tabs of the electrical connector and remove the connector from the bore in the case. Inspect the O-ring for damage.

CAUTION: Do not pull on the connector wires, or use a hammer on the connector. Damage to the connector and terminals may result.

28. Remove the main control from the case and store in a clean location.
29. Remove the thermostatic fluid level control valve bracket bolt. Remove the bracket.





30. Pull the thermostatic fluid level control valve from the case.





31. Remove forward clutch circuit filter (if equipped).

WARNING: THE SERVO COVER IS UNDER PRESSURE.








32. Using a 17 mm socket, install the Servo Cover Remover/Replacer T94P-77000-L to the pump assembly.

NOTE: To aid in the installation of the servo cover, install a nut with an integral washer (using a permanent thread sealer) onto the forcing bolt of the Servo Cover Remover/Replacer.





33. Use a 17 mm socket and tighten the bolt to compress the servo cover assembly and remove the servo cover retaining ring.

WARNING: SERVO AND SERVO COVER ARE UNDER HIGH SPRING FORCE. USE CAUTION WHEN REMOVING SERVO COVER.

34. Remove Servo Cover Remover/Replacer.
35. Remove the servo cover assembly.





36. Remove the intermediate and overdrive servo piston and return spring.
37. Inspect the following intermediate and overdrive servo parts for damage and wear:
^ cover with integral seal
^ return spring
^ apply rod and retaining clip
^ piston with integral seal
^ cushion spring and backup washer
^ case servo bore
38. Position the transaxle so the converter housing faces up.





39. Use a 10 mm socket to remove the 20 converter housing-to-transaxle case bolts.





40. Separate the converter housing from the case.

NOTE: Place the converter housing on the engine flange side after removal to prevent damage to the lube tube.

41. Remove the transaxle split flange gasket from the converter housing. Discard the transaxle split flange gasket.





42. Remove the No. 15 differential bearing, the No. 14 differential bearing shim (selective fit) and the speedometer drive gear from the final drive carrier and differential assembly.





43. Remove the final drive carrier and differential assembly.





44. Remove the front chain cover by unsnapping it from the rear chain cover.





45. Remove the No. 13 driven sprocket thrust bearing assembly.





46. Remove the No. 10 drive sprocket thrust washer from the reverse/overdrive ring gear assembly.

NOTE: The No. 10 drive sprocket thrust washer may be retained to the converter housing.





47. Lift the drive chain assembly, driven sprocket assembly, and the reverse/overdrive ring gear assembly together from the case.

WARNING: WEAR GLOVES AS PROTECTION FROM SHARP CHAIN AND SPROCKET TEETH.





48. Separate the drive chain assembly from the driven sprocket assembly, and the reverse/overdrive ring gear assembly.





49. Remove the rear chain cover (with the magnet retained) from the case. Check the magnet for excessive metal particles.





50. Assemble Blind Hole Puller Actuator Pin D80L-100-G and Collet D80L-100-Q or equivalents in recirculating seal.





51. Install the Impact Slide Hammer T50T-100-A onto Blind Hole Puller Actuator Pin D80L-100-G or equivalent.
52. Remove and discard fluid filter recirculating regulator exhaust seal.





53. Remove the fluid filter and seal assembly. Discard the fluid filter and seal assembly.





54. Remove the No. 12 driven sprocket bearing assembly and the No. 11 driven sprocket shim (selective fit) from the case.





55. Unsnap the socket end of the parking lever actuating rod from the parking cam actuator lever assembly.





56. Unsnap the socket end of the manual valve detent lever actuating rod assembly from the manual valve detent lever.





57. Remove the No. 9 reverse/overdrive ring gear thrust bearing assembly.

NOTE: The thrust bearing may be retained to drive sprocket.





58. Remove the reverse/overdrive carrier assembly with captured No. 8 thrust bearing.





59. Remove the reverse/overdrive sun gear and shell assembly.





60. Remove the No. 7 reverse/overdrive sun gear thrust bearing assembly

NOTE: The No. 7 reverse/overdrive sun gear thrust bearing assembly may be retained to the reverse/overdrive sun gear and shell assembly.





61. Remove the low-intermediate ring gear assembly.





62. Remove the No. 6 low-intermediate carrier thrust bearing assembly.

NOTE: The No. 6 low-intermediate carrier thrust bearing assembly may be retained to the low-intermediate ring gear assembly.





63. Remove the low-intermediate carrier assembly.





64. Remove the No. 5 low-intermediate sun gear thrust bearing assembly and the forward and low-intermediate sun Gear assembly.





65. Remove the No. 4 turbine shaft thrust bearing assembly.

NOTE: The No. 4 turbine shaft thrust bearing assembly may be retained to the forward one-way clutch and Low-Intermediate sun gear assembly.





66. Remove the turbine shaft assembly.





67. Remove the assembly of the forward/coast/direct cylinder assembly and reverse clutch drum assembly.








68. Remove the No. 1 pump support thrust bearing assembly.

NOTE: The No. 1 pump support thrust bearing assembly may be retained to the reverse clutch drum assembly.





69. Remove the low one-way clutch retaining ring.





70. Remove the low one-way clutch thrust plate.





71. Remove the low one-way clutch assembly.

NOTE: The low one-way clutch assembly should be removed as an assembly.





72. Remove the low/reverse clutch wave spring.

Low/Reverse Clutch Plates:

73. Remove the low/reverse clutch plates.





74. Use a screwdriver to remove the low/reverse clutch pressure plate retainer ring.





75. Remove the low/reverse clutch return spring assembly.





76. Pull the low/reverse clutch piston from the bore using a twisting motion.





77. Position the transaxle with the pump assembly facing up. Use an 8 mm socket to remove the nine pump assembly bolts.





78. Install Slide Hammer Adapter TO1P-78103-A, Pump Removal Bolts T94P-77000-G and Impact Slide Hammer T50T-100-A and remove the pump





79. Slide the intermediate and overdrive band assembly from the case.
80. Inspect the intermediate and overdrive band assembly for wear.