Part 1 of 2

1. Install Torque Converter Handles T81P-7902-C. Remove torque converter from transaxle. Drain fluid from torque converter.

CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.





2. Mount transaxle in Bench Mounted Holding Fixture T57L-500-B.





3. Remove identification tag using a screwdriver in case replacement becomes necessary.

CAUTION: Use care not to damage tag.





4. Place drain pan under transaxle. Turn transaxle in vertical position and drain fluid.





5. Remove overdrive servo cover bolts, cover, piston assembly and spring.

CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.

NOTE: Piston assembly and spring may remain in cover.





6. Remove transaxle filler tube retaining bolt and pull fluid filler tube from case. Remove and discard tube-to-case grommet.





7. Remove transmission range sensor retaining bolts and remove transmission range sensor.





8. Remove Turbine Shaft Speed (TSS) sensor retaining bolt. Remove sensor. Remove and discard O-rings from sensor.





9. Remove Vehicle Speed Sensor (VSS).





10. Install Front Cover Seal Remover T74P-6700-A and 5-1/2 inch forcing screw (from tool T88T-6701-A) into LH differential seal.





11. Screw Front Cover Seal Remover T74P-6700-A and forcing screw into outer metal protector using one-inch box wrench.

NOTE: Output shaft seal is a two-piece construction, outer metal protector and inner rubber seal.





12. Tighten forcing screw on end of tool using 3/4-inch box wrench until outer metal protector is removed. Remove outer metal protector from tool and discard.





13. Install Front Cover Seal Remover T74P-6700-A and forcing screw into seal using a one-inch box wrench.





14. Tighten forcing screw on end of tool using 3/4-inch box wrench until seal is removed. Discard seal.
15. Remove RH differential oil seal.

NOTE: Output shaft seal is a two-piece construction, outer metal protector and inner rubber seal.





a. Install Step Plate Adapter D80L-630-A or equivalent into output shaft opening. Install Front Cover Seal Remover T74P-6700-A and 5-1/2-inch forcing screw (from tool T88T-6701-A) into output shaft opening.





b. Screw Front Cover Seal Remover T74P-6700-A and 5-1/2-inch forcing screw (from tool kit T88T-6701-A), into outer metal protector using a one-inch box wrench.





c. Tighten screw on end of tool using a 3/4-inch box wrench, until outer metal protector is removed.





d. Remove outer metal protector from tool and discard. Install tool into seal using one-inch box wrench.





e. Tighten screw on the end of tool using 3/4-inch box wrench, until seal is removed. Remove seal from tool and discard.





16. Remove and discard converter impeller hub seal using Converter Seal Remover T94P-77001-BH and Impact Slide Hammer T50T-100-A.

CAUTION: Do not damage any machined surfaces.





17. Remove five T-27 Torx and two chain cover bolts from inside transaxle bell housing.
18. Rotate transaxle to vertical position.





19. Remove main control cover bolts. Remove main control cover and gasket.

Transaxle Main Control Electrical Connector And Solenoid Locations:

20. Disconnect electrical connectors from Transmission Fluid Temperature (TFT) sensor and five solenoids.

CAUTION: Use both hands to disconnect sensors. Do not pull on wires nor pry on connectors or damage to connector will result.





21. Using a 9 mm wrench on flats of manual control lever shaft, rotate shaft clockwise to manual LOW detent.

NOTE: Manual shift valve positioned all the way in.

Pump And Main Control Valve Body Assembly Retaining Bolts:

22. Remove 23 pump and main control valve body assembly retaining bolts. Note length and location of bolts.

CAUTION: Do not remove the two bolts that retain the pump and main control valve body assembly together as the pump assembly components may fall from the main control valve body.

NOTE: Do not remove pump assembly cover bolts indicated.





23. Rotate main control valve body clockwise. Remove manual control valve actuating rod from manual control valve and remove main control valve body and gasket.

NOTE: Store main control valve body in a clean location.





24. Disconnect manual control valve actuating rod from manual valve detect lever.





25. Pull pump shaft out of case.





26. Remove 18 chain cover bolts and one shift cable stud. Note length and location of bolts. Start at inside and work out.

CAUTION: Chain cover is under spring pressure. Use care when removing to prevent internal parts from being ejected from case.





27. Remove 19 transaxle pan bolts. Remove transaxle pan and gasket.





28. Remove magnet from transaxle pan.





29. Remove and discard fluid filter assembly.

NOTE: Lip seal may stick inside case.





30. If fluid filter seal did not come out of case with fluid filter, remove fluid filter seal using the large end of a 3/8 inch socket extension and discard fluid filter seal.

CAUTION: Use care not to damage any machined surfaces.





31. Remove chain cover. Remove and discard chain cover gasket.

NOTE: Plastic thrust washers No. 1 and No. 3 may come off with cover or may stay on sprockets.





32. Tag and remove four accumulator springs to be sure they can be installed in their correct positions during reassembly.





33. Simultaneously, lift out both drive sprocket and driven sprocket with drive chain.

WARNING: Chain and sprocket teeth may be sharp.

CAUTION:
^ Be careful not to damage or bend tabs on exciter ring. TSS will not operate correctly if exciter tabs are bent.
^ Be careful not to bend or damage exciter tabs on speed sensor wheel.





34. Remove No. 2 thrust washer from drive sprocket support and No. 4 thrust washer from driven sprocket support.

NOTE: Thrust washers may remain on underside of sprockets.





35. Remove and discard three roll-pins from manual control lever shaft using locking pliers.

CAUTION: Use care not to damage any machined surfaces.