Steps 1-35

Special Tools:

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

Install Torque Converter Handles 307-091 (T81P-7902-C). Remove torque converter from transaxle. Drain fluid from torque converter.

2. Mount transaxle in Bench Mounted Holding Fixture 307-003 (T57L-500-B).

3. CAUTION: Use care not to damage tag.

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

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

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

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) (all except SHO).

10. Install Front Cover Seal Remover 303-107 (T74P-6700-A) and 5 1/2 inch forcing screw (from tool 303-335 (T88T-6701-A)) into LH differential seal.

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

Screw Front Cover Seal Remover 303-107 (T74P-6700-A) and forcing screw into outer metal protector using one-inch box wrench.

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 303-107 (T74P-6700-A) and forcing screw into seal using a one-inch box wrench.

14. Tighten screw on the end of tool using a 3/4 inch box wrench until seal is removed. Discard seal.

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

a. Install Step Plate Adapter 205-DS011 (D80L-630-A) or equivalent into output shaft opening. Install Front Cover Seal Remover 303-107 (T74P-6700-A) and 5 1/2-inch forcing screw (from tool 303-335 (T88T-6701-A)) into output shaft opening.

b. Screw Front Cover Seal Remover 303-107 (T74P-6700-A) and 5 1/2-inch forcing screw (from tool kit 303-335 (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. CAUTION: Do not damage any machined surfaces.

Remove and discard converter impeller hub seal using Converter Seal Remover 307-309 (T94P-77001-BH) and Impact Slide Hammer 100-001 (T50T-100-A).

17. Remove five T27 Tort 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.

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

Transaxle Main Control Electrical Connector and Solenoid Locations - 1 Of 2:

Transaxle Main Control Electrical Connector and Solenoid Locations - 2 Of 2:

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

21. NOTE: Manual shift valves positioned all the way in.

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

22. 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.

Pump and Main Control Valve Body Assembly Retaining Bolts:

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

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

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

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

25. Pull pump shaft out of case.

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

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

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

28. Remove magnet from transaxle pan.

29. NOTE: Lip seal may stick inside case.

Remove and discard fluid filter assembly.

30. CAUTION: Use care not to damage any machined surfaces.

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.

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

Remove chain cover. Remove and discard chain cover gasket.

32. NOTE: SHO vehicles are equipped with an additional 1-2 accumulator cushion spring which fits into the center of the 1-2 shift accumulator spring. Make sure to note the position of this additional spring on SHO vehicles along with the remaining four accumulator springs.

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

33. 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.

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

34. NOTE: Thrust washers may remain on underside of sprockets.

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

35. CAUTION: Use care not to damage any machined surfaces.

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