Disassembly

Transaxle














Special Tool(s)





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

Using the special tools, remove the torque converter.





2. Using the special tool, install the transaxle.





3. NOTE: During installation of a new case, a new identification tag will need to be installed, use caution not to damage the tag.

Remove the identification tag.





4. Place a drain pan under the transaxle, rotate the transaxle to a vertical position and allow the fluid to drain. Once the fluid has drained rotate the transaxle to the horizontal position.





5. Remove the output shaft speed (OSS) sensor cover.
1. Remove the connector.
2. Remove the bolt.
3. Remove the cover.





6. Remove the output shaft speed (OSS) sensor.





7. Remove the cover.





8. Remove the filler tube and grommet.





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

Remove the overdrive servo piston and rod.
^ Remove the bolts.
^ Remove the cover.
^ Remove the piston and rod.





10. Remove the low/intermediate servo cover.





11. Remove the manual control lever.





12. Remove the digital transmission range (TR) sensor.
1. Remove the bolts.
2. Remove the sensor.





13. NOTE: The differential seal is of two-piece construction.

Install the special tool into the LH differential seal.





14. Using the special tool, remove the LH differential seal metal protector.
1. Rotate the special tool.
2. Rotate the forcing screw while holding the special tool.
3. Remove the metal protector from the left differential seal and remove protector from tool.





15. Using the special tool, remove the rubber portion of the LH differential seal.
1. Install the special tool into the left differential seal and rotate the special tool.
2. Rotate the forcing screw while holding the special tool.
3. Remove the rubber portion of the seal.





16. Install the special tools into the right differential seal.





17. Using the special tool, remove the right differential seal metal protector.
1. Rotate the special tool.
2. Rotate the forcing screw while holding the special tool.
3. Remove the metal protector.





18. Using the special tools, remove the rubber portion of the seal.
1. Rotate the special tool.
2. Rotate the forcing screw while holding the special tool.
3. Remove the rubber portion of the seal.





19. Using the special tool, remove the converter hub seal.





20. Remove the bolts.
1. Remove the Torch bolts.
2. Remove the bolts.
21. Rotate the transaxle to a vertical position.





22. NOTE: The main control cover gasket is reusable if not torn or damaged.

Remove the cover.





23. CAUTION: Do not pull on the wires or pear on the connectors. Damage to the connector will result.

Lift the locking tab and disconnect the electrical connectors.





24. NOTE: The manual valve should be inserted completely into the main control valve body.

Rotate the manual control lever to the low detent.





25. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body and become damaged.

Remove the bolts. Note the size and location of the bolts.





26. Remove the main control valve body.
^ Remove the pump assembly and main control valve body.
^ Rotate the main control valve body while lifting to remove.





27. Disconnect the manual control valve actuating rod.





28. Remove the pump shaft.





29. Remove the output shaft circlip.





30. Remove the turbine shaft speed (TSS) sensor.





31. NOTE: The transaxle pan gasket is reusable if not torn or damaged.

Remove the fluid pan.





32. Remove the magnet.





33. Remove the filter and the seal.





34. Loosen the nut and remove the reverse clutch anchor pin.





35. CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.

NOTE: Mark bolt size and location for assembly.

Remove the bolts starting from the inside and work out.





36. NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.

Remove the chain cover and gasket.





37. NOTE: Tag and mark the location of the accumulator springs.
1. Remove the drive shift accumulator spring.
2. Remove the 3-4 accumulator spring.
3. Remove the 1-2 accumulator spring.





38. CAUTION: Be careful not to damage or bend the tabs on the exciter ring. If bent, the TSS sensor will not operate.

Remove the drive sprocket, driven sprocket, and drive chain as an assembly.





39. NOTE: The thrust washers may remain on the sprockets. Remove the thrust washers.

1. Remove the No. 2 thrust washer.
2. Remove the No. 4 thrust washer.





40. Inspect the bearing for damage. Install a new bearing if necessary.





41. Using the special tools, remove the bearing.





42. Using the special tool, remove the roll pin.





43. CAUTION: Do not damage the machined surface of the case.

NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.

Remove the remaining roll pins.





44. NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.

Remove the manual control lever shaft.





45. Remove the parking lever actuating rod.





46. Using a screwdriver remove the manual control lever shaft seal.





47. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.

Remove the drive sprocket support and the No. 5 thrust washer.





48. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and the driven sprocket.

Remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.





49. Remove the plastic overdrive band retainer.





50. Remove the overdrive band.





51. Remove the bolts and the lube tube brackets.





52. Using the special tool, remove the lube tubes.





53. Remove the park pawl assembly.
1. Remove the bolts.
2. Remove the park pawl abutment.
3. Remove the park pawl shaft.
4. Remove the park pawl return spring.





54. NOTE: Do not overtighten the handle of the tool. Place two 3/8inch washers between the handle and the notched block.

Using the special tools, remove the front sun and shell assembly.





55. Using the special tool, remove the reverse clutch and planet assembly.





56. Remove the front planet and rear ring gear.





57. Remove the rear sun gear, drum, and the No. 15 rear sun gear thrust bearing and race.





58. Remove the low and intermediate band.





59. CAUTION: Do not damage any machined surfaces.

Using a screwdriver, remove the rear support snap ring through the side of the case.





60. Remove the final drive/differential assembly.





61. NOTE: The differential carrier thrust washer may remain on the differential assembly.

^ Remove the differential carrier thrust washers.
^ Remove the No. 18 differential carrier thrust washer.
^ Remove the No. 19 differential carrier thrust bearing and race.





62. Remove the final drive ring gear.





63. NOTE: The following procedures are done only if installing a new case.

Remove the bolts.





64. Remove the stator support assembly.