Disassembly

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

1. Prior to disassembling the transaxle, plug all openings and thoroughly clean the exterior of the assembly, preferably by steam.
2. Place the transmission on the workbench with the oil pan down.
3. Remove the torque converter.





4. Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required (except when major parts are replaced). Thrust washers are located between the reaction shaft support and rear clutch retainer, and between the reaction shaft support and front clutch retainer.
Mount a dial indicator to the converter housing using the special tool, with its plunger seated against the end of the input shaft.
Move the input shaft in and out with pliers to obtain the end play reading. Be careful not to scratch the input shaft. Record the indicator reading for reference when reassembling the transaxle.





5. Remove pulse generators "A" and "B".





6. Remove the manual control lever, and then remove the park/neutral position switch.





7. Snap off the snap ring and remove the kickdown servo switch.





8. Remove the oil pan and oil pan gasket.





9. Remove the oil filter.





10. Remove the oil temperature sensor bracket mounting bolts and remove the oil temperature sensor from its bracket. Using a screwdriver, push out the rubber plug, working from inside the case, and remove the oil temperature sensor from the case.





11. With their catches pressed down, force the harness grommet and connector into the transaxle case.





12. Remove the valve body mounting bolts indicated by arrows and remove the valve body from the transaxle case.





13. Remove the end clutch cover.





14. Remove the end clutch assembly.





15. Remove the thrust washer from the input shaft end.





16. Remove the end clutch hub and the thrust bearing.





17. Pull out the end clutch shaft.





18. Remove the 14 bolts indicated by arrows and remove the converter housing and gasket.





19. Remove the six oil pump mounting bolts indicated by arrows.
20. Screw the special tools (MD998333) or equivalent into the bolt holes marked A.





21. Grasping the special tools, remove the oil pump. Then, remove the gasket.





22. Remove the spacer and differential from the transaxle case.





23. Remove fiber thrust washer #1.





24. Grasp and raise the input shaft to remove both the front - and rear clutch assemblies together.





25. Remove thrust bearing #6.





26. Remove the clutch hub.





27. Remove thrust race #7 and thrust bearing #8.





28. Remove the kickdown drum.





29. Remove the kickdown band.





30. Using the special tools, push in the kickdown servo and remove the snap ring.





31. Remove the special tools and then remove the kickdown servo piston, sleeve and spring.





32. Remove the anchor rod.





33. Remove the snap ring.





34. Set the special tool on the center support and remove the center support from the case.





35. Remove reverse sun gear, thrust bearing #9, thrust race #10 and forward sun gear together.





36. Remove the planetary gear set and thrust bearing #12.





37. Remove the wave spring, return spring, reaction plate, brake discs, and brake plates.





38. Sealant has been applied to the threads of the screws on the bearing retainer. Tap the screw heads so the screws can be easily loosened.





39. Using an impact driver, loosen the screws and remove the bearing retainer.





40. Remove the idler shaft lock plate.





41. Loosen the transfer idler shaft with the special tool.





42. Pull out the transfer idler shaft. Remove the transfer idle gear and the two bearing inner races from inside the case.





43. Remove the spacer.





44. Remove the snap ring from the output flange bearing.





45. Remove the output flange from the case.





46. Remove the transfer shaft cover.





47. Straighten the locking tab of the transfer shaft lock nut where it is bent.





48. Secure the transfer shaft on the end of the converter housing.





49. Remove the lock nut.

CAUTION: The lock nut is a left-handed screw.





50. Drive out the transfer shaft toward the converter housing end and remove the transfer shaft and transfer driven gear.





51. Remove the outer races from the transfer shaft bearing.





52. Remove the set screw, sprag rod and remove the manual control shaft assembly, detent plate.