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Automatic Transmission: Disassembly: Transaxle: Disassembly

    CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
    Fig 1: Removing Torque Converter
    G02197798
  1. Using the special tools, remove the torque converter.
  2. Using the special tool, install the transaxle into the bench.
    Fig 2: Installing Special Tool Onto Transaxle
    G02197799
    3. NOTE: During a case replacement, the identification tag will need to be replaced. Use caution not to damage the tag.
    Fig 3: Removing Identification Tag
    G02197800
  3. Remove the identification tag.
  4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
    Fig 4: Rotating Transaxle To Vertical Position
    G02197801
  5. Remove the filler tube.
    Fig 5: Removing Filler Tube
    G02197802
    6. 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.
    Fig 6: Removing Overdrive Servo Piston & Rod
    G02197803
  6. Remove the overdrive servo piston and rod.
    • Remove the bolts.
    • Remove the cover.
    • Remove the piston and rod.
  7. Remove the output shaft speed (OSS) sensor cover.
    Fig 7: Removing Output Shaft Speed (OSS) Sensor Cover
    G02197804
  8. Remove the output shaft speed (OSS) sensor.
    • Unclip the harness.
    • Remove the output shaft speed (OSS) sensor.
    Fig 8: Removing Output Shaft Speed (OSS) Sensor
    G02197805
  9. Remove the digital TR sensor.
    1. Remove the bolts.
    2. Remove the digital TR sensor.
    Fig 9: Removing Digital TR Sensor
    G02197806
  10. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
    Fig 10: Remove TSS Sensor
    G02197807
    11. NOTE: The differential seal is a two-piece constructed seal.
    Fig 11: Removing LH Differential Seal
    G02197808
  11. Using the special tools, remove the LH differential seal.
  12. Using the special tools, 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 protection from the LH differential seal and remove the protector from the tool.
    Fig 12: Removing LH Differential Seal Metal Protector
    G02197809
  13. Using the special tools, remove the rubber portion of LH differential seal.
    1. Install the special tool into the LH differential seal.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 13: Removing Rubber Portion Of LH Differential Seal
    G02197810
  14. Install the special tool into the RH differential seal.
    Fig 14: Installing RH Differential Seal Remover
    G02197811
  15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
    Fig 15: Removing RH Differential Seal Metal Protector
    G02197812
  16. Using the special tool, 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.
    Fig 16: Removing Rubber Portion Of Seal
    G02197813
  17. Using the special tools, remove the converter hub seal.
    Fig 17: Removing Converter Hub Seal
    G02197814
  18. Remove the bolts.
    Fig 18: Removing Bolts
    G02197815
  19. Rotate the transaxle to a horizontal position.
  20. If not previously removed, remove the mount.
    Fig 19: Removing Mount
    G02197816
  21. Remove the bolts, and remove the pan.
    Fig 20: Removing Pan
    G02197817
    22. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
    Fig 21: Disconnecting Electrical Connectors
    G02197818
  22. Lift the locking tab and disconnect the electrical connectors.
    23. NOTE: The manual valve should be inserted completely.
    Fig 22: Rotating Manual Control Lever-To-Low Detent
    G02197819
  23. Using a 9 mm (0.36 in) wrench rotate the manual control lever to the low detent.
    24. 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.
    CAUTION: Only four of the six pump cover bolts need to be removed.
    Fig 23: Removing Bolts
    G02197820
  24. Remove the bolts.
  25. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
    Fig 24: Removing Main Control Valve Body
    G02197821
  26. Disconnect the manual control valve actuating rod.
    Fig 25: Disconnecting Manual Control Valve Actuating Rod
    G02197822
  27. Remove the pump shaft.
    Fig 26: Removing Pump Shaft
    G02197823
    28. NOTE: The transaxle pan gasket is reusable if not torn or damaged.
    Fig 27: Removing Transmission Fluid Pan & Gasket
    G02197824
  28. Remove the bolts, transmission fluid pan and gasket.
  29. Remove, clean and inspect the magnet.
    Fig 28: Locating Magnet
    G02197825
  30. Remove the filter.
    Fig 29: Removing Filter
    G02197826
    31. NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
    Fig 30: Removing Fluid Filter Seal
    G02197827
  31. Remove the fluid filter seal.
  32. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 31: Removing Reverse Clutch Anchor Pin
    G02197828
    33. 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.
    Fig 32: Removing Chain Cover Bolts
    G02197829
  33. Remove the bolts.
    34. NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.
    Fig 33: Removing Chain Cover & Gasket
    G02197830
  34. Remove the chain cover and gasket.
    35. NOTE: Tag and mark the location of the accumulator springs.
    Fig 34: Removing Accumulator Springs
    G02197831
    1. Remove the intermediate 1-2 accumulator outer spring.
    2. Remove the direct 2-3 accumulator piston spring.
    3. Remove the neutral reverse shift accumulator spring.
    4. Remove the overdrive 3-4 accumulator spring.
    36. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
    Fig 35: Removing Drive Sprocket, Driven Sprocket & Drive Chain
    G02197832
  36. Remove the drive sprocket, driven sprocket, and drive chain as an assembly.
    37. NOTE: The thrust washers may remain on the sprockets.
    Fig 36: Removing Thrust Washers
    G02197833
  37. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
    38. CAUTION: Use care not to 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.
    Fig 37: Locating Roll Pins
    G02197834
  38. Remove the roll pins.
    39. 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.
    Fig 38: Removing Manual Control Lever Shaft
    G02197835
  39. Remove the manual control lever shaft.
  40. Remove the parking lever actuating rod.
    Fig 39: Removing Parking Lever Actuating Rod
    G02197836
  41. Remove the manual control lever shaft seal.
    Fig 40: Removing Manual Control Lever Shaft Seal
    G02197837
    42. NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
    Fig 41: Removing Fluid Transfer Tubes Bolts & Brackets
    G02197838
  42. Remove the bolts and brackets.
  43. Using the special tools, remove the fluid lube tubes.
    Fig 42: Removing Fluid Transfer Tubes
    G02197839
  44. Remove the bolts and the park pawl abutment.
    Fig 43: Removing Bolts & Park Pawl Abutment
    G02197840
  45. Remove the neutral/drive accumulator bolt.
    Fig 44: Removing Neutral/Drive Accumulator Bolt
    G02197841
  46. Remove the neutral/drive accumulator.
    1. Remove the cover.
    2. Remove the spring.
    3. Remove the piston and shaft.
    Fig 45: Removing Neutral/Drive Accumulator
    G02197842
  47. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston, and rod as an assembly.
    Fig 46: Removing Coast Band Servo
    G02197843
    48. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
    Fig 47: Removing Drive Sprocket Support & No. 5 Thrust Washer
    G02197844
  48. Remove the drive sprocket support and the No. 5 thrust washer.
    49. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
    Fig 48: Removing No. 8 Driven Sprocket Support Selective Fit Rear Thrust Washer & No. 9 Needle Bearing
    G02197845
  49. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
  50. Remove the plastic overdrive band retainer.
    Fig 49: Removing Plastic Overdrive Band Retainer
    G02197846
  51. Remove the overdrive band.
    Fig 50: Removing Overdrive Band
    G02197847
    52. NOTE: Do not over-tighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
    Fig 51: Installing Clutch Pack Loading Fixture (307-171)
    G02197848
  52. Position the special tool into the case and install the hook end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
  53. Using the special tool, remove the front clutch assembly.
    Fig 52: Removing Front Clutch Assembly
    G02197849
  54. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 53: Removing Reverse Clutch & Planet Assembly
    G02197850
  55. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 54: Removing Low/Intermediate Drum, Sun Gear & One-Way Clutch Assembly
    G02197851
  56. Remove the coast band.
    Fig 55: Removing Coast Band
    G02197852
    57. CAUTION: Use care not to damage any machined surfaces.
    Fig 56: Removing Low/Intermediate Clutch Retaining Ring
    G02197853
  57. Remove the low/intermediate clutch retaining ring.
  58. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
    Fig 57: Removing Low/Intermediate Clutch Pack
    G02197854
    59. WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
    CAUTION: Use care not to damage final drive support assembly, transaxle case, or retaining ring during removal.
    Fig 58: Removing Beveled Retaining Ring
    G02197855
  59. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
  60. Remove the final drive differential and rear planet support assembly.
    Fig 59: Removing Final Drive Differential & Rear Planet Support Assembly
    G02197856
    61. NOTE: The differential carrier thrust washer may remain on the differential assembly.
    Fig 60: Removing Differential Carrier Thrust Washer
    G02197857
  61. Remove the differential carrier thrust washer.
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
  62. Remove the rear planet support spacer.
    Fig 61: Removing Rear Planet Support Spacer
    G02197858
  63. Remove the final drive ring gear.
    Fig 62: Removing Final Drive Ring Gear
    G02197859
    64. NOTE: If the drive sprocket bearing is worm or damaged install a new bearing.
    Fig 63: Removing Drive Sprocket Bearing
    G02197860
  64. Using the special tools, remove the drive sprocket bearing.
    65. NOTE: The following procedures are done only if a case replacement is necessary.
    Fig 64: Removing Case Bolts
    G02197861
  65. Remove the bolts.
  66. Remove the stator support assembly.
    Fig 65: Removing Stator Support Assembly
    G02197862
  67. Remove the park pawl shaft retaining pin.
    Fig 66: Removing Park Pawl Shaft Retaining Pin
    G02197863
  68. Using the special tools remove the cup plug.
    Fig 67: Removing Cup Plug
    G02197864
  69. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
    Fig 68: Removing Parking Pawl
    G02197865
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