Disassembled Views
| Item | Part Number | Description |
|---|---|---|
| 1 | 7005 | transaxle case |
| 2 | 7A130 | Clutch support tower |
| 3 | 7D019 | Clutch support tower seals (4 required) |
| 4 | W302855 | Clutch support tower bolt (3 required) |
| 5 | 7F242 | No. 1 thrust bearing |
| 6 | 7E005 | Intermediate (2, 6) clutch piston |
| 7 | 7B070 | Intermediate (2, 6) clutch piston return spring |
| 8 | 7D483 | Intermediate (2, 6) clutch return spring snap ring |
| 9 | 7E005 | Intermediate (2, 6) clutch apply ring |
| 10 | 7C122 | Direct (3, 5, R) clutch cylinder snap ring |
| 11 | 7F283 | Direct (3, 5, R) clutch cylinder |
| 12 | 7A262 | Direct (3, 5, R) clutch piston |
| 13 | 7F235 | Direct (3, 5, R) clutch piston return spring |
| 14 | 7C099 | Direct (3, 5, R) clutch piston inner (rear) seal |
| 15 | 7C099 | Direct (3, 5, R) clutch piston inner (front) seal |
| 16 | 7A548 | Direct (3, 5, R) clutch piston outer seal |
| 17 | 7C122 | Input shaft snap ring |
| 18 | 7G384 | Direct (3, 5, R)/overdrive (4, 5, 6) clutch cylinder and hub assembly |
| 19 | 7A548 | Overdrive (4, 5, 6) clutch piston inner seal |
| 20 | 7F213 | Input shaft |
| 21 | 7D234 | No. 2 thrust bearing |
| 22 | 7B070 | Direct (3, 5, R) clutch wave spring |
| 23 | 7B164 | Direct (3, 5, R) clutch friction plates (3 required) |
| 24 | 7B442 | Direct (3, 5, R) clutch steel plates (3 required) |
| 25 | 7B066 | Direct (3, 5, R) clutch pressure plate |
| 26 | 7D483 | Direct (3, 5, R) clutch snap ring |
| 27 | 7A548 | Overdrive (4, 5, 6) clutch piston outer (rear) seal |
| 28 | 7A548 | Overdrive (4, 5, 6) clutch piston outer (front) seal |
| 29 | 7A262 | Overdrive (4, 5, 6) clutch piston |
| 30 | 7F222 | Overdrive (4, 5, 6) clutch piston return spring |
| 31 | 7H360 | Overdrive (4, 5, 6) clutch balance piston |
| 32 | 7C122 | Overdrive (4, 5, 6) clutch piston snap ring |
| 33 | 7B164 | Overdrive (4, 5, 6) clutch friction plates (5 required) |
| 34 | 7B442 | Overdrive (4, 5, 6) clutch steel plates (5 required) |
| 35 | 7B066 | Overdrive (4, 5, 6) clutch pressure plate |
| 36 | 7D483 | Overdrive (4, 5, 6) clutch snap ring |
| 37 | 7H351 | Overdrive (4, 5, 6) clutch hub |
| 38 | 7D234 | No. 3 thrust bearing |
| 39 | 7A019 | Rear planetary sun gear and shell assembly |
| 40 | 7E085 | Intermediate (2, 6) clutch wave spring |
| 41 | 7B164 | Intermediate (2, 6) clutch friction plates (2 required) |
| 42 | 7B442 | Intermediate (2, 6) clutch steel plates (2 required) |
| 43 | 7A089 | OWC |
| 44 | 7D491 | Rear planet carrier/center ring gear |
| 45 | 7C096 | No. 6 thrust bearing |
| 46 | 7G177 | No. 5 thrust bearing |
| 47 | 7B066 | Low/reverse clutch pressure plate |
| 48 | 7B164 | Low/reverse clutch friction plates (3 required) |
| 49 | 7B442 | Low/reverse clutch steel plates (3 required) |
| 50 | 7E085 | Low/reverse clutch wave spring |
| 51 | 7C122 | Low/reverse clutch piston snap ring |
| 52 | 7H318 | Low/reverse clutch piston snap ring retainer |
| 53 | 7B070 | Low/reverse clutch piston return spring |
| 54 | 7D402 | Low/reverse clutch piston |
| 55 | 7L328 | Center support |
| 56 | 7A262 | Forward (1, 2, 3, 4) clutch piston |
| 57 | 7B070 | Forward (1, 2, 3, 4) clutch piston return spring |
| 58 | 7D041 | Forward (1, 2, 3, 4) clutch piston snap ring retainer |
| 59 | 7H365 | Forward (1, 2, 3, 4) clutch piston snap ring |
| 60 | 7D491 | Center planetary carrier/front ring gear |
| 61 | 7D063 | Center planetary sun gear |
| 62 | 7C096 | No. 7 thrust bearing |
| 63 | 7C096 | No. 8 thrust bearing |
| 64 | 7D491 | Front planetary carrier/rear ring gear |
| 65 | 7A019 | Front planetary sun gear and shell assembly |
| 66 | 7D234 | No. 10 thrust bearing |
| 67 | 7B070 | Forward (1, 2, 3, 4) clutch wave spring |
| 68 | 7B164 | Forward (1, 2, 3, 4) clutch friction plates (2 required) |
| 69 | 7B442 | Forward (1, 2, 3, 4) clutch steel plates (2 required) |
| 70 | 7B066 | Forward (1, 2, 3, 4) clutch pressure plate |
| 71 | 7D483 | Forward (1, 2, 3, 4) clutch snap ring |
| 72 | 7978 | Transmission fluid baffle |
| 73 | W500214 | Transmission fluid baffle bolt (2 required) |
| 74 | 7060 | Park gear |
| 75 | 7G132 | Drive chain drive sprocket |
| 76 | 7C122 | Drive sprocket snap ring |
| 77 | 7G099 | No. 13 thrust washer |
| 78 | 7G249 | Drive chain |
| 79 | 7D234 | No. 11 thrust bearing |
| 80 | 7048 | Input shaft seal |
| 81 | 7A098 | Transmission fluid filter |
| 82 | 7L027 | Magnet |
| 83 | W302860 | Pump-to-torque converter housing bolt (8 required) |
| 84 | 7A103 | Pump assembly |
| 85 | 7A248 | Pump assembly-to-torque converter housing O-ring seal |
| 86 | 7A248 | Torque converter hub seal |
| 87 | 7P113 | Torque converter hub seal retainer |
| 88 | 7F343 | Different ring gear |
| 89 | 7C122 | Differential ring gear snap ring |
| 90 | 7H245 | Differential transmission fluid baffle |
| 91 | 7975 | Torque converter housing |
| 92 | W701606 | Torque converter housing stud bolt |
| 93 | 7A443 | Torque converter housing bolt (16 required) |
| 94 | 7902 | Torque converter |
| 95 | 1177 | RH halfshaft seal |
| 96 | 7G355 | No. 12 thrust bearing |
| 97 | 7G132 | Drive chain driven sprocket |
| 98 | 7F342 | Differential sun gear |
| 99 | 7F465 | Differential assembly |
| 100 | 7G112 | No. 15 thrust bearing |
| 101 | 7B362 | Torque converter housing-to-transaxle case guide pins |
| 102 | 7D070 | Park pawl spring |
| 103 | 7A441 | Park pawl |
| 104 | 7D071 | Park pawl pin |
| 105 | 7F337 | Manual control shaft seal |
| 106 | 7A232 | Park pawl actuator rod |
| 107 | 7H557 | TR sensor |
| 108 | 7C493 | Manual control shaft |
| 109 | 7G100 | Manual control shaft pin |
| 110 | 7A256 | Manual control lever |
| 111 | W708455 | Manual control lever nut |
| 112 | 7E332 | Manual valve detent spring |
| 113 | W711235 | TR sensor detent spring bolt |
| 114 | 7J387 | Fluid reservoir |
| 115 | 7A248 | Clutch feed seal (large) |
| 116 | 7A248 | Clutch feed seal (small) (4 required) |
| 117 | 7B431 | Main control alignment pin |
| 118 | 7C207 | Main control stud |
| 119 | 7G199 | Main control-to-transaxle case seal (2 required) |
| 120 | W713644 | OSS sensor bolt |
| 121 | 7H103 | OSS sensor |
| 122 | 7Z490 | Main control-to-transaxle case separator plate |
| 123 | 7A100 | Main control valve body |
| 124 | N605770 | Separator plate-to-solenoid body bolt (2 required) |
| 125 | 7Z490 | Main control valve body-to-solenoid body separator plate |
| 126 | 7G391 | Solenoid body |
| 127 | W500303 | Solenoid body-to-valve body bolt (2 required) |
| 128 | W302863 | Main control-to-transaxle case bolt (long) (10 required) |
| 129 | W302862 | Main control-to-transaxle case bolt (short) (12 required) |
| 130 | W520412 | Main control nut |
| 131 | 7G276 | Main control leadframe |
| 132 | W505513 | Main control leadframe screw (5 required) |
| 133 | 7B329 | Main control-to-cover seal |
| 134 | 7G004 | Main control cover |
| 135 | W714629 | Main control cover stud bolt (5 required) |
| 136 | W500214 | Main control cover bolt (8 required) |
| 137 | 7010 | Drain plug |
| 138 | 7H398 | Line pressure tap |
| 139 | - | Oil leveling plug |
| 140 | 1177 | LH halfshaft seal |
| 141 | 7025 | LH halfshaft bushing |
| 142 | 7M101 | TSS sensor |
| 143 | W500214 | TSS sensor bolt |
| 144 | 7A246 | Vent tube |
| 145 | W500214 | Fluid reservoir bolts |
| 146 | 7G342 | Solenoid body strategy tag |
| 147 | 7B148 | transaxle service identification tag |
| 148 | - | Direct clutch (3, 5, R) |
| 149 | - | Intermediate clutch (2, 6) |
| 150 | - | Overdrive clutch (4, 5, 6) |
| 151 | - | Forward clutch (1, 2, 3, 4) |
| 152 | - | Low/reverse clutch |
- Install the special tool.
- Mount the transaxle to the bench-mounted holding fixture.
- Remove the special tool.
-
NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tools, remove the torque converter from the transaxle.
-
- Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
- A new or remanufactured torque converter must be installed if one or more of the following statements is true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes.
- Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
- If none of the above conditions are present, continue with the following fluid inspection.
- Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
- Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
-
NOTE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur.
Drain the remaining fluid from the torque converter. Apply the specified amount of automatic transmission fluid.
-
NOTE: Note the location of the stud bolts for assembly.
Remove the main control cover bolts and the main control cover.
- Disconnect the OSS
sensor electrical connector.
- Disconnect the TR
sensor electrical connector.
- Remove the main control-to-cover seal.
-
NOTE: Note the location of the short and long main control-to-transaxle case bolts for reassembly.
Remove the main control nut and the main control-to-transaxle case bolts and remove the main control assembly.
- Clean and inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it. Refer to MAIN CONTROL - OVERHAUL .
- Remove and discard the main control-to-transaxle case separator plate.
- Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transaxle case seals.
- Remove the TSS
sensor bolt and the TSS
sensor.
- Remove the TR
sensor detent spring bolt and the TR
sensor detent spring.
- Remove the OSS
sensor bolt and the OSS
sensor.
-
NOTE: Note the location of the stud bolts for assembly.
Remove the torque converter housing bolts.
- Pry the torque converter housing loose from the transaxle case.
- Remove the torque converter housing from the transaxle case.
- Remove the No. 15 differential thrust bearing.
- Remove the differential assembly.
- Check that bearings spin freely and do not move back and forth or side to side excessively. Check for damage or excessive wear. Install new components, if necessary. Refer to DIFFERENTIAL GEAR ASSEMBLY .
- Remove the differential sun gear.
- Inspect the differential sun gear for damage or wear and install new, as necessary.
-
NOTE: If the transmission plastic baffle has melted due to overheat condition the cooler must be replaced, the plastic cannot be cleaned out of a cooler even with the heated cooler flusher.
Remove the differential transmission fluid baffle.
- Simultaneously remove the drive and driven sprockets and the chain.
- Remove the drive chain from the drive and driven sprockets.
- Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
- Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
- Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
- Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
- Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if necessary.
- Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
- Install the drive chain on the drive and driven sprockets.
- Remove the fluid reservoir bolts and the fluid reservoir.
- Remove the transmission fluid baffle bolts and the transmission fluid baffle.
- Remove the park pawl pin and spring.
- Remove the park pawl.
-
NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transaxle.
Remove the forward (1, 2, 3, 4) clutch snap ring.
- Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Remove the front planetary sun gear and shell assembly.
- Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, as necessary.
- Remove the front planetary carrier/rear ring gear assembly.
- Clean and inspect the front planetary carrier/rear ring gear assembly for damage or excessive wear and install new, as necessary.
- Remove the center planetary carrier/front ring gear assembly.
- Clean and inspect the center planetary carrier/front ring gear assembly for damage or excessive wear and install new, as necessary.
- Remove the center planetary sun gear.
- Clean and inspect the center planetary sun gear for damage or excessive wear and install new, as necessary.
- Remove the center support assembly.
- Remove the rear planetary carrier/center ring gear assembly.
- Clean and inspect the rear planetary carrier/center ring gear assembly for damage or excessive wear and install new, as necessary.
- Remove the low/reverse wave spring, clutch pack and pressure plate.
- Inspect the low/reverse clutch pack and pressure plate surface for damage or excessive wear and install new, if necessary.
- Remove the low OWC
.
-
NOTE: Do not clean in water or with water-based solvents. Damage to the component may occur.NOTE: The low OWC should not be disassembled.
Clean and inspect the low OWC for cracks and damaged splines. The internal splined section should rotate clockwise and lock when rotated counterclockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC .
- Inspect the intermediate (2, 6) clutch surface for damage. If the surface is burned or worn excessively, install a new low OWC
.
-
NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.
Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.
- Inspect the intermediate (2, 6) clutch surface for damage or excessive wear and install new, if necessary.
- Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, if necessary.
- Remove the pressure plate and the wave spring.
- Inspect the pressure plate surface for damage or excessive wear and install new, if necessary.
- Remove the No. 3 thrust bearing.
- Remove the overdrive/direct clutch assembly.
-
NOTE: If the No. 1 thrust bearing is stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.
Remove the No. 1 thrust bearing.
- Remove the intermediate (2, 6) clutch apply ring.
- Remove the clutch support tower bolts and the clutch support tower.
-
NOTE: Note the location of the snap ring gap for assembly.
Remove the intermediate (2, 6) clutch return spring snap ring.
-
NOTE: Note the position of the return spring for assembly.
Remove the intermediate (2, 6) clutch return spring.
-
NOTE: Note the position of the intermediate clutch piston for assembly.
Remove the intermediate (2, 6) clutch piston.
- Remove and discard the clutch feed seals.
- Remove the manual control lever nut and the manual control lever from the manual control shaft.
-
NOTE: Do not drive the manual control shaft pin through the manual control shaft. The manual control shaft pin will contact the transaxle case causing damage to the transaxle case.
Using the special tool, pull the manual control shaft pin out of the manual control shaft.
- Remove the manual control shaft.
- Remove the TR
sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR
sensor.
- Remove and discard the manual control shaft seal.
- Remove and discard the LH
halfshaft seal.
-
-
NOTE: If the LH transaxle case bushing or the LH halfshaft bushing surface shows signs of excessive wear or damage, a new LH transaxle case bushing and a new LH halfshaft must be installed, or excessive noise or transaxle failure can occur.
Clean and inspect the LH transaxle case bushing and the bushing surface on the LH halfshaft for damage or excessive wear. If the LH transaxle case bushing or the LH halfshaft shows signs of excessive wear or damage, install new components. Refer to TRANSAXLE CASE .
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material. Refer to RTV Sealing Surface Cleaning and Preparation in ENGINE SYSTEM - GENERAL INFORMATION .
-
- Remove the pump-to-torque converter housing bolts and the pump and filter assembly.
- Remove and discard the RH
halfshaft seal.
-
- Inspect the torque converter housing and the differential ring gear for damage or excessive wear. If the differential ring gear shows signs of excessive wear or damage replace the differential ring gear. Refer to TRANSAXLE CASE .
-
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material. Refer to RTV Sealing Surface Cleaning and Preparation in ENGINE SYSTEM - GENERAL INFORMATION .
-
NOTE: Note the orientation of the transmission fluid filter to the fluid pump assembly.
Rotate the transmission fluid filter 90 degrees clockwise and pull the transmission fluid filter out of the pump assembly.
- Remove the magnet from the transmission fluid filter.
- Assemble the special tools and remove and discard the input shaft seal.
- Remove the pump assembly-to-torque converter housing O-ring seal.
- Remove the torque converter hub seal snap ring.
- Using a dent puller, remove the torque converter hub seal.
- Position the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
- Loosen the pump bolts.
- Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
- Remove the pump bolts and separate the pump assembly halves.
-
NOTE: The dot on the inner pump gear faces up.
Remove the pump gears.
- Compress the main pressure regulator valve spring with a screwdriver and remove the retainer with a magnet.
- Install a M4 bolt in the valve and remove the main pressure regulator valve assembly.
- Compress the TCC
control valve spring with a screwdriver and remove the retainer with a magnet.
- Remove the TCC
control valve assembly.
- Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump assembly for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the pump assembly as an assembly.
-
NOTE: TCC control valve retainer shown assembled in the pump body, main pressure regulator valve retainer similar.
Assemble the TCC control valve assembly and main pressure regulator valve assembly and install the valves in the pump. Compress the valve springs with a screwdriver and install the retainers.
-
NOTE: The dot on the inner pump gear faces up.
Install the pump gears.
- Position the stator support on the pump housing and install the pump bolts hand-tight.
- Install the pump assembly in the torque converter housing and install 2 pump-to-torque converter housing bolts hand-tight.
- Tighten the pump bolts.
- Remove the pump-to-torque converter housing bolts and the pump assembly from the torque converter housing.
- Install a new torque converter hub seal on the special tool.
- Using the special tool, install a new torque converter hub seal.
- Install the torque converter hub seal snap ring.
- Install a new pump assembly-to-torque converter housing O-ring seal.
- Install a new input shaft seal on the special tool.
- Using the special tool, install the input shaft seal.
- Install a new O-ring on a new transmission fluid filter and lubricate it with transmission fluid.
- Install the magnet on the transmission fluid filter.
- Install the transmission fluid filter.
-
NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When disassembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.NOTE: The low/reverse clutch piston in the center support is the side of the center support with the long legs.
Using the special tool and a press, compress the low/reverse clutch return spring and remove the snap ring and the snap ring retainer.
- Remove the low/reverse clutch return spring.
- Apply 483 kPa (70 psi) of air pressure to the low/reverse clutch piston port and remove the low/reverse clutch piston.
-
NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Using the special tool and a press, compress the forward (1, 2, 3, 4) clutch return spring and remove the snap ring and the snap ring retainer.
- Remove the return spring from the forward (1, 2, 3, 4) clutch piston.
- Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port and remove the forward (1, 2, 3, 4) clutch piston.
- Clean and inspect the center support for damage. Install a new center support if necessary.
-
NOTE: The forward clutch piston in the center support is the side of the center support with the short legs.
Install the special tools on the forward clutch piston side of the center support.
- Lubricate the sealing surfaces of the forward (1, 2, 3, 4) clutch piston with petroleum jelly.
- Position the forward (1, 2, 3, 4) clutch piston on the special tools and push it down into the center support.
-
NOTE: The piston return spring, snap ring or snap ring retainer from the low/reverse clutch side of the center support are not interchangeable with the forward clutch side of the center support. When assembling the center support, be careful not to mix the components from the low/reverse clutch side with the forward clutch side of the center support. Failure to assemble the center support with the components in the correct side will result in damage to the center support, low/reverse or forward clutch.
Install the forward (1, 2, 3, 4) clutch piston return spring.
- Using the special tools and a press, compress the forward (1, 2, 3, 4) clutch return spring and install the snap ring retainer and the snap ring.
- Inspect the snap ring to be sure it is seated in the groove on the center support.
- Turn the center support over and install the special tools on the low/reverse piston side of the center support.
- Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly.
- Position the low/reverse clutch piston on the special tools and push it down into the center support.
- Install the low/reverse piston return spring.
- Using the special tools and a press, compress the low/reverse clutch return spring and install the snap ring retainer and the snap ring.
- Inspect the snap ring to be sure it is seated in the groove on the center support.
- Remove and discard the 4 Teflon® seals.
- Clean and inspect the clutch support tower for damage. Install a new clutch support tower if damaged.
- Install the special tool on the clutch support tower and adjust the special tool to align the bottom edge of the tool with the top edge of the bottom Teflon® seal groove.
- Install a new Teflon® seal on the special tool.
- Install the special tool 307-578/2 over 307-578/3. Using the special 307-578/2, slide the Teflon® seal over the clutch support tower and into the groove.
- Remove tools and repeat steps for the other 3 Teflon® seals.
- Install the special tool on the clutch support tower to size the 4 Teflon® seals.
- Remove the input shaft snap ring.
- Remove the input shaft.
- Remove the overdrive (4, 5, 6) clutch hub, No. 2 thrust bearing.
- Remove the overdrive (4, 5, 6) clutch hub, No. 2 thrust bearing.
- Remove the overdrive (4, 5, 6) clutch snap ring.
- Remove the overdrive (4, 5, 6) clutch pressure plate and clutch assembly.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Install the special tools on the balance piston.
- Using the special tool and a press, compress the overdrive (4, 5, 6) clutch return spring and remove the snap ring.
- Remove and discard the balance piston.
- Remove the overdrive (4, 5, 6) piston return spring.
- Install the clutch support tower in the transaxle case and install the clutch support tower bolts.
- Remove the special tool.
- Install the No. 1 overdrive/direct clutch assembly thrust bearing.
- Position the overdrive/direct clutch assembly in the transaxle case.
- Apply compressed air to the overdrive (4, 5, 6) clutch piston port and remove the overdrive (4, 5, 6) clutch piston.
- Remove the overdrive/direct clutch assembly from the transaxle case.
- Remove and discard the overdrive (4, 5, 6) clutch piston seal from the overdrive/direct clutch assembly.
- Remove and discard the seals from the overdrive (4, 5, 6) clutch piston.
-
NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and remove the snap ring.
- Remove the direct (3, 5, R) clutch cylinder.
- Remove and discard the direct (3, 5, R) clutch piston.
-
NOTE: Note the position of the return spring for assembly. The flat side faces down.
Remove the direct (3, 5, R) clutch piston return spring.
- Remove the direct (3, 5, R) clutch snap ring.
- Remove the direct (3, 5, R) clutch pressure plate, clutch pack and wave spring.
- Inspect the clutch plate and pressure plate surfaces for damage or excessive wear.
- Remove and discard the direct (3, 5, R) clutch piston seals.
- Clean and inspect the overdrive/direct clutch assembly for damage or excessive wear and install new components as necessary.
- Install new direct (3, 5, R) clutch piston seals and lubricate the seals with petroleum jelly.
- Install the direct (3, 5, R) clutch wave spring.
- Soak the direct (3, 5, R) clutch pack in transmission fluid.
- Install the direct (3, 5, R) clutch assembly and pressure plate.
- Install the direct (3, 5, R) clutch snap ring.
-
NOTE: Install the direct (3, 5, R) clutch piston return spring with the flat side facing down.
- Lubricate a new direct (3, 5, R) clutch piston with petroleum jelly and install the piston.
- Install the direct (3, 5, R) clutch cylinder.
-
NOTE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.
Install the special tools on the direct (3, 5, R) clutch cylinder. Using a press, compress the direct (3, 5, R) clutch piston return spring, and install the snap ring.
- Install new seals on the overdrive (4, 5, 6) clutch piston and lubricate the seals with petroleum jelly.
- Install a new overdrive (4, 5, 6) clutch piston inner seal and lubricate the seal with petroleum jelly.
- Position the overdrive (4, 5, 6) clutch piston in place.
- Using the special tools, install the overdrive (4, 5, 6) clutch piston into the overdrive/direct clutch assembly by hand.
-
NOTE: Holes face up on the overdrive (4, 5, 6) clutch piston return spring.
Install the overdrive (4, 5, 6) clutch piston return spring.
- Lubricate the seals on a new balance piston and position the piston in place.
- Install the special tools on the balance piston.
- Using a press, compress the overdrive (4, 5, 6) clutch return spring and install the snap ring.
- Install the No. 2 thrust bearing.
- Install the overdrive (4, 5, 6) clutch hub.
- Soak the overdrive (4, 5, 6) clutch pack in transmission fluid.
- Install the overdrive (4, 5, 6) clutch pack.
- Install the overdrive (4, 5, 6) clutch pressure plate.
- Install the overdrive (4, 5, 6) clutch snap ring.
- Install the input shaft.
- While holding the input shaft in place, install the snap ring.
- Position the overdrive/direct clutch assembly in the transaxle case, install the special tool or a dial indicator and position the plunger on the overdrive (4, 5, 6) clutch pressure plate.
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NOTE: The dial indicator plunger is positioned on the overdrive (4, 5, 6) clutch pressure plate.
Apply 483 kPa (70 psi) of air pressure to the overdrive (4, 5, 6) clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.950 mm (0.037 in) and 1.778 mm (0.07 in). If the clearance is out of range, check the overdrive (4, 5, 6) clutch pack for correct installation. If the overdrive (4, 5, 6) clutch pack is correctly installed, install a new overdrive (4, 5, 6) clutch pack.
- Position the plunger on one of the top direct (3, 5, R) clutch plate tabs. Apply 483 kPa (70 psi) of air pressure to the direct (3, 5, R) clutch piston port while recording the clutch pack clearance on Dial Indicator. The clearance should be between 0.412 mm (0.016 in) and 1.728 mm (0.068 in). If the clearance is out of range, check the direct (3, 5, R) clutch pack for correct installation. If the direct (3, 5, R) clutch pack is correctly installed, install a new direct (3, 5, R) clutch pack.
- Remove the special tool, overdrive/direct clutch assembly and the No. 1 overdrive/direct clutch assembly thrust bearing.
- Assemble the special tools. Install a new LH
halfshaft seal on the special tool.
- Using the special tools, install the new LH
halfshaft seal in the transaxle case.
- Install a new manual control shaft seal on the special tool.
- Using the special tool, install the new manual control shaft seal in the transaxle case.
- Install the special tool.
- Lubricate the seals on the intermediate (2, 6) clutch piston with transmission fluid.
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NOTE: Be sure the bleed hole is aligned in the correct position as noted during disassembly or damage to the transaxle can occur.
Install the intermediate (2, 6) clutch piston on the seal protector with the bleed hole aligned at the top of the transaxle case.
- Position the clutch piston return spring on the piston to align the piston before pushing it in its bore. The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the open area at the bottom of the transaxle case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
- Remove the intermediate (2, 6) clutch piston return spring.
- Install the special tool on the intermediate (2, 6) clutch piston. Push the intermediate (2, 6) clutch piston into the clutch cylinder by hand.
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NOTE: Be sure the return spring is positioned correctly with the forward clutch bleed hole aligned between the inner double tabs and the outer tab in the clockwise most position of the slot at the bottom of the case or damage to the transaxle can occur.
The tabs of the return spring should fit into the indentions of the piston and the 2 outer tabs should be at the clockwise most position of the slot at the bottom of the case. The bleed hole on the piston should be aligned between the inner double tabs of the return spring.
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NOTE: Be sure the snap ring is aligned with the gap facing the front of the transaxle or damage to the transaxle can occur. The front of the transaxle is where the low/reverse and forward (1, 2, 3, 4) clutch hydraulic ports are located.
Align the gap of the snap ring to face the front of the transaxle.
- Install the special tool on the transaxle case to center the intermediate (2, 6) clutch return spring.
- Install the special tool on the snap ring.
- Install the special tool on the transaxle case.
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NOTE: Be sure the return spring is centered or it can bind on the snap ring groove and cause damage to the transaxle case.
Using the special tools, install the intermediate (2, 6) clutch snap ring in the groove.
- Install the intermediate (2, 6) clutch apply ring. Tap the ring in place.
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NOTE: Be sure to install the No. 1 thrust bearing with the flat side facing up or damage to the transaxle can occur.
Install the No. 1 thrust bearing with the flat side facing up.
- Install the overdrive/direct clutch assembly.
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NOTE: Be sure to install the No. 3 thrust bearing with the flat side facing down or damage to the transaxle can occur.
Install the No. 3 thrust bearing with the flat side facing down.
- Install the direct/intermediate clutch hub and rear sun gear assembly.
- Install the intermediate (2, 6) wave spring assembly.
- Soak the intermediate (2, 6) clutch assembly in transmission fluid.
- Install the intermediate (2, 6) clutch assembly, temporarily reversing the top friction and steel plates for the clutch stack-up measurement.
- Install the special tool on the transaxle case.
- Using a depth gauge, measure and record as measurement A, the distance from the special tool to the top of the intermediate (2, 6) clutch pack at 3 different points and average the 3 distances.
- Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the transaxle case step above the intermediate (2, 6) clutch.
- Subtract measurement B from measurement A The clearance should be between 0.240 mm (0.009 in) and 2.60 mm (0.102 in). If the clearance is out of range, check the intermediate (2, 6) clutch pack for correct installation. If the intermediate (2, 6) clutch pack is correctly installed, install a new clutch pack.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and check to see if it is within range of 0.240 mm (0.009 in) and 2.60 mm (0.102 in) -
NOTE: When the intermediate (2, 6) clutch is correctly installed, a friction plate is on top.
Remove the top intermediate (2, 6) clutch friction and steel plate and correctly install the plates back in the transaxle case.
- Install the OWC
assembly.
- Install the rear planetary carrier/center ring gear assembly.
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NOTE: Note the position of the pressure plate. When installing the center support, the long support legs must fit through the pressure plate and rest on the OWC .
Position the low/reverse pressure plate so that the center support legs fit through the pressure plate and rest on the OWC and install the low/reverse pressure plate.
- Soak the low/reverse clutch in transmission fluid.
- Align the low/reverse clutch pack with the pressure plate and install it in the transaxle case temporarily reversing the wave spring and top steel plate.
- Install the special tool on the side of the center support with the long support legs.
- Using a depth gauge, measure and record as measurement A, the distance from the top of the special tool to the contact surface of the low/reverse clutch piston.
- Using a depth gauge, measure and record as measurement B, the distance from the top of the special tool to the leg surface of the center support.
- Subtract measurement B from measurement A and record as measurement C.
Description Reading Measurement A Measurement B Subtract measurement B from measurement A and record as measurement C. - Install the special tool on the transaxle case.
- Using a depth micrometer, measure and record as measurement D, the distance from the special tool to the top of the OWC
.
- Using a depth gauge, measure and record as measurement E, the distance from the top of special tool to the top of the low/reverse clutch at 3 different points and average the 3 distances.
- Subtract measurement E from measurement D and record as measurement F.
Description Reading Measurement D Measurement E Subtract measurement E from measurement D and record as measurement F - Subtract measurement F from measurement C to get the low/reverse clutch clearance. The clearance should be between 0.406 mm (0.015 in) and 2.000 mm (0.078 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new clutch pack.
Description Reading Measurement C Measurement F Subtract measurement F from measurement C and check to see if it is within range of 0.406 mm (0.015 in) and 2.000 mm (0.078 in) -
NOTE: When the low/reverse clutch is correctly installed, the wave spring is on top.
Remove the top low/reverse clutch steel plate and wave spring and correctly install the plates back in the transaxle case.
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NOTE: Be sure the center support is installed with the long support legs facing down and the feed holes facing the front of the transaxle.
Install the center support with the long legs facing down and the feed holes aligned with the feed holes in the transaxle case.
- Install the center planetary sun gear.
- Install the center carrier/front ring gear assembly.
- Install the front planetary/rear ring gear assembly.
- Install the forward (1, 2, 3, 4) clutch wave spring.
- Soak the forward (1, 2, 3, 4) clutch pack in transmission fluid.
- Install the forward (1, 2, 3, 4) clutch pack.
- Install the forward (1, 2, 3, 4) clutch pressure plate.
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NOTE: Be sure to install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side facing down or the snap ring can come loose, causing damage to the transaxle.
Install the forward (1, 2, 3, 4) clutch beveled snap ring with the flat side down with the gap facing the front of the transaxle.
- Seat the snap ring in the snap ring groove.
- Install the special tool or a dial indicator on the transaxle case and position the plunger on the top forward (1, 2, 3, 4) clutch friction plate.
- Install the new low/reverse and forward (1, 2, 3, 4) clutch main control-to-transaxle case seals.
- Apply 483 kPa (70 psi) of air pressure to the forward (1, 2, 3, 4) clutch piston port while recording the clutch pack clearance on the dial indicator. The clearance should be between 0.076 mm (0.002in) and 1.840 mm (0.072 in). If the clearance is out of range, check the forward (1, 2, 3, 4) clutch pack for correct installation and the transaxle for correct assembly. If the forward (1, 2, 3, 4) clutch pack is correctly installed, install a new forward (1, 2, 3, 4) clutch pack.
- Install the front planetary sun gear and shell assembly.
- Install the park pawl.
- Install the park pawl pin and spring.
- Install the park pawl actuator rod in the TR
sensor. Position the park pawl aside and position the park pawl actuator rod and the TR
sensor in the transaxle case.
- Install the manual control shaft and align the manual control shaft pin holes.
- Install the manual control shaft pin.
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NOTE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.
Install the manual control lever and the manual control lever nut.
- Install the 5 new clutch feed seals.
- Position the transmission fluid baffle in place and install the transmission fluid baffle bolts.
- Position the fluid reservoir in place and install the fluid reservoir bolts.
- Install the differential transmission fluid baffle.
- Install the differential sun gear.
- Install the differential assembly.
- Install the No. 15 thrust bearing.
- Install the special tool on the input shaft.
- FWD
Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool.
- FWD
Vehicles.
Using the special tools, install the new RH halfshaft seal.
- AWD
Vehicles.
Assemble the special tools and install a new RH halfshaft seal on the special tool.
- AWD
Vehicles.
Using the special tools, install the new RH halfshaft seal.
- Install the pump and filter assembly in the torque converter housing and install the pump-to-torque converter housing bolts.
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NOTE: Be sure the sealing surfaces of the torque converter housing and the transaxle housing are free of oil before applying silicone.
Apply a bead of the Ultra Silicone Sealant.
- Install the torque converter housing on the transaxle case.
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NOTE: Be sure the torque converter housing stud bolt is in the correct location as noted during disassembly.
Install the torque converter housing bolts and the torque converter housing stud bolt.
- Remove the special tool.
- Install the TSS sensor and the TSS sensor bolt.
- Install the OSS sensor and the OSS sensor bolt.
- Install the new main control-to-transaxle case separator plate and align it on the stud and the guide pin.
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NOTE: Be sure that the manual pin (part of the TR sensor) is correctly installed in the manual valve.
Position the main control assembly in place and align the manual valve on the TR sensor.
- Install the main control nut hand-tight.
- Install the short main control-to-transaxle case bolts hand-tight.
- Install the long main control-to-transaxle case bolts hand-tight.
- Tighten the main control-to-transaxle case bolts and the main control nut in a crisscross pattern.
- Position the TR sensor detent spring in place with the alignment tab in the alignment hole and install the TR sensor detent spring bolt.
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NOTE: Be sure the main control-to-cover seal is installed with the holes facing up.
Install the main control-to-cover seal.
- Connect the TR
sensor electrical connector.
- Connect the OSS
sensor electrical connector.
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Make sure that the mating faces are clean and free of foreign material. Refer to RTV Sealing Surface Cleaning and Preparation in ENGINE SYSTEM - GENERAL INFORMATION .
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NOTE: Be sure the sealing surface is free of oil before applying silicone.
Apply a bead of the Ultra Silicone Sealant.
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NOTE: Install the main control cover stud bolts in the correct location as noted during disassembly.
Install the main control cover and the main control cover bolts and stud bolts.
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NOTE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using the special tools, install the torque converter.
- Install the special tool.
- Remove the transaxle from the bench-mounted holding fixture.
- Remove the special tool.