6F24 Automatic Transmission (Service Information): Disassembly: AWD

NOTE:

If the transaxle has not been drained before removal, fluid will spill from the valve body pan as it is removed.

Fig 1: Pin Punch, Manual Lever & Transmission Range Sensor

GC0154992

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Insert a suitable pin punch (2) or equivalent through the manual lever into the TRS switch (1) to hold lever in place.
Remove nut holding the manual lever to the manual shaft.

Fig 2: Manual Lever & Manual Shaft
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Separate the manual level (1) from the manual shaft.

Fig 3: Transmission Range Sensor
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Remove bolts holding the TRS (1) to the transaxle housing.

Fig 4: Transmission Range Sensor Separated From Transaxle
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Separate the TRS (1) from the transaxle.

Fig 5: Vent Hose, Spring Clamp & Pliers
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Using common pliers (3), compress the hose spring clamp (2) and slide it down the vent hose (1) away from the nipple adaptor.

Fig 6: Vent Hose End & Nipple Adapter
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Pull the vent hose end (1) off of the nipple adaptor (2).

Fig 7: Vent Tube Bracket & Bolt
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Remove bolt holding the vent tube bracket (2) to the transaxle housing.
Separate the vent tube (3) from the transaxle (1).

Fig 8: Cooler Tubes & Banjo Bolts
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Remove banjo bolts (2) holding the cooler tubes (1) to the transaxle.

Fig 9: Cooler Tubes & Transaxle
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Remove bolt holding the cooler tube (2) bracket to the transaxle (1).
Separate the cooler tubes from the transaxle.

Fig 10: Valve Body Cover
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Position the transaxle over a suitable drain pan.
Remove bolts holding the valve body cover (2) to the transaxle (1).

Fig 11: Valve Body Cover Separated From Transaxle
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Separate the cover (1) from the transaxle (2).

Fig 12: Fluid Temperature Sensor, Valve Body & Bolt
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Remove bolt holding fluid temperature sensor (1) to the valve body (2).
Pull temperature sensor (1) straight out of the port in the valve body (2).

Fig 13: Solenoid Valve Connector, Valve Body & Bolts
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Remove bolts holding the solenoid valve connector (2) to the valve body (1).

Fig 14: Solenoids & Connector
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Starting at the bottom solenoid valve, using a suitable prying tool, pry outward at each solenoid (2) until the connector (3) is disengaged.

Fig 15: Manual Shaft Detent Spring & Valve Body
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Remove the screw holding the manual shaft detent spring (1) to the valve body (2).

Fig 16: Detent Spring Separated From Valve Body
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Separate the detent spring (2) from the valve body (1).

Fig 17: Valve Body Bolts
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Remove bolts, 7 short (1) and 1 long (2) bolts, holding the valve body to the transaxle.
The manual valve is loose after the valve body is removed and may fall out during removal.

Fig 18: Valve Body Separated From Transaxle
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Separate the valve body (2) from the transaxle (1).

Fig 19: Transfer Port Seals
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Remove the two seals from the transfer ports in transaxle housing.

Fig 20: Speed Sensors, Main Wire Harness & Bolts
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Remove bolts (1) holding the speed sensors and main wire harness to transaxle.
Separate the speed sensors and main wire harness from the transaxle.

Fig 21: Hold Down Bracket, Wire Connector & Bolts
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Remove bolt holding the wire connector (1) hold down bracket (2) to the top of transaxle housing.

Fig 22: Wire Connector & Hold Down Bracket Separated From Transaxle
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Separate the wire connector (1) hold down bracket (2) from the transaxle.

Fig 23: Pushing Wire Connector Into Housing
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Push the wire connector (1) inward to the inside of the transaxle housing.

Fig 24: Main Wire Harness & Sensors
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Separate the main wire harness and sensors (1) from the transaxle.

Fig 25: Manual Shaft, Pin & Magnet
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Using a suitable magnet (2), remove the pin (3) holding the manual shaft (1) in the transaxle from the hole in the pan gasket flange.

Fig 26: Manual Shaft, Park Rod & Key Hole Slot
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Rotate manual shaft (1) counterclockwise to align the staked nub on the park rod (2) with the key hole slot (3) in the manual shaft detent comb.
Push manual shaft (1) downward until park rod (2) disengages form the detent comb.
Push the manual shaft (1) inward to the inside of the transaxle.
Separate the manual shaft (1) from the transaxle.

Fig 27: Park Rod & Park Rod Guide
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Disengage the park rod (1) from the park rod guide (2) in the transaxle housing.
Separate the park rod (1) from the transaxle.
Using a suitable tool, remove the lip seal from the manual shaft hole in the transaxle housing.

Fig 28: Transaxle Housing Bolts
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Remove five bolts from the back (2) and four bolts from the top (1) of the transaxle housing.

Fig 29: Transaxle Housing Bolts
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Remove six bolts from the bottom (2) of the transaxle housing.
Remove five bolts (1) from inside bell housing.
Using a suitable pry bar, pay the case halves apart in notch location on top of the housing.

Fig 30: Transaxle Housing Notch Locations
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Pry the case halves apart in notch location (2) on the bottom of the housing (1).

Fig 31: Transaxle Housing Halves
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Separate the bell housing (1) from the transaxle (2).
Remove bolts holding the fluid guide to the transaxle housing.
Separate the fluid guide from the transaxle.
Remove bolts holding the lubrication tube to the transaxle.
Separate the lubrication tube from the transaxle.

Fig 32: Differential Assembly Separated From Transaxle Housing
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Separate the differential assembly (1) from the transaxle housing (2).

Fig 33: Small Transfer Port Seals
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Remove seals from four small transfer ports (2) in the transaxle housing (1).

Fig 34: Large Transfer Port Seal
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Remove seal from the large transfer port (1) in the axle housing (2).

Fig 35: Fluid Filter, Fluid Pump & Bolts
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Remove bolts (1) holding the fluid filter to the fluid pump (3) housing.

Fig 36: Fluid Filter Separated From Transaxle Housing
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Separate the fluid filter (2) from the transaxle housing (1).

Fig 37: Fluid Pump Housing O-Ring Seal & Hook Tool
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Using a suitable hook tool (1), remove o-ring seal (4) from the groove (3) in the fluid pump housing (3).

Fig 38: Fluid Pump & Bolts
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Remove bolts (1) holding fluid pump (3) to the trans axle housing (2).

Fig 39: Fluid Pump Separated From Transaxle Housing
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Separate the fluid pump (2) from the transaxle housing (1).

Fig 40: Thrust Washer & Fluid Pump
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Remove the plastic thrust washer (2) from the underside of the fluid pump (1). There are three nubs that insert into holes in the fluid pump hub to prevent the thrust washer from rotating.

Fig 41: Split Seal Rings & Fluid Pump Hub
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Remove two split seal rings (3) from land-grooves (2) in fluid pump (1) hub.

Fig 42: Split Ring Seals & Input Shaft
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Remove two split ring seals (2) from the input shaft (1).

Fig 43: 2/6 Brake Wave Plate & Hub
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Remove 2/6 brake wave plate (1) from 2/6 brake hub.

Fig 44: 2/6 Brake Plates, Discs & Hub
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Remove the 2/6 brake (1) plates (3) and discs (2) from the 2/6 brake hub.

Fig 45: 2/6 Brake Select Thickness Reaction Plate & Hub
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Remove 2/6 brake select thickness reaction plate (1) from the 2/6 brake hub.

Fig 46: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly
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Remove the 3/5/R clutch assembly (1) from the 3/5/R and 2/6 brake hub (2) assembly.

Fig 47: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing
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Remove the thrust bearing (2) from the 3/5/R clutch and 2/6 brake hub. Mark the side toward 3/5/R clutch and 2/6 brake hub on bearing for installation orientation.

Fig 48: 3/5/R Clutch & 2/6 Brake Hub Assembly
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Remove the 3/5/R clutch and 2/6 brake hub (2) assembly from the underdrive brake.

Fig 49: Underdrive Brake Hub & Thrust Washer
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Remove thrust washer (2) from underdrive brake hub.

Fig 50: Underdrive Brake Hub
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Remove underdrive brake hub (1) assembly from transaxle.

Fig 51: Underdrive Brake, Underdrive Brake Drum, & Large Snap Ring
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Remove large snap ring (3) holding underdrive brake (1) into underdrive brake drum.

Fig 52: Underdrive Brake Plates, Discs & Drum
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Separate underdrive brake plates and discs from underdrive brake drum.
Turn the transaxle over to gain access to the rear cover.

Fig 53: Transaxle Rear Cover & Bolts
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Remove bolts holding the rear cover (1) to the transaxle.

Fig 54: Prying Locations At Rear Cover
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In three locations (1) on the rear cover, pry upward using a suitable pry bar (3).

Fig 55: Rear Cover Separated From Transaxle
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Separate the rear cover (1) from the transaxle.

Fig 56: Selective Spacer, Bearing & Rear Cover
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Remove the selective spacer (3) and bearing (1) from under rear cover (2).

Fig 57: Split Seal Rings & Rear Cover Hub
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Remove the two split seal rings (2) from the lands in the rear cover (1) hub.

Fig 58: Transfer Port Seals In Transaxle Housing
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Using a suitable hook tool (1), Remove the four seals (2) from transfer ports in transaxle housing.

Fig 59: Thrust Bearing & Overdrive Clutch Hub Assembly
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Remove thrust bearing from the overdrive clutch hub assembly.

Fig 60: Overdrive Clutch Assembly & One Way Clutch
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Remove the overdrive clutch assembly (1) from the one way clutch (2).

Fig 61: Thrust Washer & Planetary Gear Assembly Hub
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Remove the plastic thrust washer (1) from the planetary gear assembly hub.

Fig 62: Thrust Bearing, Race Set & Middle/Rear Planetary Gear Assembly
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Using a suitable hook tool, lift the thrust bearing (1) and race set out of the center of the middle/rear planetary gear assembly (2).
Turn transaxle over to gain access to the underdrive springs.

Fig 63: Tool 5058A & Tool 10426
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Insert the bolt for tool (special tool #5058A, Compressor, Spring) through tool (special tool #10426, Compressor, Underdrive Spring).

Fig 64: Special Tool #5058A-3
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Fig 65: Special Tool #10426
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Fig 66: Tool Bolt & Tool Cross Bar
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Insert the tool bolt with the spring compressor (special tool #5058A, Compressor, Spring) through the center of the transaxle and out the back into the threaded center bore of the tool cross bar spanning the back of the transaxle. Compress the underdrive springs (3) to gain access to the snap ring.

Fig 67: Special Tool #5058A-3
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Fig 68: Underdrive Spring Plate Snap Ring
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Remove the snap ring holding the underdrive spring plate to the underdrive brake hub.

Fig 69: Underdrive Spring Retainer & Underdrive Brake Piston
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Remove the spring compressor tool from the transaxle.
Separate the underdrive spring retainer (1) from the underdrive brake piston (2).

Fig 70: Underdrive Brake Piston & Underdrive Brake Chamber
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Using a suitable pick tool (2) lift the underdrive brake piston (3), in several locations, from the underdrive brake chamber.

Fig 71: Underdrive Brake Piston & Location Tabs
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Remove the underdrive brake piston (1) from the underdrive brake piston chamber.
NOTE:
The location tabs (2) on the underdrive brake piston should be oriented toward the valve body opening in the transaxle.
Remove the D-ring outer seal and the O-ring inner seal from the underdrive piston.

Fig 72: Underdrive Brake Chamber & Bolts
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Remove bolts (1) holding the underdrive brake chamber (2) to the transaxle housing.

Fig 73: Underdrive Brake Chamber & Transaxle Housing
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Separate the underdrive brake chamber from the transaxle housing.

Fig 74: Underdrive Brake Retainer & Bolts
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Mark the location and direction of the underdrive brake retainer in relation to the bolt holes in the transaxle housing to ensure proper installation.
Using an impact driver (1), loosen the bolts holding the underdrive brake retainer (2) to the transaxle housing without damaging the Torx® drive heads.

Fig 75: Underdrive Brake Retainer & Bolts
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Remove bolts (2) holding the underdrive brake retainer (1) to the transaxle housing.

Fig 76: Underdrive Brake Retainer & Transaxle Housing
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Separate the underdrive brake retainer (2) from the transaxle housing (1).

Fig 77: Park Rod Guide & Bolts
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Remove bolts holding the park rod guide (1) from the transaxle housing.

Fig 78: Park Sprag Spring & Park Sprag
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Using a suitable hook tool (1), lift the park sprag spring (2) off the park sprag.

Fig 79: Park Sprag Spring, Shaft & Transaxle Housing
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Remove the park sprag spring and shaft (1) from the transaxle housing.

Fig 80: Park Sprag & Transaxle Housing
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Separate the park sprag (1) from the transaxle housing.

Fig 81: Park Sprag Support Shaft & Transaxle Housing
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Remove the park sprag support shaft (1) from the transaxle housing.

Fig 82: Transfer Driven Gear Assembly & Transaxle
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Remove the transfer driven gear (1) assembly from the transaxle (2).
Turn the transaxle over to gain access to the One-way-clutch.

Fig 83: One-Way-Clutch Snap Ring
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Remove the snap ring (1) holding the OWC to the transaxle housing.

Fig 84: One-Way-Clutch
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Separate the OWC (1) from the transaxle. Mark the one way clutch to aid installation orientation.

Fig 85: Low/Reverse Brake & Snap Ring
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Remove the snap ring (2) holding low/reverse brake into transaxle.

Fig 86: One Way Clutch Race & Snap Ring
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Separate the low & reverse brake pressure plate, cushion plate and discs and plates, in order, from transaxle.
Compress snap ring (1) holding one way clutch race (2) into transaxle.

Fig 87: One Way Clutch Inner Race
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Separate the one way clutch inner race (1) from the transaxle.

Fig 88: Rear Annulus Gear & Snap Ring
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Remove the snap ring (2) holding the rear annulus gear (1) into transaxle.

Fig 89: Rear Annulus Gear
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Separate the rear annulus gear (1) from the transaxle.

Fig 90: Middle/Rear Planetary Gear Assembly
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Separate the middle/rear planetary gear assembly (1) and from the planetary gear hub.

Fig 91: Front Planetary Gear Hub Thrust Washer
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Remove the thrust washer (1) from front planetary gear hub.

Fig 92: Middle Sun Gear & Planetary Gear Hub
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Separate the middle sun gear (1) from the planetary gear hub (2).

Fig 93: Planetary Gear Hub Bearing And Race Set
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Remove the bearing (2) and race (1) set from the planetary gear hub.

Fig 94: Front Sun Gear
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Separate the front sun gear (1) from front planetary gear assembly.

Fig 95: Front Planetary Gear & Front Annulus Gear Assembly
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Separate the front planetary gear (1) the front annulus gear assembly (2).

Fig 96: Front Annulus Gear Thrust Bearing And Race
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Separate the front annulus gear thrust bearing and race from the front annulus gear hub,

Fig 97: Front Annulus Gear
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Separate the front annulus gear (1) from the low/reverse brake assembly.

Fig 98: Special Tool #5058A-3
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Insert (special tool #5058A-3, Screw, Forcing) through center hole in (special tool #8621, Compressor, Spring)

Fig 99: Special Tool #5058A-3
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Fig 100: Special Tool #8621
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Insert the screw through the transfer gear and into the threaded cross bar across the bell housing opening.

Fig 101: Compressing Low/Reverse Spring Retainer
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Compress the low/reverse spring retainer.

Fig 102: Low/Reverse Brake Spring Retainer Snap Ring
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Remove snap ring holding low/reverse brake spring retainer to the low/reverse brake piston.
Remove spring compressor tools from transaxle.

Fig 103: Low/Reverse Brake Piston Spring Retainer
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Remove low & reverse brake piston spring retainer.

Fig 104: Low/Reverse Brake Piston
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Separate low & reverse brake piston (1) from the transaxle housing.
Remove inside and outside D-ring seals from the low & reverse brake piston (1).

Fig 105: Transfer Drive Assembly & Bolts
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Remove bolts (2) holding transfer drive assembly (1) to the transaxle housing.

Fig 106: Transfer Drive Assembly
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Remove the transfer drive assembly (1) from the transaxle case