Transaxle Disassembly
- Drain transaxle and differential oil. Pull out torque converter horizontally. DO NOT scratch bushing inside oil pump shaft. Remove oil pump shaft, input shaft and strut bar bracket. Disconnect air breather hoses and clips. Remove oil filler pipe. Remove "O" ring from flange face and attach to pipe. Remove oil cooler inlet and outlet pipes. Use caution not to lose balls and springs used with retaining screws. Remove harness from bracket.
- Remove converter case bolts and lightly tap off converter case from transmission case. Ensure not to damage oil seal and bushing inside converter case. On all models, remove vehicle speed sensor No. 1 and extension housing bolts. Pull off extension housing slightly and disconnect duty solenoid "C" connector.
- Remove reduction drive gear assembly from rear of transmission case. Set range selector lever to "P" position. Unstake and remove reduction driven gear lock nut. Drill 2 holes into Puller Set (899524100 ) plate. See Fig 1 . Remove reduction driven gear.
- Remove parking pawl, return spring and shaft. Loosen, but do not remove, roller bearing retainer bolts. Place 2 wooden blocks on workbench and stand transmission case with rear end facing down. Ensure rear mating surface of case is not scratched or damaged. Remove oil pan and gasket.
- Remove oil cooler outlet pipe. DO NOT twist pipe. Disconnect harness connectors for shift solenoids, duty solenoids and ground cable. Remove oil filter. Ensure oil filter "O" ring is not damaged. Remove 11 Yellow bolts and 6 Black bolts and remove valve body. Remove 3 accumulator springs.
- Loosen reverse clutch drum slightly by turning adjusting screw. Remove oil pump housing. DO NOT lose total end play adjusting thrust washer. Loosen and remove brake band screw and strut. Remove brake band and reverse clutch. When removing high clutch, high clutch hub, thrust bearing, front sun gear, thrust bearing, front planetary carrier, thrust bearing, rear planetary carrier, thrust bearing and rear sun gear, do not lose thrust needle bearings and races. See Fig 4 .
- Remove rear internal gear, thrust bearing, one-way clutch outer race and thrust bearing. Remove overrunning clutch hub, thrust washer, and thrust bearing and forward clutch drum. Remove low and reverse brake snap ring. Remove pressure plate, drive and driven plates and dish plates as a unit.
- Turn case upside-down. Remove one-way clutch inner race and spring retainer assembly. Remove low and reverse piston by applying compressed air. Remove servo piston inner snap ring. Hold servo piston with cloth and remove servo piston by applying compressed air from the release pressure side.CAUTION: DO NOT allow finger to be pinched between pipe and retainer.
- Apply compressed air from operating pressure side and remove 4 accumulators. See Fig 2 . Remove range select lever and detent spring. Remove parking rod with manual lever. Drive out roll pin and remove manual shaft. Remove inhibitor switch and transmission harness.
- Wrap left and right drive axle shafts with tape. Remove differential side retainers using Wrench (499787000 ). See Fig 2 . Hold differential case assembly by hand to avoid damaging retainer mounting hole of converter case and speedometer gears. Remove axle shaft circlip (DO NOT reuse), and pull out axle shaft using Remover (499095500 ) and Installer (499247300 ).
- Remove differential case assembly. Remove seal pipe if attached (DO NOT reuse). Use caution not to damage retainer mounting hole of torque converter clutch case and speedometer gears. Remove speedometer driven gear snap ring and speedometer driven gear. Remove vehicle speed sensor No. 2. Tap out speedometer shaft to outside of case. Remove oil seal. Remove transfer clutch from extension by tapping end of rear drive shaft. DO NOT damage oil seal in extension housing. Remove transfer pipe and transfer valve body bolts. Remove duty solenoid "C" and transfer valve body. Remove inlet filter.