Disassembly

Special Tools:

1. CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.

Install the Torque Converter Handles and remove the torque converter.

2. Install the transaxle into the Bench Mounted Holding Fixture.

3. NOTE: During a case replacement the identification tag will need to be replaced, use caution not to damage the tag.

Remove the identification tag.

4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.

5. 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.

Remove the overdrive servo piston and rod.
^ Remove the bolts.
^ Remove the cover.
^ Remove the piston and rod.

6. Remove the filler tube.
1 Remove the bolt.
2 Remove the filler tube.
3 Remove the filler tube grommet.

7. Remove the digital TR sensor.
1 Remove the bolts.
2 Remove the digital TR sensor.

8. Remove the TSS sensor.
1 Remove the bolt.
2 Remove the sensor.

9. NOTE: The differential seal is a two piece constructed seal.

Remove the LH differential seal.
^ Install Front Cover Seal Remover and 5 1/2 inch forcing screw (part of Crankshaft Seal Replacer/Cover Aligner) into the LH differential seal.

10. Remove the LH differential seal metal protector.
1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the front cover seal remover.
3 Remove the metal protector from the LH differential seal and remove protector from tool.

11. Remove the rubber portion of LH differential seal.
1 Install Front Cover Seal Remover and 5 1/2 inch forcing screw into the LH differential seal and rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the front cover seal remover.
3 Remove the rubber portion of the seal.

12. Install the Step Plate Adapter with Front Cover Seal Remover and the 5 1/2 inch forcing screw into the RH differential seal.

13. Remove the RH differential seal metal protector.
1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the front cover seal remover.
3 Remove the metal protector of the seal.

14. Remove the rubber portion of the seal.
1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the front Cover Seal Remover.
3 Remove the rubber portion of the seal.

15. Remove the converter hub seal.
1 Install the Puller.
2 Install the Slide Hammer.
3 Remove the converter seal.

16. Remove the bolts.
17. Rotate the transaxle to a horizontal position.

18. NOTE: The main control cover gasket is reusable if not tom or damaged. Remove the bolts, main control cover and gasket.

19. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result. Lift the locking tab and disconnect the electrical connectors.

20. NOTE: The manual valve should be inserted completely. Using a 9 mm wrench rotate the manual control lever to the low detent.

21. 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 4 of the 6 pump cover bolts need to be removed.

^ Remove the bolts.

22. Remove the main control valve body.
^ Remove the pump assembly and main control valve body.
^ Rotate the main control valve body while lifting off.

23. Disconnect the manual control valve actuating rod.

24. Remove the pump shaft.

25. NOTE: The transaxle pan gasket is reusable if not torn or damaged.

Remove the bolts, transmission fluid pan and gasket.

26. Remove, clean and inspect the magnet.

27. Remove the filter.

28. NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.

Remove the fluid filter seal.

29. Loosen the nut and remove the reverse clutch anchor pin.

30. 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.

Remove the bolts.

31. NOTE: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.

Remove the chain cover and gasket.

32. NOTE: Tag and mark the location of the accumulator springs.

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.

33. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.

Remove the drive sprocket, driven sprocket, and drive chain as an assembly.

34. NOTE: The thrust washers may remain on the sprockets.

Remove the thrust washers.
1 Remove the No.2 thrust washer.
2 Remove the No. 4 thrust washer.

35. CAUTION: Use care not to damage the machined surface of the case.

Remove the roll pins.

36. Remove the manual control lever shaft.

37. Remove the parking lever actuating rod.

38. Remove the manual control lever shaft seal.

39. NOTE: During the complete disassembly of the transaxle the fluid transfer tubes must be removed.

Remove the bolts and brackets.

40. Using the Lube Tube Remover and the Impact Slide Hammer, remove the fluid lube tubes.

41. Remove the bolts and the park pawl abutment.

42. Remove the neutral/drive accumulator bolt.

43. Remove the neutral/drive accumulator.
1 Remove the cover.
2 Remove the spring.
3 Remove the piston and shaft.

44. Remove the coast band servo.
1 Install the Servo Piston Remover/Replacer.
2 Remove the snap ring.
3 Remove the cover, piston, and rod as an assembly.

45. NOTE: The No. 5 thrust washer may stick to the drive sprocket support.

Remove the drive sprocket support and the No. 5 thrust washer.

46. NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.

Using the O-Ring Tool remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.

47. Remove the plastic overdrive band retainer.

48. Remove the overdrive band.

49. NOTE: Do not over-tighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.

Position the Front Clutch Loading 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.

50. Remove the front clutch assembly.

51. Use the Front Clutch Loading Tool Screw and the handle from the Front Clutch Loading Tool to remove the reverse clutch and planet assembly.

52. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.

53. Remove the coast band.

54. CAUTION: Use care not to damage any machined surfaces.

Remove the low/intermediate clutch retaining ring.

55. 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.

56. 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.

Remove the beveled retaining ring and record the shape of the ring end.

57. Remove the final drive/differential and rear planet support assembly.

58. NOTE: The differential carrier thrust washer may remain on the differential assembly.

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.

59. Remove the rear planet support spacer.

60. Remove the final drive ring gear.

61. NOTE: If the drive sprocket bearing is worn or damaged it will need to be replaced.

Using the Impact Slide Hammer with the Bearing Remover, remove the drive sprocket bearing.

62. NOTE: The following procedures are done only if a case replacement is necessary.

Remove the bolts.

63. Remove the stator support assembly.

64. Remove the park pawl shaft retaining pin.

65. Using the Blind Hole Puller, Collet, and Impact Slide Hammer, remove the cup plug.

66. Remove the parking pawl.
1 Use a magnet to remove the parking pawl shaft.
2 Remove the parking pawl retune spring.