Transaxle - Disassembly

TRANSAXLE - DISASSEMBLY





1. Install the Holding Fixture.





2. Using the Holding Fixture, install the transaxle on a bench-mounted holding fixture.





3. Remove the Torque Converter Retainer.





4. Install the Torque Converter Handle.





5. Using Torque Converter Handle, remove the torque converter from the transaxle.

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






6. Remove the 13 bolts and the main control cover.

NOTE:Note the location of the stud bolts for assembly.






7. Disconnect the output shaft speed (OSS) sensor electrical connector.





8. Disconnect the transmission range (TR) sensor electrical connector.





9. Remove the solenoid body-to-main control cover grommet.





10. Remove the nut and the 22 Torx bolts and remove the main control assembly.

NOTE:Note the location of the short and long main control bolts for reassembly.






11. Remove the main control-to-transaxle case separator plate.





12. Remove the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center support seals.
a. Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal.

b. Low/reverse clutch transaxle case-to-center support seal.





13. Remove the internal cooler bypass spring, sleeve and valve.





14. Remove the bolt and the turbine shaft speed (TSS) sensor.





15. Remove the bolt and the TR sensor detent spring.





16. Remove the bolt and the OSS sensor.





17. Remove the 17 torque converter housing bolts.

NOTE:Note the location of the stud bolts for assembly.






18. Using a suitable tool, pry the torque converter housing loose from the transaxle case.





19. Remove the torque converter housing loose from the transaxle case.





20. Remove the No. 15 differential thrust bearing.





21. Remove the differential.





22. Remove the differential planetary sun gear.





23. Remove the No. 13 thrust washer.





24. Remove the No. 11 drive sprocket thrust bearing.





25. Simultaneously remove the drive and driven sprockets and the chain.





26. Remove the No. 12 driven sprocket thrust bearing.





27. Remove the No. 10 front sun gear and shell assembly thrust bearing.





28. Remove the 2 bolts and the transaxle fluid reservoir hold-down bracket.





29. Remove the transaxle fluid reservoir.





30. Remove the transaxle fluid baffle.





31. Remove the park pawl pin and spring.





32. Remove the park pawl.





33. Remove the forward (1, 2, 3, 4) clutch snap ring.

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.






34. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.





35. Remove the front sun gear and shell assembly.





36. Remove the front planetary carrier/rear ring gear assembly.





37. Remove the No. 7 and No. 8 thrust bearings.
a. No. 7 thrust bearing.

b. No. 8 thrust bearing.





38. Remove the center planetary carrier/front ring gear assembly.





39. Remove the center planetary sun gear.





40. Remove the No. 5 and No. 6 thrust bearings.
a. No. 5 thrust bearing.

b. No. 6 thrust bearing.





41. Remove the center support assembly.





42. Remove the rear planetary carrier/center ring gear assembly.





43. Remove the low/reverse wave spring, clutch pack and pressure plate.





44. Remove the low one way clutch (OWC).





45. Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.

NOTE:The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.






46. Remove the pressure plate and the wave spring.





47. Remove the No. 3 thrust bearing.





48. Remove the overdrive/direct clutch assembly.





49. Remove the No. 1 thrust bearing.

NOTE:If the No. 1 thrust bearing stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.






50. Remove the intermediate (2, 6) clutch apply ring.





51. Remove the 3 bolts and the clutch support tower.





52. Remove the intermediate (2, 6) clutch return spring snap ring.

NOTE:Note the location of the snap ring gap for assembly.






53. Remove the intermediate (2, 6) clutch return spring.

NOTE:Note the position of the return spring for assembly.






54. Remove the intermediate (2, 6) clutch piston.

NOTE:Note the position of the intermediate clutch piston for assembly.






55. Remove the 5 clutch feed seals.





56. Remove the nut and the manual lever from the manual shaft.





57. Using the Roll Pin Remover, pull the roll pin out of the manual shaft.

CAUTION:Do not drive the roll pin through the manual shaft. The roll pin will contact the transaxle case causing damage to the transaxle case.






58. Remove the manual shaft.





59. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.





60. Using a suitable tool, remove the manual shaft seal.





61. Using a suitable tool, remove the LH halfshaft seal.





62. Remove the 2 bolts and the oil baffle from the torque converter housing.





63. Remove the 9 bolts and the pump and filter assembly.

NOTE:Note the location of the 6-mm bolt for assembly.






64. Remove the differential ring gear snap ring.





65. Remove the differential ring gear.





66. Using a suitable tool, remove the RH halfshaft seal.