Part 1

DISASSEMBLY

Special Tools:



























NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure Quick Learn Procedure .

NOTE: This procedure does not include final drive (differential) disassembly.

1. Remove input and output speed sensors.
2. Remove three solenoid/pressure switch assembly-to-case bolts.
3. Remove solenoid/pressure switch assembly (1)(Figure 1) and gasket (2).










4. Remove oil pan-to-case bolts (1)(Figure 2).










5. Remove oil pan (1)(Figure 3).










6. Remove oil filter (1)(Figure 4).










7. Turn manual valve fully clock-wise to get park rod into position for removal.
8. Remove valve body-to-case bolts (1)(Figure 5).










CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.

9. Using a screwdriver (2)(Figure 6), push park rod rollers (1) away from guide bracket (3).










10. Remove valve body assembly (1)(Figure 7).










NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.

11. Remove underdrive (2)(Figure 8) and overdrive (4) accumulators.










12. Remove low/reverse accumulator snap ring (1)(Figure 9).










13. Remove low/reverse accumulator plug (2)(Figure 10).










14. Remove low/reverse accumulator piston (1)(Figure 11) using suitable pliers.










15. Remove piston (1) along with the seal rings (2) and springs (3)(Figure 12).










16. Measure input shaft end play using (8266B) (1)(Figure 13) and (C-3339A) (3). Place transaxle so input shaft is vertical. Set up end play set and dial indicator. Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.) If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.










17. Remove oil pump-to-case bolts (1)(Figure 14).










CAUTION: Be sure input speed sensor is removed before removing oil pump.

18. Install (C-3752) (1)(Figure 15).










19. "Push in" on input shaft while removing pump (1)(Figure 16).










20. Remove oil pump assembly (1)(Figure 17).











21. Remove oil pump gasket (1)(Figure 18).










CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.

22. Remove cooler bypass valve (1)(Figure 19).










23. Remove #1 needle bearing (1)(Figure 20).










24. Remove input clutch assembly (1)(Figure 21).










25. Remove #4 thrust plate (2)(Figure 22).










26. Remove front sun gear assembly (1)(Figure 23) and #4 thrust washer (2).










27. Remove front carrier/rear annulus assembly (2)(Figure 24) and #6 needle bearing (1).










28. Remove rear sun gear (2)(Figure 25).










NOTE: The number 7 needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

29. Remove needle bearing (1)(Figure 26).










30. Setup (5058A) (1)(Figure 27). compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).

NOTE: Verify that (5058A) is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten (5058A) bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.











NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.