Disassembly

Before disassembling transaxle, move the shift lever clockwise as far as it will go. This should be one position past the L position. Then remove the shift lever.

NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.

CAUTION: Do not intermix clutch discs or plates as the unit might then fail.

Measure Input Shaft End Play:

Measuring input shaft end play before disassembly will usually indicate when a #4 thrust plate change is required. The number 4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft. Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transaxle.

Remove Input And Output Speed Sensor:

Remove Transaxle Oil Pan:

Remove Transaxle Oil Filter:

Remove both speed sensors from transaxle case.

Remove Valve Body Bolts (17):

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.

Remove Valve Body From Transaxle:

NOTE: For valve body recondition procedure, refer to valve body overhaul.

Remove Underdrive Accumulator And Spring:

Remove Overdrive Accumulator And Springs:

Accumulator Locations:

Remove Low/Reverse Accumulator:

Remove Low/Reverse Accumulator Plug:

Remove Low/Reverse Accumulator Piston:

Low/Reverse Accumulator:

CAUTION: Tag the springs for the Overdrive Accumulator so that they are not confused with the springs in the Low/Reverse Accumulator.

Remove Long Stub Shaft Snap Ring:

Remove Long Stub Shaft From Bellhousing:

NOTE: Remove driveshaft retainer clips from driveshafts.

Remove Oil Pump Attaching Bolts:

Oil Pump Pullers:

Remove Oil Pump:

Remove Oil Pump Gasket:

NOTE: To align oil pump during installation, use threaded dowels or Phillips screwdrivers.

Remove By-Pass Valve:

CAUTION: By-pass valve must be replaced if transmission failure occurs.

Remove No. 1 Caged Needle Bearing:

Remove Input Clutch Assembly:

Remove No. 4 Thrust Plate:

Remove Front Sun Gear Assembly:

Remove Front Carrier And Rear Annulus Assembly:

Remove Rear Sun Gear:

Number 7 Bearing:

The number 7 needle bearing has antireversal tabs and is common with the number 5 and number 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.

Remove 2/4 Clutch Retainer Snap Ring:

Remove 2/4 Clutch Retainer:

2/4 Clutch Retainer:

Remove 2/4 Clutch Return Spring:

Remove 2/4 Clutch Pack:

Remove Tapered Snap Ring:

Remove One Disc:

Remove Low/Reverse Reaction Plate Snap Ring:

Remove Low/Reverse Clutch Pack:

Stand trans upright on bellhousing

Remove Chain Cover:

Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.

Remove Chain Oiler:

Remove Chain Snubber:

CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.

Remove Output Shaft Sprocket Snap Ring And Wave Washer:

Remove Transfer Shaft Sprocket Snap Ring And Wave Washer:

Install Chain Spreader:

Remove Chains And Both Sprockets As An Assembly:

Output Sprocket Spacer:

CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, removal or installation will be difficult. Overspreading of the chain sprockets will also make sprocket removal difficult.

Main Sump Vent Baffle Location:

Remove main sump baffle from transaxle case.

Grinding Stakes:

CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.

WARNING: Wear safety goggles while grinding stake nuts.

Stake Grinding Pattern:

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Opening Nut Stakes:

Using a small chisel, carefully open stakes on nut.

Remove Output Shaft Nut:

Use Arbor Press To Remove Output Shaft From Case:

Use special tool 6497 and 6498, or equivalents to remove the transfer shaft nut or the output shaft nut. Note that your breaker bar will turn clockwise to remove the nut and counter clockwise to install the nut.

Remove Front Bearing Cup:

Use special tool 6596, or equivalent to remove front output shaft bearing cup.

Remove Rear Bearing Cup:

Use special tool 6597 and handle C-4171 and C-4171-2, or equivalents to press rear output shaft bearing cup rearward.

Remove Rear Carrier Front Bearing Cone:

Low/Reverse Spring Compressor Tool:

Compressor Tool In Use:

Remove Snap Ring:

Low/Reverse Piston Return Spring:

Remove Parking Sprag Pivot Retaining Screw:

Anchor Shaft Removal:

Guide Bracket Pivot Shaft:

Guide Bracket Disassembled:

NOTE: Using a pin punch, drive out guide bracket pivot shaft.

Remove Low/Reverse Clutch Piston:

Remove Piston Retainer Attaching Screws:

Remove Piston Retainer:

Remove Piston Retainer Gasket:

At this point the Centerline of the transaxle has been removed. If the condition for disassembly did not pertain to the differential, it's disassembly may not be required. Inspect the rear transfer shaft area and the transfer shaft seal area for contamination. If evidence of contamination is present, replace the rear transfer shaft bearing and/or the transfer shaft seal.

To disassemble the input clutch assembly, refer to Input Clutches-Recondition.