Disassembly
Installing Torque Converter Handles:
1. Install Torque Converter Handles T81P-7902-C. Remove torque converter from transaxle.
CAUTION: The torque converter is heavy. Be careful not to drop it.
2. Mount transaxle in Bench Mounted Holding Fixture T57L-500-B.
Transaxle In Vertical Position:
3. Turn transaxle in vertical position and drain fluid.
4. Return transaxle to horizontal position.
Speedometer Cover And Components:
5. Remove 8mm cover bolts, speedometer cover and seal. Discard seal. A new seal must be installed during assembly.
Speedometer Drive Gear Components:
6. Lift speedometer drive gear and shaft and speedometer thrust bearing and race out of case.
NOTE: Bearing sits on top of speedometer drive gear and shaft.
Overdrive Servo Components:
7. Remove three 8mm overdrive servo cover bolts, cover, servo piston and spring assembly.
CAUTION: The overdrive band servo cover is under spring tension. Care must be taken when removing.
NOTE: Piston assembly and spring may remain in cover.
NOTE: Discard servo cover seal.
Low/Intermediate Servo Components:
8. Remove three 8mm low/intermediate servo cover bolts, cover, servo piston and piston spring.
CAUTION: The low/intermediate servo cover is under spring tension. Care must be taken when removing.
NOTE: Piston assembly and spring may remain in cover.
9. Remove and discard servo cover gasket and servo cover to case seal.
RH Differential Shaft Seal:
10. The differential shaft seal is a two-piece construction, outer metal protector and inner rubber seal. Inspect RH differential seal and replace if damaged. Remove as follows:
a. Install Step Plate Adapter D80L-630-3 or equivalent into output shaft opening. Use grease to hold tool in place.
Front Cover Seal Removal:
b. Screw Front Cover Seal Remover T74P-6700-A into metal seal protector.
c. Tighten screw on end of tool until metal seal protector is removed.
d. Remove metal seal protector from tool, and install tool into seal.
e. Tighten screw on the end of tool until seal is removed.
Transmission Range Sensor Retaining Bolts:
11. Remove two 8mm Transmission Range (TR) sensor retaining bolts and remove sensor.
Filler Tube Retaining Bolt:
12 Remove one 8mm filler tube retaining bolt and pull filler tube and grommet from case.
Chain Cover Bolts:
13. Remove five 10mm and four 8mm chain cover bolts from inside transmission housing cover.
Converter Hub Seal:
14. Remove and discard converter impeller hub seal using Converter Seal Remover T94P-77001-BH and Impact Slide Hammer T50T-100-A.
15. Rotate transaxle to vertical position.
Servicing Pump/Valve Body Cover Bolts:
16. Remove twelve 10mm pump and valve body cover (upper reservoir) bolts. Remove cover and discard gasket.
Electrical Connectors:
17. Disconnect electrical connectors from Transmission Fluid Temperature (TFT) sensor and solenoids. Remove wire retaining clip from oil pump body separating plate.
CAUTION: Do not pull on wires.
Rotating Manual Control Lever Shaft:
18. Using a 9mm wrench on flats on end of manual control lever shaft, rotate shaft clockwise to position manual linkage in LOW detent (valve positioned all the way in).
Main Control Valve Body Bolts:
19. Remove twenty-two 8mm pump and main control valve body assembly retaining bolts. Note length and location of bolts.
CAUTION: Do not remove the two bolts that retain the pump and valve body assembly together.
CAUTION: Do not remove pump cover bolts.
Rotating Valve Body:
20. Rotate main control valve body clockwise. Remove manual valve link from manual valve and remove main control valve body.
21. Disconnect manual valve link from manual valve detent lever.
Oil Pump Shaft:
22. Pull oil pump shaft out of case. Remove and discard four Teflon(R) seals from oil pump shaft.
Output Shaft Circlip:
23. Inspect and replace if necessary the output shaft circlip.
Servicing LH Differential Seal:
24. Remove LH differential seal as follows:
a. Screw Front Cover Seal Remover T74P-6700-A into metal seal protector.
b. Tighten screw on the end of tool until metal seal protector is removed.
c. Remove metal seal protector from tool and install tool into seal.
d. Tighten screw on end of tool until seal is removed.
Turbine Shaft Speed Sensor:
25. Remove Turbine Shaft Speed (TSS) sensor.
Location Of Bolts And Mounting Stud:
CAUTION: Chain cover is under spring pressure. Use care when removing.
26. Remove thirteen 10mm, one 13mm and one 8mm bolt, and one 24mm mounting stud. Note length and location of bolts. Start at inside and work out.
Accumulator Springs:
27. Remove chain cover and tag accumulator springs to be sure they are installed in their correct positions during assembly. Remove and discard chain cover gasket.
No. 1 & No. 3 Thrust Washers:
28. Remove No. 1 and No. 3 thrust washers from chain cover.
Drive Chain And Sprockets:
29. Simultaneously, lift out both drive sprocket and driven sprocket with drive chain.
CAUTION: Be careful not to damage or bend tabs on exciter ring.
No. 2 & No. 4 Thrust Washers:
30. Remove No. 2 thrust washer from drive sprocket support and No. 4 thrust washer from driven sprocket support.
NOTE: Thrust washers may remain on driven sprocket.
Drive Sprocket Bearing:
31. Inspect drive sprocket bearing to determine if it needs to be replaced. If OK, go to Step 33.
Drive Sprocket Bearing Removal:
32. If necessary, remove drive sprocket bearing using Impact Slide Hammer T5OT-100-A and Stator and Driven Bearing Remover T94P-77001-KH.
Manual Control Shaft Removal:
Roll Pins And Manual Control Shaft:
33. Remove and discard three roll pins from manual control shaft using Locknut Pin Remover D81P-3504-N or equivalent.
CAUTION: Use care not to damage any machined surfaces.
34. Remove manual detent lever, slide manual control shaft out of case.
Manual Control Shaft Seal:
35. Remove manual control shaft seal from case.
CAUTION: Do not damage any machined surface.
36. Remove driven sprocket support.
No. 5 Thrust Washer And Driven Sprocket Support:
37. Remove No. 5 selective thrust washer.
NOTE: Thrust washer may remain on driven sprocket support.
No. 9 Needle Bearing And No. 8 Thrust Washer:
38. Using 0-Ring Tool T71P-19703-C, remove No. 8 selective thrust washer and No. 9 needle bearing from bottom of cylinder.
NOTE: Thrust washer and No. 9 needle bearing may remain on driven sprocket support when it is removed.
Overdrive Band Anchor Strut:
39. Remove plastic overdrive band anchor strut.
Overdrive Band:
40. Remove overdrive band. Remove screen filter and clean with compressed air.
41. Rotate transaxle to horizontal position with transmission pan up.
Transmission Pan:
42. Remove seventeen pan retaining bolts. Remove pan and discard pan gasket.
Transmission Pan Magnet:
43. Remove magnet from transmission pan assembly.
Transmission Filter And Filter Seal:
44. Remove filter screen and discard filter seal.
NOTE: Filter seal may stick inside case.
Tube Support Brackets:
45. Remove four 8mm tube bracket bolts, one center screw and tube support brackets.
NOTE: For complete transaxle disassembly, the reverse clutch apply transfer tube and rear lube transfer tube must be removed prior to removing the reverse clutch or the differential.
Lube Tube Removal:
46. Remove and discard lube tubes using Lube Tube Remover T94P-7001-CH and Impact Slide Hammer T50T-100-A.
Parking Lever Actuating Rod:
47. Remove two 1Omm parking lever actuating rod support bolts. Remove support. Remove parking lever actuating rod.
48. Using Locknut Pin Remover D81P-3504-N or equivalent, remove parking pawl shaft roll pin.
Parking Pawl Shaft:
49. Use magnet to remove parking pawl shaft, and remove parking pawl and parking pawl return spring.
Front Sun And Shell:
50. Rotate transaxle to vertical position. Using Front Clutch Loading Tool T86P-70389-A, install hook end of tool into one of the six lube holes in front sun and shell. Position notched block over edge of assembly and tighten handle. Do not overtighten handle. Lift assembly out of case.
Reverse Anchor Pin Bolt And Nut:
51. Loosen 19mm reverse clutch anchor pin nut and remove 6mm Allen head bolt.
Reverse Clutch:
52. Position hook portion of Front Clutch Loading Tool T86P-70389-A on inner diameter of reverse clutch hub. Grasp outer diameter of cylinder with fingertips and slide reverse clutch out of case.
Planet Assembly:
53. Holding the front planetary shaft, lift out both front planet and rear planet.
Rear Sun Gear And Drum:
54. Lift out rear sun gear and drum assembly.
55. Remove low and intermediate band.
Rear Support Snap Ring:
56. Remove rear support snap ring from case using a screwdriver inserted through side of case.
Differential Assembly:
57. Lift out differential assembly using output shaft.
No. 18 Thrust Washer And No. 19 Needle Bearing:
58. Remove No. 18 thrust washer and No. 19 needle bearing.
NOTE: No. 18 thrust washer may remain on the differential assembly next to speedometer drive gear.
Final Drive Ring Gear:
59. Remove final drive ring gear from case.
Stator Support:
60. If case replacement is necessary, rotate case 180 degrees and remove six T-30 Torx(R) bolts retaining stator support to case.