Part 1
Transaxle - Overhaul
Disassembled Views
1. Install the Holding Fixture 307-625.
2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.
3. Remove the Torque Converter Retainer 307-566.
4. Install the Torque Converter Handle 307-091.
5. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.
6. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur. Use only clean transmission fluid designated for the transaxle and torque converter being serviced.
Clean and inspect the torque converter for damage.
1. Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
2. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes.
- Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
3. If none of the above conditions are present, continue with the following fluid inspection.
4. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
5. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
6. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur.
If the fluid passed inspection:
- drain the remaining fluid from the torque converter.
- using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand.
- thoroughly drain the fluid.
7. NOTE: Note the location of the stud bolts for assembly.
Remove the 13 main control cover bolts and the main control cover.
8. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
9. Disconnect the Transmission Range (TR) sensor electrical connector.
10. Remove the main control-to-cover seal.
11. NOTE: Note the location of the short and long main control-to-transaxle case bolts for reassembly.
Remove the main control nut and the main control-to-transaxle case bolts and remove the main control assembly.
12. Clean and inspect the main control assembly for damage. If damage is found install a new main control assembly. If the main control assembly is not damaged, disassemble the main control assembly and clean it. For additional information, refer to Main Control- Overhaul Main Control - Overhaul.
13. Remove and discard the main control-to-transaxle case separator plate.
14. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch main control-to-transaxle case seals.
1. Forward (1, 2, 3, 4) clutch main control-to-transaxle case seal.
2. Low/reverse clutch main control-to-transaxle case seal.
15. Remove the Turbine Shaft Speed (TSS) sensor bolt and the TSS (Turbine Shaft Speed) sensor.
16. Remove the TR (Transmission Range) sensor detent spring bolt and the TR (Transmission Range) sensor detent spring.
17. Remove the OSS (Output Shaft Speed) sensor bolt and the OSS (Output Shaft Speed) sensor.
18. NOTE: Note the location of the stud bolts for assembly.
Remove the 17 torque converter housing bolts.
19. Pry the torque converter housing loose from the transaxle case.
20. Remove the torque converter housing from the transaxle case.
21. Remove the No. 15 differential thrust bearing.
22. Remove the differential assembly.
23. Clean and inspect the differential assembly for damage or excessive wear and install new components, if necessary. For additional information, refer to Differential Gear Assembly .
- Thrust bearing surfaces
- Spider gear and side gear teeth
- Differential planetary gear teeth
- Differential planetary gear teeth to be sure they spin freely and do not move back and forth or side to side excessively
24. Remove the differential sun gear.
25. Clean and inspect the differential sun gear for damage or wear and install new, as necessary.
- Sun gear teeth
- Spline teeth
26. Remove the No. 13 thrust washer.
27. Remove the No. 11 drive sprocket thrust bearing.
28. Simultaneously remove the drive and driven sprockets and the chain.
29. Remove the drive chain from the drive and driven sprockets.
30. Clean and inspect the drive chain for damage or excessive wear and install new, if necessary.
- Check the drive chain for wear, stretching or tightness of the chain links.
- Check that the chain moves freely.
31. Inspect the driven sprocket for damage or excessive wear and install new, if necessary.
- Chain teeth
- Spline teeth
- Thrust bearing surfaces
- Bearing
32. Remove the snap ring and remove the drive sprocket from the front planetary hub/park gear assembly.
33. Inspect the drive sprocket for damage or excessive wear and install new, if necessary.
- Chain teeth
- Spline teeth
- Thrust washer surface
34. Inspect the front planetary hub/park gear assembly for damage or excessive wear and install new, if necessary.
- Park gear teeth
- Spline teeth
- Thrust washer surface
- Thrust bearing surface
- Bearing surfaces
- Needle bearing
35. Install the drive sprocket on the front planetary hub/park gear assembly and install the snap ring.
36. Install the drive chain on the drive and driven sprockets.
37. Remove the No. 12 driven sprocket thrust bearing.
38. Remove the No. 10 front sun gear and shell assembly thrust bearing.
39. Remove the 2 fluid reservoir bolts and the fluid reservoir.
40. Remove the 2 transmission fluid baffle bolts and the transmission fluid baffle.
41. Remove the park pawl pin and spring.
42. Remove the park pawl.
43. 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.
Remove the forward (1, 2, 3, 4) clutch snap ring.
44. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.
45. Remove the front planetary sun gear and shell assembly.
46. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, as necessary.
- Gear teeth
- Shell-to-clutch pack surfaces
- Thrust bearing surfaces
47. Remove the front planetary carrier/rear ring gear assembly.
48. Clean and inspect the front planetary carrier/rear ring gear assembly for damage or excessive wear and install new, as necessary.
- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Spline teeth
- Thrust bearing
- Thrust bearing surfaces
- Ring gear teeth
49. Remove the No. 7 and No. 8 thrust bearings.
1. No. 7 thrust bearing
2. No. 8 thrust bearing
50. Remove the center planetary carrier/front ring gear assembly.
