Overhaul - Automatic Transmission: Disassembly

Before disassembling transaxle, move the shift lever clockwise as far as it will go and then remove the shift lever.

1. Measure input shaft end play using Tool 8266. Set up Tool 8266 and a dial indicator as shown in Fig 1. 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. If end play exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.
   Fig 1: Measuring Input Shaft End Play Using Tool 8266 (Typical)

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2. Remove input and output speed sensors. See Fig 2.
   Fig 2: Removing Input and Output Speed Sensors

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3. Remove transaxle oil pan. See Fig 3.
   Fig 3: Removing Transaxle Oil Pan

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4. Remove transaxle oil filter. See Fig 4.
   Fig 4: Removing Transaxle Oil Filter

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5. Remove seven valve body-to-case bolts. See Fig 5.
   Fig 5: Removing Valve Body Bolts (17)

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   CAUTION: Do not  handle the valve body by the manual shaft. Damage could result.
6. Remove valve body from transaxle. See Fig 6.
   Fig 6: Removing Valve Body From Transaxle

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   NOTE: For valve body recondition procedure, (Refer to VALVE BODY ).
7. Remove underdrive accumulator and spring. See Fig 7 and Fig 8 .
   Fig 7: Removing Underdrive Accumulator & Springs

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Fig 8: Locating Accumulator
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8. Remove overdrive accumulator and springs. See Fig 9 and Fig 8 .
   Fig 9: Removing Overdrive Accumulator & Springs

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   CAUTION: Tag the springs for the Overdrive Accumulator so that they are not confused with the springs in the Low/Reverse Accumulator.
9. Remove the low/reverse accumulator snap ring. See Fig 10.
   Fig 10: Removing Low/Reverse Accumulator

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10. Remove the low/reverse accumulator plug. See Fig 11.
    Fig 11: Removing Low/Reverse Accumulator Plug

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11. Remove low/reverse accumulator piston and springs. See Fig 12 and Fig 13 .
    Fig 12: Removing Low/Reverse Accumulator Piston

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    Fig 13: Identifying Low/Reverse Accumulator Components

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12. Remove long stub shaft bearing snap ring. See Fig 14.
    Fig 14: Removing Long Stub Shaft Snap Ring

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13. Remove long stub shaft and bearing from bellhousing using Tools 8420A and C-3752. See Fig 15.
    Fig 15: Removing Long Stub Shaft From Bellhousing

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14. Remove oil pump-to-case bolts. See Fig 16.
    Fig 16: Removing Oil Pump Attaching Bolts

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15. Remove oil pump using C-3752 Pullers. See Fig 17.
    Fig 17: Identifying Oil Pump Pullers

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16. Remove oil pump while pushing in on input shaft. See Fig 18.
    Fig 18: Removing Oil Pump

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17. Remove oil pump gasket. See Fig 19.
    Fig 19: Removing Oil Pump Gasket

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    CAUTION: Bypass valve must be replaced if transmission failure occurs.
18. Remove cooler bypass valve. See Fig 20.
    Fig 20: Removing Bypass Valve

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19. Remove #1 caged needle bearing. See Fig 21.
    Fig 21: Removing No. 1 Caged Needle Bearing

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20. Remove input clutch assembly. See Fig 22.
    Fig 22: Removing Input Clutch Assembly

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21. Remove #4 thrust plate. See Fig 23.
    Fig 23: Removing No. 4 Thrust Plate

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22. Remove front sun gear assembly and #4 thrust washer (if still in place). See Fig 24.
    Fig 24: Removing Front Sun Gear Assembly

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23. Remove front carrier/rear annulus and #6 needle bearing. See Fig 25.
    Fig 25: Removing Front Carrier/Rear Annulus

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24. Remove rear sun gear and #7 needle bearing. See Fig 26 and Fig 27 .
    Fig 26: Removing Rear Sun Gear

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    NOTE: The number seven 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. See Fig 27. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 27: Identifying Number 7 Bearing

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25. Install and load Tool 5058 to remove 2/4 clutch retainer snap ring. See Fig 28.
    Fig 28: Removing 2/4 Clutch Retainer Snap Ring

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26. Remove 2/4 clutch retainer. See Fig 29 and Fig 30 .
    Fig 29: Removing 2/4 Clutch Retainer (1 Of 2)

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    Fig 30: Removing 2/4 Clutch Retainer (2 Of 2)

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27. Remove 2/4 clutch return spring. See Fig 31.
    Fig 31: Removing 2/4 Clutch Return Spring

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28. Remove 2/4 clutch pack. See Fig 32.
    Fig 32: Removing 2/4 Clutch Pack

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29. Remove tapered snap ring. See Fig 33.
    Fig 33: Removing Tapered Snap Ring

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30. Remove low/reverse reaction plate. See Fig 34.
    Fig 34: Removing Low/Reverse Reaction Plate

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31. Remove one (1) low/reverse clutch disc to facilitate snap ring removal. See Fig 35.
    Fig 35: Removing One Disc

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32. Remove low/reverse reaction plate snap ring. See Fig 36.
    Fig 36: Removing Low/Reverse Reaction Plate Snap Ring

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33. Remove low/reverse clutch pack. See Fig 37.
    Fig 37: Removing Low/Reverse Clutch Pack

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34. Remove chain cover. See Fig 38.
    Fig 38: Removing Chain Cover

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35. Stand trans upright on bellhousing.
36. Remove chain oiler. See Fig 39.
    Fig 39: Removing Chain Oiler

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    CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
37. Remove chain snubber. See Fig 40.
    Fig 40: Removing Chain Snubber

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38. Remove transfer and output shaft sprocket snap rings and wave washers. See Fig 41 and Fig 42 .
    Fig 41: Removing Output Shaft Sprocket Snap Ring & Wave Washer

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    Fig 42: Removing Transfer Shaft Sprocket Snap Ring & Wave Washer

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    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.
39. Install Tool 6550 and apply a light amount of pressure to facilitate removal. See Fig 43.
    Fig 43: Installing Chain Spreader

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40. Remove transfer chain and sprockets as an assembly. See Fig 44.
    Fig 44: Removing Chain & Both Sprockets As An Assembly

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41. Remove output shaft sprocket spacer. See Fig 45.
    Fig 45: Removing Output Sprocket Spacer

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42. Remove main sump baffle from transaxle case. See Fig 46.
    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.
    Fig 46: Locating Main Sump Vent Baffle

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    WARNING: Wear safety goggles while grinding stake nuts.
43. Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in Fig 47 and Fig 48 . Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
    Fig 47: Grinding Stakes

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    Fig 48: Identifying Stake Grinding Pattern

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44. Using a small chisel, carefully open stakes on nut. See Fig 49.
    Fig 49: Opening Nut Stakes

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45. Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut. See Fig 50.
    Fig 50: Removing Output Shaft Nut

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46. Remove output shaft from case using a shop press. See Fig 51.

    Use special tool 6596 with a shop press to remove front output shaft bearing cup. See Fig 52.

    Fig 51: Using Arbor Press To Remove Output Shaft From Case

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    Fig 52: Removing Front Bearing Cup

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47. Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rearward. See Fig 53.
    Fig 53: Removing Rear Bearing Cup

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48. Remove rear carrier front bearing cone. See Fig 54.
    Fig 54: Removing Rear Carrier Front Bearing Cone

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49. Install and load compressor as shown in Fig 55 and Fig 56 .
    Fig 55: Identifying Low/Reverse Spring Compressor Tool

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    Fig 56: Compressor Tool in Use

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50. Remove snap ring. See Fig 57.
    Fig 57: Removing Snap Ring

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51. Remove low/reverse piston belleville spring. See Fig 58.
    Fig 58: Removing Low/Reverse Piston Belleville Spring

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52. Remove park sprag pivot retaining screw. See Fig 59.
    Fig 59: Removing Parking Sprag Pivot Retaining Screw

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53. Drive out anchor shaft using suitable punch. See Fig 60.
    Fig 60: Removing Anchor Shaft

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54. Remove guide bracket pivot shaft. See Fig 61. Inspect all components for wear and replace if necessary. See Fig 62.
    Fig 61: Removing Guide Bracket Pivot Shaft

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    Fig 62: Exploded View Of Guide Bracket

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55. Remove low/reverse clutch piston. See Fig 63.
    Fig 63: Removing Low/Reverse Clutch Piston

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56. Remove low/reverse piston retainer screws. See Fig 64.
    Fig 64: Removing Piston Retainer-To-Case Screws

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57. Remove low/reverse piston retainer. See Fig 65.
    Fig 65: Removing Piston Retainer

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58. Remove low/reverse piston retainer gasket. See Fig 66.
    Fig 66: Removing Piston Retainer Gasket

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