Automatic Transmission: Disassembly: Transaxle

Special Tool(s) 

Fig 1: Identifying Special Tools (1 Of 4)

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Fig 2: Identifying Special Tools (2 Of 4)

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Fig 3: Identifying Special Tools (3 Of 4)

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Fig 4: Identifying Special Tools (4 Of 4)

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CAUTION: The torque converter is heavy. Be careful not to drop it or damage will result.
Fig 5: Removing Torque Converter
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1. Using the special tools, remove the torque converter.
2. Using the special tool, install the transaxle into the bench.
   Fig 6: Installing Transaxle Into Bench

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NOTE: During a case replacement, a new identification tag will need to be installed. Use caution not to damage the tag.
Fig 7: Removing Identification Tag
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3. Remove the identification tag.
4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
   Fig 8: Placing Drain Pan Under Transaxle

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5. Remove the filler tube.
   Fig 9: Removing Filler Tube

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CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.
Fig 10: Removing Overdrive Servo Piston And Rod
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6. Remove the overdrive servo piston and rod.
   • Remove the bolts.
   • Remove the cover.
   • Remove the piston and rod.
7. Remove the output shaft speed (OSS) sensor cover.
   Fig 11: Removing Output Shaft Speed Sensor Cover

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8. Remove the output shaft speed (OSS) sensor.
   • Unclip the harness.
   • Remove the output shaft speed (OSS) sensor.
   Fig 12: Removing Output Shaft Speed Sensor

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9. Remove the digital TR sensor.
   1. Remove the bolts.
   2. Remove the digital TR sensor.
   Fig 13: Removing Digital TR Sensor

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10. Remove the TSS sensor.
    1. Remove the bolt.
    2. Remove the sensor.
    Fig 14: Removing TSS Sensor

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NOTE: The differential seal is a two-piece constructed seal.
Fig 15: Removing LH Differential Seal
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11. Using the special tools, remove the LH differential seal.
12. Using the special tools, remove the LH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector from the LH differential seal and remove the protector from the tool.
    Fig 16: Removing LH Differential Seal Metal Protector

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13. Using the special tools, remove the rubber portion of LH differential seal.
    1. Install the special tool into the LH differential seal.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 17: Removing Rubber Portion Of LH Differential Seal

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14. Install the special tool into the RH differential seal.
    Fig 18: Installing Special Tool Into RH Differential Seal

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15. Using the special tools, remove the RH differential seal metal protector.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the metal protector of the seal.
    Fig 19: Removing RH Differential Seal Metal Protector

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16. Using the special tool, remove the rubber portion of the seal.
    1. Rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
    Fig 20: Removing Rubber Portion Of Seal

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17. Using the special tools, remove the converter hub seal.
    Fig 21: Removing Converter Hub Seal

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18. Remove the bolts.
    Fig 22: Removing Bolts

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19. Rotate the transaxle to a horizontal position.
20. If not previously removed, remove the mount.
    Fig 23: Removing Mount

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21. Remove the bolts, and remove the pan.
    Fig 24: Removing Bolts And Pan

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CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
Fig 25: Disconnecting Electrical Connectors
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22. Lift the locking tab and disconnect the electrical connectors.
NOTE: The manual valve should be inserted completely.
Fig 26: Rotating Manual Control Lever To Low Detent
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23. Using a 9 mm (0.36 in) wrench rotate the manual control lever to the low detent.
CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body.
CAUTION: Only four of the six pump cover bolts need to be removed.
Fig 27: Removing Manual Valve Bolts
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24. Remove the bolts.
25. Remove the main control valve body.
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
    Fig 28: Removing Main Control Valve Body

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26. Disconnect the manual control valve actuating rod.
    Fig 29: Disconnecting Manual Control Valve Actuating Rod

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27. Remove the pump shaft.
    Fig 30: Removing Pump Shaft

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NOTE: The transaxle pan gasket is reusable if not torn or damaged.
Fig 31: Removing Bolts, Transmission Fluid Pan And Gasket
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28. Remove the bolts, transmission fluid pan and gasket.
29. Remove, clean and inspect the magnet.
    Fig 32: Removing Magnet

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30. Remove the filter.
    Fig 33: Removing Filter

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NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
Fig 34: Removing Fluid Filter Seal
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31. Remove the fluid filter seal.
32. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 35: Removing Reverse Clutch Anchor Pin

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CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.
NOTE: Mark bolt size and location for assembly.
Fig 36: Removing Chain Cover Bolts
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33. Remove the bolts.
NOTE: The plastic thrust washers No.1 and 3 may stick to the cover or to the sprockets.
Fig 37: Removing Chain Cover And Gasket
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34. Remove the chain cover and gasket.
35. Tag and mark the location of the accumulator springs.
    1. Remove the intermediate 1-2 accumulator outer spring.
    2. Remove the direct 2-3 accumulator piston spring.
    3. Remove the neutral reverse shift accumulator spring.
    4. Remove the overdrive 3-4 accumulator spring.
    Fig 38: Removing Accumulator Springs

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CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
Fig 39: Removing Drive Sprocket, Driven Sprocket, And Drive Chain
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36. Remove the drive sprocket, driven sprocket, and drive chain as an assembly.
NOTE: The thrust washers may remain on the sprockets.
Fig 40: Removing Thrust Washers
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37. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
CAUTION: Use care not to damage the machined surface of the case.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 41: Removing Roll Pins
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38. Remove the roll pins.
NOTE: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.
Fig 42: Removing Manual Control Lever Shaft
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39. Remove the manual control lever shaft.
40. Remove the parking lever actuating rod.
    Fig 43: Removing Parking Lever Actuating Rod

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41. Remove the manual control lever shaft seal.
    Fig 44: Removing Manual Control Lever Shaft Seal

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NOTE: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.
Fig 45: Removing Bolts And Brackets
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42. Remove the bolts and brackets.
43. Using the special tools, remove the fluid lube tubes.
    Fig 46: Removing Fluid Lube Tubes

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44. Remove the bolts and the park pawl abutment.
    Fig 47: Removing Bolts And Park Pawl Abutment

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45. Remove the neutral/drive accumulator bolt.
    Fig 48: Removing Neutral/Drive Accumulator Bolt

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46. Remove the neutral/drive accumulator.
    1. Remove the neutral/drive accumulator cover.
    2. Remove the neutral/drive accumulator springs.
    3. Remove the neutral/drive accumulator piston and shaft.
    Fig 49: Removing Neutral/Drive Accumulator

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47. Using the special tool, remove the coast band servo.
    1. Install the special tool.
    2. Remove the snap ring.
    3. Remove the cover, piston, and rod as an assembly.
    Fig 50: Removing Coast Band Servo

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NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
Fig 51: Removing Drive Sprocket Support
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48. Remove the drive sprocket support and the No. 5 thrust washer.
NOTE: The No. 8 thrust washer and the No. 9 thrust bearing may remain on the drive sprocket support and driven sprocket.
Fig 52: Removing Driven Sprocket Support Selective Fit Rear Thrust Washer And Needle Bearing
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49. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
50. Remove the plastic overdrive band retainer.
    Fig 53: Removing Plastic Overdrive Band Retainer

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51. Remove the overdrive band.
    Fig 54: Removing Overdrive Band

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NOTE: Do not over-tighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
Fig 55: Positioning Special Tool Into Case
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52. Position the special tool into the case and install the hook end of tool into one of the lube holes in the front sun shell. Position the block over the edge of the assembly and tighten the handle.
53. Using the special tool, remove the front clutch assembly.
    Fig 56: Removing Front Clutch Assembly

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54. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 57: Removing Reverse Clutch And Planet Assembly

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55. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 58: Removing Low/Intermediate Drum, Sun Gear, And One-Way Clutch Assembly

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56. Remove the coast band.
    Fig 59: Removing Coast Band

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CAUTION: Use care not to damage any machined surfaces.
Fig 60: Removing Low/Intermediate Clutch Retaining Ring
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57. Remove the low/intermediate clutch retaining ring.
58. Remove the low/intermediate clutch pack.
    1. Remove the low/intermediate clutch pressure plate.
    2. Remove the low/intermediate clutch plates.
    3. Remove the low/intermediate clutch cushion spring.
    Fig 61: Removing Low/Intermediate Clutch Pack

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WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
CAUTION: Use care not to damage final drive support assembly, transaxle case, or retaining ring during removal.
Fig 62: Removing Beveled Retaining Ring
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59. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
60. Remove the final drive differential and rear planet support assembly.
    Fig 63: Removing Final Drive Differential And Rear Planet Support Assembly

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NOTE: The differential carrier thrust washer may remain on the differential assembly.
Fig 64: Removing Differential Carrier Thrust Washer
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61. Remove the differential carrier thrust washer.
    1. Remove the No. 18 differential carrier thrust washer.
    2. Remove the No. 19 differential carrier thrust bearing and race.
62. Remove the rear planet support spacer.
    Fig 65: Removing Rear Planet Support Spacer

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63. Remove the final drive ring gear.
    Fig 66: Removing Final Drive Ring Gear

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NOTE: If the drive sprocket bearing is worn or damaged install a new bearing.
Fig 67: Removing Drive Sprocket Bearing
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64. Using the special tools, remove the drive sprocket bearing.
NOTE: The following procedures are done only if a case replacement is necessary.
Fig 68: Removing Case Bolts
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65. Remove the bolts.
66. Remove the stator support assembly.
    Fig 69: Removing Stator Support Assembly

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67. Remove the park pawl shaft retaining pin.
    Fig 70: Removing Park Pawl Shaft Retaining Pin

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68. Using the special tools remove the cup plug.
    Fig 71: Removing Cup Plug

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69. Remove the parking pawl.
    1. Use a magnet to remove the parking pawl shaft.
    2. Remove the parking pawl and return spring.
    Fig 72: Removing Parking Pawl

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