Automatic Transaxle Overhaul: Disassembly: Transaxle

Fig 1: Special Tool(s)

Fig 2: Special Tool(s)

Fig 3: Special Tool(s)

Fig 4: Special Tool(s)

CAUTION: The torque converter (7902) is heavy. Be careful not to drop it or damage will result.
Fig 5: Removing Torque Converter Using Special Tools

1. Using the special tools, remove the torque converter.
2. Using the special tool, install the transaxle onto the bench.
   Fig 6: Install Transaxle Onto The Bench

   
NOTE: During a case replacement the identification tag will need to be replaced. Use caution not to damage the tag.
Fig 7: Removing Identification Tag

3. Remove the identification tag.
4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.
   Fig 8: Draining Transaxle

   
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.
5. Remove the overdrive servo piston and rod.
   • Remove the bolts.
   • Remove the cover.
   • Remove the piston and rod.
     Fig 9: Removing Overdrive Servo Piston & Rod

     
6. Remove the filler tube.
   1. Remove the bolt.
   2. Remove the filler tube.
   3. Remove the filler tube grommet.
      Fig 10: Removing Filler Tube

      
7. Remove the digital TR sensor.
   1. Remove the bolts.
   2. Remove the digital TR sensor.
      Fig 11: Removing Digital TR Sensor

      
8. Remove the TSS sensor.
   1. Remove the bolt.
   2. Remove the sensor.
      Fig 12: Removing TSS Sensor

      
NOTE: The differential seal is a two-piece constructed seal.
Fig 13: Removing LH Differential Seal

9. Using the special tools, remove the LH differential seal.
10. 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 protector from special tool.
       Fig 14: Removing LH Differential Seal Metal Protector

       
11. Using the special tools, remove the rubber portion of the LH differential seal.
    1. Install the special tools into the LH differential seal and rotate the special tool.
    2. Rotate the forcing screw while holding the special tool.
    3. Remove the rubber portion of the seal.
12. Install the special tools into the RH differential seal.
    Fig 15: Installing Special Tools Into RH Differential Seal

    
13. 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 16: Removing RH Differential Seal Metal Protector

       
14. Using the special tools, 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 17: Removing Rubber Portion Of Seal

       
15. Using the special tool, remove the converter hub seal.
    Fig 18: Removing Converter Hub Seal

    
16. Remove the bolts.
    Fig 19: Removing Bolts

    
17. Rotate the transaxle to a horizontal position.
NOTE: The main control cover gasket is reusable if not torn or damaged.
Fig 20: Removing Bolts, Main Control Cover & Gasket

18. Remove the bolts, main control cover and gasket.
CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.
Fig 21: Disconnecting Electrical Connectors

19. Lift the locking tab and disconnect the electrical connectors.
NOTE: The manual valve should be inserted completely.
Fig 22: Rotating Manual Control Lever To Low Detent

20. Using a 9 mm 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 4 of the 6 pump cover bolts need to be removed.
Fig 23: Removing Main Control Valve Body Bolts

21. Remove the bolts.
22. Remove the main control valve body (7A100).
    • Remove the pump assembly and main control valve body.
    • Rotate the main control valve body while lifting off.
      Fig 24: Removing Main Control Valve Body

      
23. Disconnect the manual control valve actuating rod.
    Fig 25: Disconnecting Manual Control Valve Actuating Rod

    
24. Remove the pump shaft.
    Fig 26: Removing Pump Shaft

    
NOTE: The transaxle pan gasket is reusable if not torn or damaged.
Fig 27: Removing Bolts, Transmission Fluid Pan & Gasket

25. Remove the bolts, transmission fluid pan (7A194) and gasket.
26. Remove, clean and inspect the magnet.
    Fig 28: Locating Magnet

    
27. Remove the filter.
    Fig 29: Removing Filter

    
NOTE: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.
Fig 30: Removing Fluid Filter Seal

28. Remove the fluid filter seal.
29. Loosen the nut and remove the reverse clutch anchor pin.
    Fig 31: Removing Reverse Clutch Anchor Pin

    
CAUTION: The chain cover (7G188) is under spring pressure. Care must be taken to prevent internal parts from being ejected.
NOTE: Mark bolt size and location for assembly.
Fig 32: Removing Chain Cover Bolts

30. Remove the bolts.
NOTE: The plastic thrust washers No.1 and 3 may stick to the cover or to the sprockets.
Fig 33: Removing Chain Cover And Gasket

31. Remove the chain cover and gasket.
32. 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 34: Tagging & Marking Location Of Accumulator Springs

       
CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.
Fig 35: Removing Drive Chain Assembly

33. Remove the drive sprocket, driven sprocket and drive chain as an assembly.
NOTE: The thrust washers may remain on the sprockets.
34. Remove the thrust washers.
    1. Remove the No. 2 thrust washer.
    2. Remove the No. 4 thrust washer.
       Fig 36: Removing Thrust Washers

       
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 37: Removing Roll Pins

35. 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 38: Removing Manual Control Lever Shaft

36. Remove the manual control lever shaft.
37. Remove the parking lever actuating rod.
    Fig 39: Removing Parking Lever Actuating Rod

    
38. Remove the manual control lever shaft seal.
    Fig 40: Removing Manual Control Lever Shaft Seal

    
NOTE: During the complete disassembly of the transaxle the fluid transfer tubes must be removed.
Fig 41: Removing Fluid Lube Tube Bolts & Brackets

39. Remove the bolts and brackets.
40. Using the special tools, remove the fluid lube tubes.
    Fig 42: Removing Fluid Lube Tubes

    
41. Remove the bolts and the park pawl abutment.
    Fig 43: Removing Bolts & Park Pawl Abutment

    
42. Remove the neutral/drive accumulator bolt.
    Fig 44: Removing Neutral/Drive Accumulator Bolt

    
43. Remove the neutral/drive accumulator.
    1. Remove the cover.
    2. Remove the spring.
    3. Remove the piston and shaft.
       Fig 45: Removing Neutral/Drive Accumulator

       
44. 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 46: Removing Coast Band Servo

       
NOTE: The No. 5 thrust washer may stick to the drive sprocket support.
Fig 47: Removing Drive Sprocket Support

45. 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 48: Removing No. 8 Driven Sprocket Support Selective Fit Rear Thrust Washer & No. 9 Needle Bearing

46. Using the special tool, remove the No. 8 driven sprocket support selective fit rear thrust washer and the No. 9 needle bearing.
47. Remove the plastic overdrive band retainer.
    Fig 49: Removing Plastic Overdrive Band Retainer

    
48. Remove the overdrive band.
    Fig 50: Removing Overdrive Band

    
NOTE: Do not overtighten the handle of the tool. Place two 3/8 inch washers between the handle and the notched block.
Fig 51: Installing Special Tool Onto Front Clutch Assembly

49. 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.
50. Using the special tool, remove the front clutch assembly.
    Fig 52: Removing Front Clutch Assembly

    
51. Using the special tools, remove the reverse clutch and planet assembly.
    Fig 53: Removing Reverse Clutch & Planet Assembly

    
52. Remove the low/intermediate drum, sun gear, and one-way clutch assembly.
    Fig 54: Removing Low/Intermediate Drum, Sun Gear, & One-Way Clutch Assembly

    
53. Remove the coast band.
    Fig 55: Removing Coast Band

    
CAUTION: Use care not to damage any machined surfaces.
Fig 56: Removing Low/Intermediate Clutch Retaining Ring

54. Remove the low/intermediate clutch retaining ring.
55. 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 57: Removing Low/Intermediate Clutch Pack

       
WARNING: Use caution when unloading the beveled retaining ring. Personal injury could occur.
CAUTION: Use care not to damage the final drive support assembly, transaxle case, or retaining ring during removal.
Fig 58: Removing Beveled Retaining Ring

56. Using the special tool, remove the beveled retaining ring and record the shape of the ring end.
57. Remove the final drive differential and rear planet support assembly.
    Fig 59: Removing Final Drive Differential & Rear Planet Support Assembly

    
NOTE: The differential carrier thrust washer (7G103) may remain on the differential assembly.
58. 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.
       Fig 60: Removing Differential Carrier Thrust Washer

       
59. Remove the rear planet support spacer.
    Fig 61: Removing Rear Planet Support Spacer

    
60. Remove the final drive ring gear.
    Fig 62: Removing Final Drive Ring Gear

    
NOTE: If the drive sprocket bearing is worn or damaged it will need to be replaced.
Fig 63: Removing Drive Sprocket Bearing

61. Using the special tools, remove the drive sprocket bearing.
NOTE: The following procedures are done only if a case replacement is necessary.
Fig 64: Removing Stator Support Assembly Bolts

62. Remove the bolts.
63. Remove the stator support assembly.
    Fig 65: Removing Stator Support Assembly

    
64. Remove the park pawl shaft retaining pin.
    Fig 66: Removing Park Pawl Shaft Retaining Pin

    
65. Using the special tools, remove the cup plug.
    Fig 67: Removing Cup Plug

    
66. Use a magnet to remove the parking pawl shaft.
67. Remove the parking pawl.
    1. Remove the parking pawl.
    2. Remove the parking pawl return spring.
       Fig 68: Removing Parking Pawl