Transaxle Disassembly
NOTE:
For exploded views of internal parts, thrust washer and thrust needle bearing locations, see Figure
-Figure
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- Place transaxle on workbench. Remove transaxle and differential drain plugs and drain oil. Pull out torque converter horizontally. DO NOT scratch bushing inside oil pump shaft. Remove oil pump shaft, input shaft and strut bar bracket. Remove transaxle harness connector from stay. Disconnect air breather hoses and clips. Remove dipstick tube and remove "O" ring from flange face. Remove oil cooler inlet and outlet pipes. Use caution not to lose balls and springs retained behind screws.
- Remove converter case bolts and lightly tap torque converter case from transaxle case. See Figure . Ensure not to damage oil seal and bushing inside converter case. Remove vehicle speed sensor No. 1, extension housing bolts and extension housing.
- Place transaxle in "P" position. Remove reduction drive gear assembly from rear of transaxle case by unstaking and removing reduction driven gear lock nut. Using Special Puller Tools (499737000), (899524100) and (499737100), remove reduction drive gear. See Fig 1 .
- Disconnect harness connector from transfer duty solenoid. Remove transfer valve body and transfer duty solenoid. Remove inlet filter from transaxle case bore located behind transfer valve body. Remove parking pawl, return spring and shaft. Loosen, but DO NOT remove, roller bearing retainer bolts. Place 2 wooden blocks on workbench and stand transaxle case with rear of case facing downward. Ensure rear mating surface of case is not scratched or damaged.
- Remove oil pan and gasket. Disconnect harness connectors for shift solenoids, duty solenoids, ATF temperature sensor and ground cable. Remove valve body bolts and remove valve body. Ensure when removing valve body not to interfere with transfer duty solenoid wiring. Remove vehicle speed sensor No. 2 and torque converter turbine speed sensor. See Figure and Figure . Remove transaxle harness.
- Remove oil pump housing. DO NOT lose total end play adjusting thrust washer. Remove 2-4 brake seal from bottom of transaxle case. Remove high clutch and reverse clutch assembly. Remove high clutch hub, thrust needle bearing, front sun gear and thrust needle bearing. See Figure . Remove 2-4 brake leaf spring from transaxle case. DO NOT bend leaf spring when removing. Remove snap ring from 2-4 brake and thrust needle bearing from top of planetary gear assembly.
- Remove 2-4 brake retaining plate, drive plates, driven plates and rear pressure plate. Remove thrust needle bearing, planetary gear assembly and low clutch assembly. See Fig 2 . Remove snap ring retaining 2-4 brake return spring assembly and remove return spring. Remove 2-4 brake piston and piston retainer. Remove low and reverse brake leaf spring from transaxle case. DO NOT bend leaf spring when removing.
- Remove low and reverse brake snap ring. Remove low and reverse brake retaining plate, drive and driven plates. Note low and reverse brake dish plate position for reassembly reference and remove from case. Turn case upside-down. Remove bolts retaining one-way clutch inner race and spring retainer assembly and remove inner race and spring assembly. Remove low and reverse brake piston by applying compressed air to low and reverse brake pressure feed hole in transaxle case. See Figure .
- Remove spin-on oil filter from transaxle case. Remove manual lever straight pin. Remove selector lever, manual lever and parking rod. Remove detent spring and inhibitor switch. Remove parking support from rear of transaxle case.
- Wrap left and right axle shafts with tape. Remove differential side retainers using Wrench (499787000). See Fig 3 . Hold differential case assembly by hand to avoid damaging retainer mounting hole of torque converter case. Remove axle shafts using Special Tools (499095500) and (499247300). See Fig 4 . Remove and discard axle shaft circlips.
- Remove differential case assembly. Remove and discard seal pipe if attached. Use caution not to damage retainer mounting hole of torque converter clutch case. Remove transfer clutch from extension housing by tapping end of rear drive shaft. DO NOT damage oil seal in extension housing. Use caution not to bend transfer pipe and remove transfer pipe.