Disassembly
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure Quick Learn Procedure.
NOTE: This procedure does not include final drive (differential) disassembly.
1. Remove input and output speed sensors.
2. Remove three solenoid/pressure switch assembly-to-case bolts.
3. Remove solenoid/pressure switch assembly (1) and gasket (2).
4. Remove oil pan-to-case bolts (1).
5. Remove oil pan (1).
6. Remove oil filter (1).
7. Turn manual valve fully clockwise to get park rod into position for removal.
8. Remove valve body-to-case bolts (1).
CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.
9. Using a screwdriver (2), push park rod rollers (1) away from guide bracket (3).
10. Remove valve body assembly (1).
NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.
11. Remove underdrive (2) and overdrive (4) accumulators.
12. Remove low/reverse accumulator snap ring (1).
13. Remove low/reverse accumulator plug (2).
14. Remove low/reverse accumulator (1) and springs (3).
15. Measure input shaft end play using End Play Socket Set 8266-8 (1) and C-3339 (3). Place transaxle so input shaft is vertical. Set up End Play Socket set and Dial Indicator. Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.) If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.
16. Remove oil pump-to-case bolts (1).
CAUTION: Be sure input speed sensor is removed before removing oil pump.
17. Install Pullers C-3752 (1).
18. "Push in" on input shaft while removing pump (1).
19. Remove oil pump assembly (1).
20. Remove oil pump gasket (1).
CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
21. Remove cooler bypass valve (1).
22. Remove #1 needle bearing (1).
23. Remove input clutch assembly (1).
24. Remove #4 thrust plate (2).
25. Remove front sun gear assembly (1)and #4 thrust washer (2).
26. Remove front carrier/rear annulus assembly (2) and #6 needle bearing (1).
27. Remove rear sun gear (2).
28. Remove needle bearing (1).
29.
NOTE: The number 7 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
30. Setup Compressor 5058 (1). Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).
NOTE: Verify that Compressor 5058 is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the Compressor5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
31. Remove 2/4 clutch retainer (1).
32. Remove 2/4 clutch return spring (1).
33. Remove 2/4 clutch pack. Tag 2/4 clutch pack for reassembly identification.
34. Remove tapered snap ring (3).
35. Remove low/reverse reaction plate (1).
36. Remove one low/reverse clutch disc (1).
37. Remove low/reverse reaction plate snap ring (2).
38. Remove low/reverse clutch pack.
39. Remove transfer gear cover-to-case bolts (1).
40. Remove transfer gear cover (1).
41. Using Holder 6259(3).
42. Remove transfer shaft gear-to-shaft nut (3) and coned washer (2).
43. Using Gear Puller L-4407A (3), remove transfer shaft gear.
44. Remove transfer gear shim (select) (3).
45. Remove bearing cup retainer (2).
46. Remove transfer gear bearing cone using Puller Set 5048 with jaws 5048-4 and button -4539-2.
47. Remove transfer shaft bearing cup from retainer using Remover 6062 (2).
48. Using Snap Ring Pliers 6051(1), remove transfer shaft bearing snap ring (2).
49. Using Remover/Installer 5049A (1), remove transfer shaft (2) from transaxle.
50. Slip bearing cup retainer and oil baffle off of shaft.
51. Using Bearing Splitter P-334(3), press transfer shaft bearing cone (4) off of shaft (2).
52. Bend output gear retaining strap (1) ears flat to allow bolt removal.
53. Remove output shaft stirrup strap bolts (3).
54. Remove stirrup (3) and strap (2).
55. Using Holder 6259 (2).
56. Remove output shaft gear-to-shaft bolt (2) and washer (3).
57. Using Gear Puller L4407A (4), and button 6055 (2), remove output gear (1) from shaft.
58. Remove output gear bearing shim (select) (2).
59. Using Puller Set 5048 with jaws 5048-5 and button L-4539-2(1), remove output gear bearing cone.
60. Remove rear carrier assembly (1) from transaxle.
61. Remove rear carrier assembly (3) bearing cone using Puller Set 5048 with jaws 5048-3 and button 6055.
62. Low/reverse spring compressor Disk 6057(1), Compressor 5059 (2) and Compressor 5058-3 (3).
63. Install low/reverse spring compressor 6057 (1), compressor 5059 (2) and compressor 5058-3 (3).
64. Compress low/reverse piston return spring and remove snap ring (1).
65. Remove low/reverse spring compressor tool and low reverse piston return spring (1).
66. Using a suitable punch ,drive out park guide bracket pivot shaft (2) plug.
67. Using ordinary pliers, remove pivot shaft (3) and guide bracket assembly (2).
68. Inspect guide bracket (2) components for excessive wear and replace if necessary.
NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
69. Remove low/reverse clutch piston (1).
70. Remove low/reverse piston retainer-to-case screws (3).
71. Remove low/reverse piston retainer (1).
72. Remove low/reverse piston retainer-to-case gasket (2).
73. Using a hammer (2) and suitable drift (3), drive out inner output bearing cup (1).
74. Using Remover 6062 (1), remove outer output bearing cup.