Disassembly
DISASSEMBLYBefore disassembling transaxle, move the shift lever clockwise as far as it will go and then remove the shift lever.
NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as the unit might then fail.
(1) Measure input shaft end play using Tool 8266. Set up Tool 8266 and a dial indicator as shown in (Fig. 11). 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 endplay exceeds the specified range, the # 4 thrust plate needs to be inspected and changed if necessary.
(2) Remove input and output speed sensors (Fig. 12).
(3) Remove transaxle oil pan (Fig. 13).
(4) Remove transaxle oil filter (Fig. 14).
(5) Remove seven valve body-to-case bolts (Fig. 15).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
(6) Remove valve body from transaxle (Fig. 16).
NOTE: For valve body recondition procedure, refer to Valve Body.
(7) Remove underdrive accumulator and spring (Fig. 17) (Fig. 19).
(8) Remove overdrive accumulator and springs (Fig. 18) (Fig. 19).
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 (Fig. 20).
(10) Remove the low/reverse accumulator plug (Fig. 21).
(11) Remove low/reverse accumulator piston and springs (Fig. 22) (Fig. 23).
(12) Remove long stub shaft bearing snap ring (Fig. 24).
(13) Remove long stub shaft and bearing from bellhousing using Tools 8420A and C-3752 (Fig. 25).
(14) Remove oil pump-to-case bolts (Fig. 26).
(15) Remove oil pump using C-3752 Pullers (Fig. 27).
(16) Remove oil pump while pushing in on input shaft (Fig. 28).
(17) Remove oil pump gasket (Fig. 29).
CAUTION: By-pass valve must be replaced if transmission failure occurs.
(18) Remove cooler by-pass valve (Fig. 30).
(19) Remove # 1 caged needle bearing (Fig. 31).
(20) Remove input clutch assembly (Fig. 32).
(21) Remove # 4 thrust plate (Fig. 33).
(22) Remove front sun gear assembly and # 4 thrust washer (if still in place) (Fig. 34).
(23) Remove front carrier/rear annulus and # 6 needle bearing (Fig. 35).
(24) Remove rear sun gear and # 7 needle bearing (Fig. 36) (Fig. 37).
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 (Fig. 37). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
(25) Install and load Tool 5058 to remove 2/4 clutch retainer snap ring (Fig. 38).
(26) Remove 2/4 clutch retainer (Fig. 39) (Fig. 40).
(27) Remove 2/4 clutch return spring (Fig. 41).
(28) Remove 2/4 clutch pack (Fig. 42).
(29) Remove tapered snap ring (Fig. 43).
(30) Remove one (1) low/reverse clutch disc to facilitate snap ring removal (Fig. 44).
(31) Remove low/reverse reaction plate snap ring (Fig. 45).
(32) Remove low/reverse clutch pack (Fig. 46).
(33) Remove chain cover (Fig. 47).
(34) Stand trans upright on bellhousing.
(35) Remove chain oiler (Fig. 48).
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
(36) Remove chain snubber (Fig. 49).
(37) Remove transfer and output shaft sprocket snap rings and wave washers (Fig. 50) (Fig. 51).
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.
(38) Install Tool 6550 and apply a light amount of pressure to facilitate removal (Fig. 52).
(39) Remove transfer chain and sprockets as an assembly (Fig. 53).
(40) Remove output shaft sprocket spacer (Fig. 54).
(41) Remove main sump baffle from transaxle case (Fig. 55).
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.
WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
(42) Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in (Fig. 56) (Fig. 57). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
(43) Using a small chisel, carefully open stakes on nut (Fig. 58).
NOTE: Transfer shaft and output shaft utilize left handed threads.
(44) Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut (Fig. 59).
(45) Remove output shaft from case using a shop press (Fig 60).
Use special tool 6596 with a shop press to remove front output shaft bearing cup (Fig. 61).
(46) Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rearward (Fig. 62).
(47) Remove rear carrier front bearing cone (Fig. 63).
(48) Install and load compressor (Fig. 64) as shown in (Fig. 65).
(49) Remove snap ring (Fig. 66).
(50) Remove low/reverse piston belleville spring (Fig. 67).
(51) Remove park sprag pivot retaining screw (Fig. 68).
(52) Drive out anchor shaft using suitable punch (Fig. 69).
(53) Remove guide bracket pivot shaft (Fig. 70). Inspect all components (Fig. 71) for wear and replace if necessary.
(54) Remove low/reverse clutch piston (Fig. 72).
(55) Remove low/reverse piston retainer screws (Fig. 73).
(56) Remove low/reverse piston retainer (Fig. 74).
(57) Remove low/reverse piston retainer gasket (Fig. 75).
At this point the Centerline of the transaxle has been removed. If the condition for disassembly did not pertain to the differential, its disassembly may not be required. Inspect the rear transfer shaft area and the transfer shaft seal area for contamination. If evidence of contamination is present, replace the rear transfer shaft bearing and/or the transfer shaft seal.