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.

NOTE: This procedure does not include final drive (differential) disassembly.

1) Remove input and output speed sensors.

Fig. 15 Solenoid/Pressure Switch Assembly andGasket:

2) Remove three solenoid/pressure switch assembly-to-case bolts (1) (Fig. 15).
3) Remove solenoid/pressure switch assembly and gasket (2).

Fig. 16 Remove Oil Pan Bolts:

4) Remove oil pan-to-case bolts (1) (Fig. 16).

Fig. 17 Remove Oil Pan:

5) Remove oil pan (1) (Fig. 17).

Fig. 18 Remove Oil Filter:

6) Remove oil filter (1) (Fig. 18).
7) Turn manual valve fully clockwise to get park rod into position for removal.

Fig. 19 Remove Valve Body Attaching Bolts:

8) Remove valve body-to-case bolts (1) (Fig. 19).

Fig. 20 Push Park Rod Rollers from Guide Bracket:

9) Using a screwdriver, push park rod rollers away from guide bracket (Fig. 20).

Fig. 21 Remove Valve Body:

10)
CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result. Remove valve body assembly (1) (Fig. 21)..

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.

Fig. 22 Remove Underdrive and OverdriveAccumulators:

11) Remove underdrive (2) (Fig. 22) and overdrive (4) accumulators.

Fig. 23 Remove Low/Reverse Accumulator SnapRing:

12) Remove low/reverse accumulator snap ring (1) (Fig. 23).

Fig. 24 Remove Low/Reverse Accumulator Plug(Cover):

13) Remove low/reverse accumulator plug (2) (Fig. 24).

Fig. 25 Low/Reverse Accumulator Piston:

14) Remove low/reverse accumulator piston (1) (Fig. 25) using suitable pliers.

Fig. 26 Low/Reverse Accumulator:

15) Remove low/reverse accumulator return springs (3) (Fig. 26).

Fig. 27 Measure Input Shaft End Play Using EndPlay Set 8266:

16) Measure input shaft end play. Place transaxle so input shaft is vertical. Set up End Play Socket Set and dial indicator (1,2) (Fig. 27). Input shaft end play should be within 0.13 - 0.64 mm (0.005 - 0.025 inch). If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.

Fig. 28 Remove Pump Attaching Bolts:

17) Remove oil pump-to-case bolts (1) (Fig. 28).

CAUTION: Be sure input speed sensor is removed before removing oil pump.

Fig. 29 Install Tool C-3752:

18) Install oil pump puller C-3752 (1) (Fig. 29).

Fig. 30 Remove Oil Pump:

19) Remove oil pump assembly (1) (Fig. 30).

Fig. 31 Remove Oil Pump Gasket:

20) Remove oil pump gasket (1) (Fig. 31).

CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.

Fig. 32 Remove Bypass Valve:

21) Remove cooler bypass valve (1) (Fig. 32).

Fig. 33 Remove Caged Needle Bearing:

22) Remove #1 needle bearing (1) (Fig. 33).

Fig. 34 Remove Input Clutch Assembly:

23) Remove input clutch assembly (1) (Fig. 34).

Fig. 35 No. 4 Thrust Plate:

24) Remove #4 thrust plate (2) (Fig. 35).

Fig. 36 Remove Front Sun Gear Assembly:

25) Remove front sun gear assembly (1) (Fig. 36) and #4 thrust washer (2).

Fig. 37 Remove Front Carrier and Rear AnnulusAssembly:

26) Remove front carrier/rear annulus assembly (2) (Fig. 37) and #6 needle bearing (1).

Fig. 38 Remove Rear Sun Gear:

27) Remove rear sun gear (2) (Fig. 38) and #7 needle bearing (1).

Fig. 39 Number 7 Bearing:

28)

NOTE: The number 7 needle bearing (1) (Fig. 39) 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 (1). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig. 40 Remove 2/4 Clutch Retainer Snap Ring:

29) Setup compressing tool 5058 (1) (Fig. 40), Compress 2/4 clutch return spring (4) Oust enough to remove snap ring) and remove snap ring (3).

NOTE: Verify that Compressing tool 5058 is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058 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.

Fig. 41 2/4 Clutch Retainer:

30) Remove 2/4 clutch retainer (1) (Fig. 41).

Fig. 42 Remove 2/4 Clutch Return Spring:

31) Remove 2/4 clutch return spring (1) (Fig. 42).

Fig. 43 Remove 2/4 Clutch Pack:

32) Remove 2/4 clutch pack (1,2) (Fig. 43). Tag 2/4 clutch pack for reassembly identification.

Fig. 44 Remove Tapered Snap Ring:

33) Remove tapered snap ring (3) (Fig. 44).

Fig. 45 Remove Low/Reverse Reaction Plate:

34) Remove low/reverse reaction plate (1) (Fig. 45).

Fig. 46 Remove One Disc:

35) Remove one low/reverse clutch disc (1) (Fig. 46).

Fig. 47 Remove Low/Reverse Reaction Plate SnapRing:

36) Remove low/reverse reaction plate snap ring (2) (Fig. 47).

Fig. 48 Remove Low/Reverse Clutch Pack:

37) Remove low/reverse clutch pack (1,2) (Fig. 48).

Fig. 49 Remove Rear Cover Bolts:

38) Remove transfer gear cover-to-case bolts (1) (Fig. 49).

Fig. 50 Remove Rear Cover:

39) Remove transfer gear cover (1) (Fig. 50).

Fig. 51 Remove Transfer Shaft Gear Nut:

40) Install holder 6259 (3) (Fig. 51).

Fig. 52 Transfer Shaft Gear Nut and Coned Washer:

41) Remove transfer shaft gear-to-shaft nut (3) (Fig. 52) and coned washer (2).

Fig. 53 Remove Transfer Shaft Gear:

42) Using Gear Puller L-4407 A,(3) (Fig. 53) remove transfer shaft gear (2).

Fig. 54 Remove Transfer Shaft Gear and (Select)Shim:

43) Remove transfer gear shim (select) (3) (Fig. 54).

Fig. 55 Remove Bearing Cup Retainer:

44) Remove bearing cup retainer (2) (Fig. 55).

Fig. 56 Remove Transfer Gear Bearing Cone:

45) Remove transfer gear bearing cone using setup using Puller Set 5048 with jaws 5048-4 and button 1-4539-2 (2) (Fig. 56).

Fig. 57 Remove Transfer Shaft Bearing Cup:

46) Remove transfer shaft bearing cup from retainer (3) (Fig. 57) using Remover 6062-A (2).

Fig. 58 Remove Transfer Shaft Bearing Snap Ring:

47) Using Snap Ring Pliers 6051,((1)) (Fig. 58) remove transfer shaft bearing snap ring (2).

Fig. 59 Remove Transfer Shaft:

48) Using the Remover/Installer 5049-A, (1) (Fig. 59) remove transfer shaft (2) from transaxle.

Fig. 60 Bearing Cup Removed:

49) Slip bearing cup retainer (1) (Fig. 60) and oil baffle (4) off of shaft.

Fig. 61 Remove Transfer Shaft Bearing Cone:

50) Using Bearing Splitter P-334,(3) (Fig. 61) press transfer shaft bearing cone (4) off of shaft (2).

Fig. 62 Remove Strap Bolts:

51) Bend output gear retaining strap (1) (Fig. 62) ears flat to allow bolt removal.
52) Remove output shaft stirrup strap bolts (3).

Fig. 63 Remove Stirrup Strap:

53) Remove stirrup (3) (Fig. 63) and strap (2).

Fig. 64 Remove Output Gear Bolt:

54) Using Holding Tool 6259 (1) (Fig. 64).

Fig. 65 Output Gear Bolt and Washer:

55) Remove output shaft gear-to-shaft bolt (2) (Fig. 65) and washer (3).

Fig. 66 Remove Output Gear:

56) Using Gear Puller 1-4407A, (4) (Fig. 66) and button 6055 (2), remove output gear (1) from shaft.

Fig. 67 Output Gear and (Select) Shim:

57) Remove output gear bearing shim (select) (2) (Fig. 67).

Fig. 68 Remove Bearing Cone:

58) Using Puller Set 5048 with jaws 5048-5 and button 1-4539-2 (1) (Fig. 68) Remove output gear bearing cone.

Fig. 69 Remove Rear Carrier Assembly:

59) Remove rear carrier assembly (1) (Fig. 69) from transaxle.

Fig. 70 Remove Rear Carrier Bearing Cone:

60) Remove rear carrier assembly (3) (Fig. 70) bearing cone using Puller Set 5048 with jaws 5048-3 and button 6055.

Fig. 71 Low/Reverse Spring Compressor Tool:

61) Install Disc 6057 (1) (Fig. 71), compressor 5059 (2) and compressor bar 5058-3 (3).

Fig. 72 Compressor Tool in Use:

62) Install low/reverse spring compressor (Fig. 72).

Fig. 73 Remove Snap Ring:

63) Compress low/reverse piston return spring and remove snap ring (1) (Fig. 73).

Fig. 74 Low/Reverse Piston Return Spring:

64) Remove low/reverse spring compressor tool and low reverse piston return spring (1) (Fig. 74).

Fig. 75 Remove Anchor Shaft and Plug:

65) Using a suitable punch, drive out park guide bracket pivot shaft plug (3) (Fig. 75).

Fig. 76 Pivot Shaft and Guide Bracket:

66) Using ordinary pliers, remove pivot shaft (3) (Fig. 76) and guide bracket assembly (2).

Fig. 77 Guide Bracket Disassembled:

67) Inspect guide bracket components for excessive wear and replace if necessary (Fig. 77).

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.