Part 1

DISASSEMBLY




Figure 1 Solenoid/Pressure Switch Assembly and Gasket







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




Figure 2 Remove Oil Pan Bolts

1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)

4. Remove oil pan-to-case bolts (1) (Figure 2).




Figure 3 Remove Oil Pan






5. Remove oil pan (1) (Figure 3).




Figure 4 Remove Filter and O-Ring






6. Remove oil filter (1) (Figure 4).




Figure 5 Remove Valve Body-to-Case Bolts






7. Turn manual valve fully clockwise to get park rod into position for removal.
8. Remove valve body-to-case bolts (1) (Figure 5).




Figure 6 Push Park Rod Rollers from Guide Bracket







CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.

9. Using a screwdriver (2) (Figure 6), push park rod rollers (1) away from guide bracket (3).




Figure 7 Valve Body Removal/Installation

1 - VALVE BODY

10. Remove valve body assembly (1) (Figure 7).




Figure 8 Underdrive and Overdrive Accumulators







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) (Figure 8) and overdrive (4) accumulators.




Figure 9 Remove Low/Reverse Accumulator Snap Ring






12. Remove low/reverse accumulator snap ring (1) (Figure 9).




Figure 10 Remove Low/Reverse Accumulator Plug






13. Remove low/reverse accumulator plug (2) (Figure 10).




Figure 11 Low/Reverse Accumulator






14. Remove low/reverse accumulator (1) (Figure 11) and springs (3).




Figure 12 Measure Input Shaft End Play






15. Measure input shaft end play using End Play Socket Set 8266-8 (1) (Figure 12) 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.




Figure 13 Remove Oil Pump-to-Case Bolts






16. Remove oil pump-to-case bolts (1) (Figure 13).




Figure 14 Install Tool C-3752







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

17. Install Pullers C-3752 (1) (Figure 14).




Figure 15 Remove Oil Pump

1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

18. "Push in" on input shaft while removing pump (1) (Figure 15).




Figure 16 Oil Pump Removed






19. Remove oil pump assembly (1) (Figure 16).




Figure 17 Remove Oil Pump Gasket

1 - PUMP GASKET

20. Remove oil pump gasket (1) (Figure 17).




Figure 18 Remove Bypass Valve

1 - COOLER BYPASS VALVE

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) (Figure 18).




Figure 19 Remove No. 1 Caged Needle Bearing






22. Remove #1 needle bearing (1) (Figure 19).




Figure 20 Remove Input Clutch Assembly






23. Remove input clutch assembly (1) (Figure 20).




Figure 21 No. 4 Thrust Plate






24. Remove #4 thrust plate (2) (Figure 21).




Figure 22 Remove Front Sun Gear Assembly






25. Remove front sun gear assembly (1) (Figure 22)and #4 thrust washer (2).




Figure 23 Remove Front Carrier/Rear Annulus Assembly






26. Remove front carrier/rear annulus assembly (2) (Figure 23) and #6 needle bearing (1).




Figure 24 Remove Rear Sun Gear






27. Remove rear sun gear (2) (Figure 24).




Figure 25 Number 7 Bearing






28. Remove needle bearing (1) (Figure 25).
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.




Figure 26 Remove 2/4 Clutch Retainer Snap Ring






30. Setup Compressor 5058 (1) (Figure 26). 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.




Figure 27 2/4 Clutch Retainer







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) (Figure 27).




Figure 28 Remove 2/4 Clutch Return Spring

1 - 2/4 CLUTCH RETURN SPRING

32. Remove 2/4 clutch return spring (1) (Figure 28).




Figure 29 Remove 2/4 Clutch Pack






33. Remove 2/4 clutch pack(Figure 29). Tag 2/4 clutch pack for reassembly identification.




Figure 30 Remove Tapered Snap Ring






34. Remove tapered snap ring (3) (Figure 30).




Figure 31 Remove Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

35. Remove low/reverse reaction plate (1) (Figure 31).




Figure 32 Remove One Disc

1 - ONE DISC FROM LOW/REVERSE CLUTCH

36. Remove one low/reverse clutch disc (1) (Figure 32).




Figure 33 Remove Low/Reverse Reaction Plate Snap Ring






37. Remove low/reverse reaction plate snap ring (2) (Figure 33).




Figure 34 Remove Low/Reverse Clutch






38. Remove low/reverse clutch pack(Figure 34).