Part 1

Transaxle





All vehicles

1. Using the Holding Fixture 307-580, install the transaxle onto the bench.





2. NOTICE: Only thread the bolts 6 to 8 turns or do not exceed 12 mm (0.472 in) into the torque converter. If the bolts are threaded too far, damage to the torque converter clutch surface can occur causing torque converter failure.

Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter.





3. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.

Remove the torque converter from the transaxle.





4. Remove the nut and the manual lever.





5. NOTE: Note the location of the of the studbolts for assembly.

Remove the 14 bolts and the main control cover.





6. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.





7. Disconnect the TR sensor electrical connector.





8. Disconnect the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensor electrical connectors.

1. TSS sensor

2. OSS sensor





9. Remove the OSS sensor wire from the retainer.





10. NOTICE: Handle the solenoid body with care or damage to the solenoid body may occur.

NOTE: Note the location of the different length bolts for assembly.

Remove the 11 bolts and the solenoid body.





11. Remove the 10 main control valve body bolts and the valve body.





12. NOTICE: Gently pry the pin out of the hole from under the head on each side with a suitable tool or the pin may be broken off in the hole.

Using a suitable tool, remove and discard the TR sensor locking pin.





13. Remove the TR sensor.

1. Slide the TR sensor out of the transaxle case.

2. Rotate the TR sensor detent plate until it rests against the transaxle case.

3. Remove the park pawl actuator rod from the detent lever and remove the TR sensor.





14. Using a suitable tool, remove the manual lever shaft seal.





15. Using a suitable tool, remove the forward clutch feed seal.





16. Remove the bolt and the OSS sensor.





17. Remove the 10 cover assembly bolts.





18. Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transaxle case.





19. Remove the cover assembly gasket.





20. Remove the No. 1 cover assembly thrust bearing.





21. Remove the overdrive/direct clutch hub and turbine shaft assembly.





22. Remove No. 3 rear sun gear thrust bearing.





23. Remove the intermediate clutch shell and sun gear assembly.





24. Remove the intermediate clutch assembly.





25. NOTE: The location of the tab on the bottom pressure plate is aligned with the gap for the low One-Way Clutch (OWC) snap ring.

Remove the low/reverse clutch assembly.





26. Remove the rear planetary carrier and center ring gear assembly.





27. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.





28. Remove the center planetary sun gear.





29. Remove the center planetary carrier and front ring gear assembly.





30. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.





31. Remove the front planetary carrier and rear ring gear assembly.





32. Remove the front planetary sun gear and shell assembly.





33. Remove the No. 10 front sun gear thrust bearing.





34. Remove the front planetary carrier hub assembly.





35. Remove the No. 11 support assembly thrust bearing.





36. NOTE: Note the orientation of the snap ring for assembly. The snap ring gap must fit around the tab of the low/reverse clutch pressure plate.

Remove the low OWC snap ring.





37. Remove the low OWC.





38. Remove the forward clutch assembly.





39. NOTE: Install the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) with the stepped end of the cylinder facing upward when compressing the forward clutch piston return spring.

Using the Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) compress the forward clutch piston return spring.





40. NOTE: The Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) are not shown for clarity.

Remove the forward clutch piston return spring snap ring.





41. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and Forward/Intermediate Spring Compressor 307-584 (307-584/1 and 307-584/2).





42. Remove the forward clutch piston return spring.





43. Using a suitable tool, remove and discard the forward clutch piston.





44. NOTE: Note the location of the studbolts for assembly.

Remove the 19 torque converter housing bolts.





45. NOTICE: Carefully pry on the transaxle torque converter housing and the case to separate the torque converter housing from the case. Do not pry up on the silicone sealant mating surfaces, damage to the mating surfaces may occur. Carefully lift the torque converter housing off the dowel pins.

Using a suitable tool, carefully pry the torque converter housing off the transaxle case just enough to break the seal of the silicone and remove the torque converter housing from the transaxle case.





46. Remove the transaxle lube tube.





47. Remove the differential and ring gear assembly.





48. Remove the transfer shaft and gear assembly.





49. Remove the pump-to-case seal.





50. Remove the 2 bolts and the oil reservoir.