Disassembly

Transaxle





1. Install the Holding Fixture 307-625.





2. Using the Holding Fixture 307-625, install the transaxle on a bench-mounted holding fixture.





3. Remove the Torque Converter Retainer 307-566.





4. Install the Torque Converter Handle 307-091.





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

Using Torque Converter Handle 307-091, remove the torque converter from the transaxle.





6. NOTE: Note the location of the stud bolts for assembly.

Remove the 13 bolts and the main control cover.





7. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.





8. Disconnect the Transmission Range (TR) sensor electrical connector.





9. Remove the solenoid body-to-main control cover grommet.





10. NOTE: Note the location of the short and long main control bolts for reassembly.

Remove the nut and the 22 Torx bolts and remove the main control assembly.





11. Remove and discard the main control-to-transaxle case separator plate.





12. Remove and discard the forward (1, 2, 3, 4) clutch and low/reverse clutch transaxle case-to-center support seals.

1. Forward (1, 2, 3, 4) clutch transaxle case-to-center support seal.

2. Low/reverse clutch transaxle case-to-center support seal.





13. Remove the internal cooler bypass spring, sleeve and valve.





14. Remove the bolt and the Turbine Shaft Speed (TSS) sensor.





15. Remove the bolt and the TR sensor detent spring.





16. Remove the bolt and the OSS sensor.





17. NOTE: Note the location of the stud bolts for assembly.

Remove the 17 torque converter housing bolts.





18. Using a suitable tool, pry the torque converter housing loose from the transaxle case.





19. Remove the torque converter housing loose from the transaxle case.





20. Remove the No. 15 differential thrust bearing.





21. Remove the differential.





22. Remove the differential planetary sun gear.





23. Remove the No. 13 thrust washer.





24. Remove the No. 11 drive sprocket thrust bearing.





25. Simultaneously remove the drive and driven sprockets and the chain.





26. Remove the No. 12 driven sprocket thrust bearing.





27. Remove the No. 10 front sun gear and shell assembly thrust bearing.





28. Remove the 2 bolts and the transmission fluid reservoir hold-down bracket.





29. Remove the transmission fluid reservoir.





30. Remove the transmission fluid baffle.





31. Remove the park pawl pin and spring.





32. Remove the park pawl.





33. NOTE: The forward (1, 2, 3, 4) clutch snap ring is beveled. The beveled side of the snap ring goes up (flat side down).

NOTE: The forward (1, 2, 3, 4) clutch snap ring gap faces the front of the transmission.

Remove the forward (1, 2, 3, 4) clutch snap ring.





34. Remove the forward (1, 2, 3, 4) clutch pressure plate, clutch assembly and wave spring.





35. Remove the front sun gear and shell assembly.





36. Remove the front planetary carrier/rear ring gear assembly.





37. Remove the No. 7 and No. 8 thrust bearings.

1. No. 7 thrust bearing

2. No. 8 thrust bearing





38. Remove the center planetary carrier/front ring gear assembly.





39. Remove the center planetary sun gear.





40. Remove the No. 5 and No. 6 thrust bearings.

1. No. 5 thrust bearing

2. No. 6 thrust bearing





41. Remove the center support assembly.





42. Remove the rear planetary carrier/center ring gear assembly.





43. Remove the low/reverse wave spring, clutch pack and pressure plate.





44. Remove the low One-Way Clutch (OWC).





45. NOTE: The intermediate (2, 6) clutch is removed with the rear planetary sun gear and shell assembly.

Remove the rear planetary sun gear and shell assembly and remove the intermediate (2, 6) clutch from the assembly.





46. Remove the pressure plate and the wave spring.





47. Remove the No. 3 thrust bearing.





48. Remove the overdrive/direct clutch assembly.





49. NOTE: If the No. 1 thrust bearing stuck to the overdrive/direct clutch assembly, remove the No. 1 thrust bearing from the overdrive/direct clutch assembly.

Remove the No. 1 thrust bearing.





50. Remove the intermediate (2, 6) clutch apply ring.





51. Remove the 3 bolts and the clutch support tower.





52. NOTE: Note the location of the snap ring gap for assembly.

Remove the intermediate (2, 6) clutch return spring snap ring.





53. NOTE: Note the position of the return spring for assembly.

Remove the intermediate (2, 6) clutch return spring.





54. NOTE: Note the position of the intermediate clutch piston for assembly.

Remove the intermediate (2, 6) clutch piston.





55. Remove and discard the 5 clutch feed seals.





56. Remove the nut and the manual lever from the manual shaft.





57. NOTICE: Do not drive the roll pin through the manual shaft. The roll pin will contact the transaxle case causing damage to the transaxle case.

Using Roll Pin Remover 211-061, pull the roll pin out of the manual shaft.





58. Remove the manual shaft.





59. Remove the TR sensor and the park pawl actuator rod and remove the park pawl actuator rod from the TR sensor.





60. Using a suitable tool, remove and discard the manual shaft seal.





61. Using a suitable tool, remove and discard the LH halfshaft seal.





62. NOTE: Press the bushing out of the transaxle case from the outside to the inside so that the transaxle case rests on a flat surface.

Using the Wheel Speed Sensor Ring Installer 206-084/2 and a suitable press, remove and discard the LH transaxle case bushing from the transaxle case.





63. Remove the 2 bolts and the oil baffle from the torque converter housing.





64. NOTE: Note the location of the 6-mm bolt for assembly.

Remove the 9 bolts and the pump and filter assembly.





65. Remove the differential ring gear snap ring.





66. Remove the differential ring gear.





67. Using a suitable tool, remove and discard the RH halfshaft seal.