Part 1
Transaxle - Overhaul
Disassembled Views
All vehicles
1. Using the Holding Fixture 307-580, install the transaxle onto the bench.
2. Remove the Torque Converter Retainer 307-346.
3. 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.
4. NOTICE: The torque converter is heavy. Be careful not to drop it or damage will result.
Remove the torque converter from the transaxle.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur. Use only clean transmission fluid designated for the transaxle and torque converter being serviced.
Clean and inspect the torque converter for damage.
1. Inspect the sealing surface for a groove worn from the seal. Install a new torque converter if necessary.
2. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transaxle assembly or fluid contamination due to the following transaxle or converter failure modes.
- Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
3. If none of the above conditions are present, continue with the following fluid inspection.
4. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter.
5. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
6. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transaxle damage will occur.
If the fluid passed inspection:
- drain the remaining fluid from the torque converter.
- using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand.
- thoroughly drain the fluid.
6. NOTE: Note the location of the of the studbolts for assembly.
Remove the 14 bolts and the main control cover.
7. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.
8. Disconnect the TR (Transmission Range) sensor electrical connector.
9. Disconnect the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensor electrical connectors.
1. TSS (Turbine Shaft Speed) sensor
2. OSS (Output Shaft Speed) sensor
10. Remove the OSS (Output Shaft Speed) sensor wire from the retainer.
11. 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.
12. Remove the 10 main control valve body bolts and the valve body.
13. Clean and inspect the main control valve body for damage. If damage is found install a new main control valve body. If the main control valve body is not damaged, disassemble the main control valve body and clean it. For additional information, refer to Main Control- Overhaul .
14. Remove the forward clutch feed seal.
15. Remove the bolt and the OSS (Output Shaft Speed) sensor.
16. Remove the 10 cover assembly bolts.
17. Remove the cover assembly and carefully route the TSS (Turbine Shaft Speed) sensor wiring harness and electrical connector out of the transaxle case.
18. Remove the cover assembly gasket.
19. Remove the No. 1 cover assembly thrust bearing.
20. Remove the overdrive/direct clutch hub and turbine shaft assembly.
21. Remove No. 3 rear sun gear thrust bearing.
22. Remove the intermediate clutch shell and sun gear assembly.
23. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, as necessary.
- Gear teeth
- Shell-to-clutch pack surfaces
- Thrust bearing surfaces
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. Clean and inspect the rear planetary gear carrier assembly for damage or wear and install new, as necessary.
- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Spline teeth
- Thrust bearing
- Thrust bearing surfaces
- Ring gear teeth
28. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
29. Remove the center planetary sun gear.
30. Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary.
- Sun gear teeth
- Spline teeth
31. Remove the center planetary carrier and front ring gear assembly.
32. Clean and inspect the center planetary gear carrier assembly for damage or wear and install new, as necessary
- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Thrust bearing surfaces
- Ring gear teeth
33. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
34. Remove the front planetary carrier and rear ring gear assembly.
35. Clean and inspect the front planetary gear carrier assembly for damage or wear and install new, if necessary.
- Spline teeth
- Thrust bearing surfaces
- Ring gear teeth
- Shell-to-clutch pack surfaces
- Pinion gear teeth
- Pinion gear surfaces
- Pinion gear bearings
- Thrust bearing
