Part 1
GENERAL NOTES1. Disassemble the transaxle in a clean area (dust proof work space) to prevent the entry of dust into the mechanism.
2. Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during disassembly.
3. Use only plastic hammers when applying force to separate the light alloy case joints.
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
5. Several parts look alike; organize them so they do not get mixed up.
6. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burnt or when the ATF has degenerated.
CLEANING NOTES
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and verify that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
Part 1 Of 4:
Part 2 Of 4:
Part 3 Of 4:
Part 4 Of 4:
PROCEDURE
1. Remove the torque converter from the transaxle. Drain the fluid from converter.
2. Remove the oil pump shaft by pulling it from the end of the turbine shaft.
3. Install the Special Service Tools (SSTs) or equivalent on the transaxle case. Position a drain pan under the transaxle.
4. Remove the drain plug from the transaxle case. Allow the transaxle to drain completely.
5. Remove the turbine shaft speed sensor mounting bolt.
6. Pull the sensor from the bore.
7. Remove the O-ring seal. Discard the O-ring seal.
8. Remove the two transaxle range switch mounting bolts.
9. Pull the transaxle range switch from the shaft.
10. Use the SSTs or equivalent to remove the RH and LH differential seals. Check the seal contact surfaces on the LH joint shaft and the RH drive shaft for excessive wear.
NOTE: Do not remove the stator support bolts behind the impeller hub seal.
11. Use the SSTs or equivalent to remove the torque converter impeller hub seal. Check the seal contact surface on the torque converter impeller hub for excessive wear.
12. Remove the oil filler tube mounting bolt.
13. Pull the tube from the bore.
14. Remove the tube seal grommet.
15. Remove the vehicle speedometer sensor bolt.
16. Remove the sensor from the bore.
17. Remove the O-ring seal from the sensor. Discard the O-ring seal.
18. Remove the fourteen control valve body cover-to-transaxle case bolts.
19. Pull the cover from the transaxle case.
20. Separate the cover from the gasket. Discard the gasket.
21. Inspect the vent and grommet.
22. Remove the twelve control valve body assembly mounting bolts shown.
CAUTION: Do not allow the loose manual valve to become damaged.
23. Pull the control valve body slightly away from the transaxle case. Disconnect the Z-link from the manual valve.
CAUTION: Do not pull on the connector wires or use a hammer on the connector.
24. Squeeze the retainer tabs of the solenoid body connector and remove the connector from the bore in the case.
25. If seepage is found around the solenoid body connector area, inspect the O-ring for damage and discard it.
26. Remove the control valve body from the transaxle and store it in a clean location.
27. Remove the thermostatic oil level valve bracket bolt. Remove the bracket. Remove the filter from the forward clutch circuit.
28. Pull the thermostatic oil level valve from the transaxle case.
29. If equipped, remove the cap from the 2/4 servo assembly by using the SST. Discard the cap.
SST 49 UN01 104 Servo Cover Remover Replacer:
30. Install a nut with an integral washer onto the forcing bolt of the servo cover remover/replacer tool with a permanent thread sealer. This nut and washer will aid in the installation of the cover.
WARNING: The servo cover is under high spring pressure.
31. Attach the SST or equivalent to the pump.
32. Screw in the bolt to compress the servo cover and remove the retaining ring.
33. Remove the SST.
34. Remove the servo cover from the bore.
35. Remove the 2/4 servo assembly.
36. Position the transaxle so the converter housing faces up.
37. Remove the twenty converter housing-to-transaxle case bolts.
38. Separate the converter housing from the transaxle case.
39. Remove the split flange gasket from the converter housing. Discard the split flange gasket.
40. Remove the #15 differential bearing.
41. Remove the #14 differential bearing shim (selective fit) from the differential case.
42. Remove the speedometer drive gear from the differential case.
43. remove the final drive carrier/differential case.
44. Remove the front part of the chain cover by unsnapping it from the rear part.
45. Remove the #13 driven sprocket thrust bearing.
NOTE: The thrust washer may be attached to the converter housing.
46. Remove the #10 drive sprocket thrust washer (selective fit) from the drive sprocket.
WARNING: Wear gloves as personal protection from the sharp chain and sprocket teeth.