Disassembly
DISASSEMBLECAUTION: Keep all transaxle components away from dirt and other contaminants. Removed parts should be placed in a clean area, covered with a clean lint-free towel.
1. Remove torque converter from transaxle.
2. Remove transaxle drain plug and drain transaxle fluid into suitable container.
3. Use holding wire to hold torque converter one-way bearing support and turn one-way clutch with screwdriver. Ensure one-way clutch only turns clockwise. If one-way clutch rotates in both directions, replace torque converter.
4. Remove transaxle oil cooler tube from transaxle case.
5. Set manual shift linkage rod to Park position.
6. Remove Manual Lever Position (MLP) switch.
7. Remove transaxle oil pan bolts and the oil pan. Discard oil pan bolts and gasket.
8. Mark position of oil pan magnets, then remove and clean both magnets.
9. Remove and discard transaxle oil filter and gaskets.
Valve Body Bolt Removal:
10. Remove valve body bolts a, b, and c.
11. Remove spring clip from valve body wiring harness grommet.
12. Slide valve body wiring harness through transaxle case.
13. Remove main control valve body.
14. Remove D-R accumulator return spring from D-R accumulator piston.
Accumulator Piston Removal:
15. Apply compressed air to D-R accumulator piston to remove it from bore.
16. Remove and discard two upper accumulator seals from D-R accumulator piston.
17. Apply compressed air to N-D accumulator piston to remove it from bore.
18. Remove and discard two upper accumulator seals from N-D accumulator piston.
19. Inspect accumulator pistons and contact surfaces for wear or damage.
20. Remove N-D piston spring from its bore.
21. Remove four 0-rings from transaxle case. Discard 0-rings.
Low/Reverse Clutch Apply Oil Transfer Tube Bolt Removal:
22. Remove low/reverse clutch apply oil transfer tube and seal.
23. Remove torque converter housing to transaxle case bolts.
24. Lightly tap on torque converter housing with soft hammer to separate from transaxle case.
25. Remove differential oil port 0-ring from differential oil port. Discard 0-ring.
26. Remove differential from transaxle case.
27. Use impact slide hammer tool No. T50T-100-A, or equivalent stator and driven sprocket bearing remover tool No. T86P-70043-A, and adapter or equivalent to remove differential bearing outer race from transaxle case.
28. Remove differential bearing shim from transaxle case.
Differential Side Bearing Outer Race Removal:
29. Use impact slide hammer tool No. T50T-10O-A or equivalent, stator and driven sprocket bearing remover tool No. T86P-70043-A, and adapter or equivalent, to remove differential side bearing outer race from torque converter housing.
30. Use seal remover and impact slide hammer tool No. T50T-100-A or equivalent to remove differential oil seal from torque converter housing.
31. Remove differential lubricant tube from torque converter housing.
32. Remove and discard input shaft 0-ring.
33. Remove eight oil pump bolts, then lift oil pump assembly and baffle plate from torque converter housing.
NOTE: The 3-4 clutch drum bearing race may not come out with the oil pump assembly. If it does, remove reverse clutch drum thrust washer and the 3-4 clutch drum bearing race at this time.
34. If reverse clutch drum thrust washer and 3-4 clutch drum bearing race are not removed with oil pump assembly, remove washer and bearing race from transaxle.
35. While holding band adjustment stop, loosen band adjusting stop locknut.
36. Remove band adjusting stop, washer, and locknut.
37. Remove 2-4 band and strut from transaxle case. Secure 2-4 band with a band retaining clip or mechanic's wire.
38. Remove four 2-4 servo piston retainer bolts, then the 2-4 servo piston retainer and gasket.
39. Remove 2-4 servo assembly from transaxle case by applying compressed air.
40. Remove input shaft along with 3-4 clutch/reverse clutch assembly.
41. Remove reverse clutch assembly from input shaft and 3-4 clutch assembly.
42. Remove 3-4 clutch drum and input shaft upper thrust washer and the 3-4 clutch hub bearing from 3-4 clutch drum and input shaft.
43. Remove input shaft along with 3-4 clutch/reverse clutch assembly.
44. Remove reverse clutch assembly from input shaft and 3-4 clutch assembly.
45. Remove 3-4 clutch drum and input shaft along with 3-4 clutch/reverse clutch assembly.
46. Remove reverse clutch assembly from input shaft and 3-4 clutch assembly.
47. Remove 3-4 clutch drum and input shaft upper thrust washer and 3-4 clutch hub bearing from 3-4 clutch drum and input shaft.
48. Remove 3-4 clutch hub and primary sun gear upper thrust washer from 3-4 clutch hub.
49. Remove primary sun gear bearing race from top of primary sun gear.
50. Remove primary sun gear lower thrust washer from the front planetary gear.
51. Use screwdriver to remove low one-way clutch pressure plate retainer snap ring.
52. Turn transaxle over.
CAUTION: Hold one-way clutch to ensure it does not fall on the ground.
53. Rotate front planetary gear and remove low one-way clutch. If low one-way clutch does not slide out, tap transaxle case with plastic hammer to remove.
Exploded View Of Low/Reverse Clutch:
54. Turn transaxle case back over and use screwdriver to remove low/reverse clutch piston pressure plate retainer snap ring. Refer to the Exploded View Of Low/Reverse Clutch image when disassembling low/reverse clutch.
55. Remove front planetary gear and low/reverse clutch piston assembly.
56. Remove low/reverse clutch piston spring retainer from low/reverse clutch piston.
57. Remove rear sun gear front thrust bearing and low/reverse clutch piston assembly from front planetary gear.
58. Remove rear planetary gear assembly from transaxle case.
59. Remove rear sun gear from rear planetary gear.
60. Remove two thrust bearings from rear planetary gear.
61. Remove forward clutch hub and ring gear assembly from transaxle case.
62. Remove coasting clutch hub from transaxle case.
63. Remove forward clutch hub upper thrust washer from coasting clutch hub.
64. Remove forward clutch hub assembly from transaxle case.
65. Remove forward clutch hub assembly lower thrust washer from transaxle case.
66. Use screwdriver to remove low/reverse clutch pressure plate retainer snap ring from transaxle case.
67. Remove low/reverse clutch pressure plate, low/reverse dish plate, seven low/reverse internal spline clutch plates, and eight low/reverse external spline clutch plates.
68. Remove side cover bolts.
NOTE: Two types of bolts are used to attach side cover to transaxle case. Identify placement of B bolts for installation, and discard side cover A bolts.
69. Remove side cover by lightly tapping it with rubber hammer.
NOTE: Output shaft assembly may drop out when side cover is removed.
70. Remove output shaft bearing selective shim.
71. Remove output shaft assembly if it was not removed with side cover.
72. Remove output shaft hub thrust washer.
73. Use Torx T-40 bit to remove output shaft bearing retainer bolts, then remove output shaft bearing retainer.
74. Remove lubrication circuit seal rings from output shaft and bearing retainer. Discard seal rings.
75. Move manual shift linkage rod into Park position to lock idle gear.
NOTE: Do not remove idler gear, idler gear shaft, or reduction gear unless idler or reduction gear is worn or if bearings are worn.
76. Use mainshaft locknut staking tool No. T77J-7025-F, or equivalent, to unstake locknut, then remove and discard locknut.
77. Use slide hammer adapter tool No. T81P-78103-A, or center bolt from output shaft seal remover tool No. T86T-7034-AH, or equivalent, and bolts (part of shim selection set No. T88C-77000-JF to remove idler gear.
78. Remove reduction gear from transaxle case.
79. Remove reduction gear bearing adjusting shim from reduction gear.
80. Use adapter and puller tool No. T58L-101-B or equivalent and stator and driven sprocket bearing replacer tool No. T86P-70043-A or equivalent, to remove idler gear bearing outer race from transaxle case.
81. Remove reduction gear bearing outer race.
82. Use screwdriver to remove parking pawl shaft and parking pawl.
83. Remove parking pawl shaft from transaxle case.
84. Remove two parking actuator support bolts, then the parking actuator support.
85. Remove manual detent spring from transaxle case.
86. Use pin punch to drive manual detent lever inner pin from manual detent lever. Discard pinch
87. Use locknut pin remover to remove park actuator support roll pinch Discard pin.
Exploded View Of Manual Shift Linkage:
88. Remove park actuator support from manual shift linkage rod. Refer to the Exploded View Of Manual Shift Linkage image when disassembling manual shift linkage.
89. Remove parking lever actuating rod from transaxle case.
90. Pull manual shift linkage rod roll pin from transaxle case. Discard pin.
91. Remove manual shift linkage rod and manual detent lever from transaxle case.
92. Use adapter from puller tool No. T58L-101-B, or equivalent, and impact slide hammer to remove manual control lever oil seal.
93. Use seal remover and impact slide hammer to remove differential oil seal from transaxle case.