Step 1-40

Special Tools:

1. Inspect transaxle during disassembly.

CAUTION: In the case of abraded particles of metal, replace the valve body, fluid pipes, fluid cooler and torque converter.

NOTE:
- Clean the transmission assembly to prevent the entry of dirt when reassembling.
- Do not clean brake band and friction plates with cleaning agents.
- If, during repair work, abraded particles are found in the transmission fluid (particles from the clutch or metal chips or debris), the transmission must be disassembled completely and cleaned. Also, clean fluid pipes, fluid cooler and torque converter carefully; in case of extreme soiling the fluid pipes, fluid cooler and torque converter should be replaced.
- In case of clutch abrasion, rinse the torque converter with clean automatic transmission fluid.
- Before taking measurements, compress all the clutches where axial play is detected to squeeze the oil out from between the plates.

2. Remove the Torque Converter Holding Tool.

3. Remove the torque converter using Torque Converter Handles.

CAUTION: Do not tilt the torque converter when removing it to avoid damaging the torque converter hub.

NOTE: The torque converter is filled with fluid. Position it on a table so that fluid will drain out of the torque converter into a drain pan.

4. Secure the transaxle to Bench Mounted Holding Fixture.

5. Position the drain pan under the transaxle, remove the drain plug, and drain the transmission fluid.

6. Remove the pump assembly driveshaft.

7. Remove and discard the torque converter impeller hub seal.

8. Remove the LH and RH differential seals.
1 Install Converter Seal Remover.
2 Install Impact Slide Hammer.
3 Remove and discard the differential seals.

9. Remove the Turbine Shaft Speed (TSS) sensor.
1 Remove the bolt.
2 Remove the TSS sensor.

10. Remove and discard the TSS sensor O-ring.

11. Remove the transaxle fluid filler tube bolt.

12. Remove the transaxle fluid filler tube.

13. Remove and discard the transaxle filler tube grommet.

14. Remove the speedometer driven gear assembly.
1 Remove the bolt and clamp.
2 Remove the speedometer driven gear assembly.

NOTE: Before removing the speedometer driven gear, position the transaxle with the pump facing downward.

15. Remove and discard the speedometer driven gear O-ring.

16. Remove the speedometer driven gear from its bore, and inspect the speedometer driven gear for nicks, chips or wear (replace if necessary).

NOTE: This transaxle uses a speedometer driven gear that can be taken apart.

17. Remove the Transmission Range (TR) sensor.
1 Remove the bolts.
2 Remove the TR sensor from the manual valve detent lever shaft.

18. Remove the main control cover bolts, and cover.

19. Remove and discard the gasket.
20. Inspect the main control vent tube nipple for blockage.

21. Remove the solenoid body assembly wiring harness retaining clip.

22. Remove the twelve main control bolts.

23. Disconnect the Z-link from the manual valve when lifting the main control valve body from the case.

CAUTION: Do not allow loose manual valve to become damaged.

24. Remove the solenoid body electrical connector.
1 Release the retaining tabs and push the connector through the transaxle case.
2 Remove and discard the electrical connector O-ring.

CAUTION: Do not pull on solenoid body electrical connector wires, or use a hammer on the electrical connector.

25. Support the manual valve and remove the main control.
- Store the main control in a clean, dry location.

26. Remove the thermostatic fluid level control valve bracket.
1 Remove the bolt.
2 Remove the bracket.

27. Remove the thermostatic fluid level control valve.

28. Remove the forward clutch circuit filter (if equipped).

29. Assemble Servo Cover Remover/Replacer.

WARNING: THE SERVO IS UNDER PRESSURE.

WARNING: SERVO AND SERVO COVER ARE UNDER HIGH SPRING FORCE. USE CAUTION WHEN REMOVING SERVO COVER. FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN PERSONAL INJURY.

NOTE: To aid in the removal of the servo cover, install a nut with an integral washer N621943-S2 (using permanent thread sealer) onto the forcing bolt of the servo cover.

30. Remove the servo assembly.
1 Install the tool.
2 Compress the servo assembly by tightening the bolt.
3 Remove the retaining ring
31. Remove the servo cover assembly.
32. Remove the intermediate and overdrive servo piston and return spring.

33. Inspect the intermediate and overdrive servo assembly and bore for damage or wear.
1 Servo cover with integral seal.
2 Servo return spring.
3 Servo apply rod.
- Case servo bore.

34. Remove the twenty torque converter housing to transaxle case bolts.

NOTE: Position the transaxle with the torque converter housing facing upward.

35. Separate the torque converter housing from the transaxle case.
- Remove and discard the transaxle split flange gasket.

NOTE: Place the torque converter housing on the engine flange side after removal to prevent damage to the lube tube.

36. Remove the speedometer drive gear.
1 Remove the differential bearing(number 15).
2 Remove the differential bearing shim (number 14).
3 Remove the speedometer drive gear.

37. Remove the final drive carrier and differential assembly.

38. Unsnap and remove the chain pan cover.

39. Remove the driven sprocket thrust bearing (number I3).

40. Remove the driven sprocket thrust washer from the reverse/overdrive ring gear assembly (number 10).

NOTE: The driven sprocket thrust washer may adhere to the converter housing.