Steps 1 - 44

Special Tools:

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





Using the special tools, remove the torque converter.





2. Using the special tool, install the transaxle into the bench.

3. Note: During a case installation a new identification tag will need to be installed, use caution not to damage the tag.





Remove the identification tag.





4. Place a drain pan under the transaxle and rotate the transaxle to a vertical position.





5. Remove the filler tube.

6. CAUTION: The overdrive band servo spring cover is under spring tension. Care must be taken when removing as components may be ejected from the case.





Remove the overdrive servo piston and rod.
- Remove the bolts.
- Remove the cover.
- Remove the piston and rod.





7. Remove the Output Shaft Speed (OSS) sensor cover.





8. Remove the Output Shaft Speed (OSS) sensor.
- Unclip the harness.
- Remove the Output Shaft Speed (OSS) sensor.

9. Remove the digital TR sensor.





1 Remove the bolts.
2 Remove the digital TR sensor.

10. Remove the TSS sensor.





1 Remove the bolt.
2 Remove the sensor.

11. Note: The differential seal is a two-piece constructed seal.





Using the special tools, remove the LH differential seal.
12. Using the special tools, remove the LH differential seal metal protector.





1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the Front Cover Seal Remover.
3 Remove the metal protector from the LH differential seal and remove the protector from the tool.

13. Using the special tools, remove the rubber portion of LH differential seal.





1 Install the special tool into the LH differential seal.
2 Rotate the forcing screw while holding the Front Cover Seal Remover.
3 Remove the rubber portion of the seal.





14. Install the special tool into the RH differential seal.
15. Using the special tools, remove the RH differential seal metal protector.





1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the Front Cover Seal Remover.
3 Remove the metal protector of the seal.

16. Using the special tool, remove the rubber portion of the seal.





1 Rotate the Front Cover Seal Remover.
2 Rotate the forcing screw while holding the Front Cover Seal Remover.
3 Remove the rubber portion of the seal.





17. Using the special tools, remove the converter hub seal.





18. Remove the bolts.
19. Rotate the transaxle to a horizontal position.

20. Note: The main control cover gasket is reusable ii not torn or damaged.





Remove the bolts, main control cover and gasket.





21. For vehicles equipped with a structural side pan, remove the mount.





22. For vehicles equipped with a structural side pan, remove the bolts, and remove the pan.

23. CAUTION: Do not pull on the wires or pry on the connectors. Damage to the connector will result.





Lift the locking tab and disconnect the electrical connectors.

24. Note: The manual valve should be inserted completely.





Using a 9 mm wrench rotate the manual control lever to the low detent.

25. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body.

CAUTION: Only 4 of the 6 pump cover bolts need to be removed.





Remove the bolts.





26. Remove the main control valve body.
- Remove the pump assembly and main control valve body.
- Rotate the main control valve body while lifting off.





27. Disconnect the manual control valve actuating rod.





28. Remove the pump shaft.

29. Note: The transaxle pan gasket is reusable if not torn or damaged.





Remove the bolts, transmission fluid pan and gasket.





30. Remove, clean and inspect the magnet.





31. Remove the filter.

32. Note: Use a 3/8 inch extension so as not to damage the case while removing the fluid filter seal.





Remove the fluid filter seal.





33. Loosen the nut and remove the reverse clutch anchor pin.

34. CAUTION: The chain cover is under spring pressure. Care must be taken to prevent internal parts from being ejected.

Note: Mark bolt size and location for assembly.





Remove the bolts.

35. Note: The plastic thrust washers No. 1 and 3 may stick to the cover or to the sprockets.





Remove the chain cover and gasket.

36. Note: Tag and mark the location of the accumulator springs.





1 Remove the intermediate 1-2 accumulator outer spring.
2 Remove the direct 2-3 accumulator piston spring.
3 Remove the neutral reverse shift accumulator spring.
4 Remove the overdrive 3-4 accumulator spring .

37. CAUTION: Be careful not to damage or bend the tabs on the exciter ring or the TSS sensor will not operate.





Remove the drive sprocket, driven sprocket, and drive chain as an assembly.

38. Note: The thrust washers may remain on the sprockets.

Remove the thrust washers.





1 Remove the No. 2 thrust washer.
2 Remove the No. 4 thrust washer.

39. CAUTION: Use care not to damage the machined surface of the case.

Note: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.





Remove the roll pins.

40. Note: The position of the manual valve detent lever is different than past models. The roll pin and shoulder point toward the driven sprocket support. Note the position of the lever during disassembly for correct assembly.





Remove the manual control lever shaft.





41. Remove the parking lever actuating rod.





42. Remove the manual control lever shaft seal.

43. Note: During the complete disassembly of the transaxle, the fluid transfer tubes must be removed.





Remove the bolts and buckets.





44. Using the special tools, remove the fluid lube tubes.