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Transmission Overhaul ProcedureTools Required
^ J35405 Differential Preload Wrench
1. Remove the breather plug O-ring and close from the transaxle case.
2. Remove the breather plug.
3. Remove the nut, washer and control shift lever from the transaxle.
4. Pry up the lock tab on the washer, then remove the retaining nut.
5. Remove the 2 PNP switch retaining bolts. then remove the switch from the transaxle.
6. Remove the 2 oil cooler unions from the transaxle.
7. Remove the O-rings from the unions.
Important: Do not turn the transaxle over to remove the oil pan as it will contaminate the valve body with foreign material within the oil pan.
8. Remove the oil pan retaining bolts, then the oil pan.
9. Place the transaxle on wooden blocks to prevent damage to the pipes.
10. Remove the 3 oil filter retaining bolts, then the oil filter and gasket.
11. Remove the bolt, manual detent spring and spring cover.
12. Disconnect the solenoid connectors.
13. Remove the 17 valve body retaining bolts.
14. Disconnect the connecting rod from the manual valve.
15. Remove the valve body from the transaxle case.
16. Remove the transaxle wiring harness retaining bolt.
17. Remove the wiring harness from the transaxle case.
18. Remove the O-ring from the harness connector.
19. Remove the check ball body and spring from the transaxle case.
20. Remove the governor apply gasket from the transaxle case.
21. Remove the brake drum gasket from the transaxle case.
22. Cover the B-2 accumulator piston with a shop towel.
23. Using compressed air at low pressure 98 kPa (14 psi) push out the B-2 accumulator piston from the transaxle case.
24. Remove the 2 O-rings from the accumulator piston.
25. Cover the C-2 accumulator piston with a shop towel.
26. Using compressed air at low pressure 98 kPa (14 psi) push out the C-2 accumulator piston from the transaxle case.
27. Remove the 2 O-rings from the accumulator piston.
28. Cover the C-1 accumulator piston with a shop towel.
29. Using compressed air at low pressure 98 kPa (14 psi) push out the C-1 accumulator piston from the transaxle case.
30. Remove the 2 O-rings from the accumulator piston.
31. Cover the C-3 accumulator piston with a shop towel.
32. Using compressed air at low pressure 98 kPa (14 psi) push out the C-3 accumulator piston from the transaxle case.
33. Remove the 2 O-rings from the accumulator piston.
34. Using a screwdriver and a hammer, unstake the spacer then remove the spacer from the transaxle case.
Important: Drive out the spring pin slowly so that it does not fall into the transaxle case.
35. Using a punch and hammer, remove the spring pin.
36. Remove the retainer spring.
37. Slide out the manual valve lever shaft, then remove the manual valve lever assembly and washer plate.
38. Using a screwdriver, remove the manual valve lever shaft oil seal.
39. Remove the 17 transaxle case bolts.
40. Separate the transaxle housings.
41. Remove the differential assembly from the transaxle case.
42. Remove the transaxle case plate bolt and transaxle case plate from the transaxle housing.
43. Remove the governor apply gasket from the transaxle case.
44. Remove the 6 oil pump assembly retaining bolts.
45. Lift out the oil pump assembly from the transaxle case.
46. Using a screwdriver, remove the O-ring from the oil pump.
47. Remove the bolt and the apply tube clamp from the transaxle case.
48. Remove the governor pressure tube from the transaxle case.
49. Apply a index mark to the piston at the point where it meets the transaxle case.
Important: If the piston stroke is not within 1.5 - 3.0 mm (0.059 - 0.118 inch). Inspect the brake band.
50. While applying and releasing compressed air at a pressure of 392 - 785 kPa (57 - 114 psi) measure the piston stroke.
51. Remove the 2nd coast brake piston snap ring.
52. Using compressed air at low pressure 98 kPa (14 psi) push out the cover into a shop towel.
53. Remove the cover, 2nd coast brake piston assembly and spring.
54. Remove the 2 O-rings from the coast brake cover.
55. Remove the direct clutch with the forward clutch from the transaxle case.
56. Remove the direct clutch from the forward clutch.
57. Remove the clutch drum thrust washer and the 2 thrust needle roller bearings from the forward clutch.
58. Pull out the 2nd coast brake band pin.
59. Remove the 2nd coast brake band assembly from the transaxle case.
60. Inspect the 2nd coast brake band assembly. If peeled, discolored, or if a part of the printed numbers (1) are defaced, replace the 2nd coast brake band assembly.
61. Remove the front planetary ring gear assembly from the transaxle case.
62. Remove the thrust bearing and thrust bearing race from the front planetary ring gear assembly.
63. Remove the front planetary gear assembly and the thrust bearing race from the transaxle case.
64. Remove the thrust bearing and the thrust bearing race from the front planetary gear assembly.
65. Using a feeler gage, measure the planetary pinion gear thrust clearance. If clearance exceeds 0.5 mm (0.020 inch), replace the front planetary gear assembly.
66. Remove the planetary sun gear sub-assembly with the sun gear input drum and planetary thrust washer from the transaxle case.
67. Remove the 1 way clutch assembly from the transaxle case.
68. Hold the sun gear (1) and turn the hub (4). The hub should turn freely clockwise (3) and should lock if turned counterclockwise (2).
69. Using compressed air, check that the 2nd brake piston moves smoothly.
70. Remove the bolt and brake band guide plate retainer and the 2nd coast brake band guide plate from the transaxle case.
71. Using a screwdriver, remove the snap ring from the transaxle case.
72. Remove the 2nd brake piston return spring assembly from the transaxle case.
73. Remove the 2nd brake piston return spring assembly from the transaxle.
74. Remove the plates, 2nd brake clutch disc and flange from the transaxle case.
75. Check the 2nd brake clutch discs. If the sliding surfaces of the discs, plates and flanges are worn, discolored, or if a part of the printed numbers (1) are defaced, replace all the discs and plates.