Part 1

Transmission Overhaul Procedure
1. Remove the bolt and the speedometer driven hole cover.





2. Remove the nut, washer and control shift lever from the transaxle.
3. Pry up the lock tab on the washer, then remove the retaining nut.
4. Remove the 2 park neutral position (PNP) switch retaining bolts, then remove the switch from the transaxle.





5. Remove the bolt and the input shaft turbine sensor from the transaxle case.





6. Remove the breather plug, O-ring and hose from the transaxle case.
7. Remove the breather plug.





8. Remove the outlet oil cooler union from the transaxle.
9. Remove the O-rings from the union.





10. Remove the inlet oil cooler union from the transaxle.
11. Remove the O-rings from the union.





12. Remove the 4 transaxle case No.1 plugs from the transaxle housing and transaxle case.





13. Remove the transaxle case No.1 plug from the transaxle cases.
14. Remove the 5 O-rings from the transaxle case.





15. 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.

Place the transaxle on 2 blocks of wood.





16. Remove the oil pan retaining bolts, then the oil pan.





17. Remove the 3 oil filter retaining bolts, then the oil filter and gasket.





18. Remove the O-ring from the oil filter.





19. Disconnect the 5 solenoid connectors.
20. Remove the bolt, lock plate and automatic transmission fluid (ATF) temperature sensor.





21. Remove the 2 bolts, manual detent spring and spring cover.





22. Remove the 13 valve body retaining bolts.
23. Remove the valve body from the transaxle case.





24. Remove the transaxle wiring harness retaining bolt.
25. Remove the wiring harness from the transaxle case.
26. Remove the O-ring from the harness connector.





27. Remove the transaxle case 2nd brake gasket.





28. Remove the transaxle case gasket.





29. Remove the brake drum gasket.





30. Remove the check ball body and spring from the transaxle case.





31. Cover the B-2 accumulator piston with a shop towel.
32. Using compressed air at low pressure 392 kPa (57 psi) push out the C-3 accumulator piston from the transaxle case.
33. Remove the accumulator spring from the transaxle case.





34. Remove the 2 O-rings from the accumulator piston.





35. Cover the C-3 accumulator piston with a shop towel.
36. Using compressed air at low pressure 392 kPa (57 psi) push out the C-3 accumulator piston from the transaxle case.
37. Remove the accumulator spring from the transaxle case.





38. Remove the 2 O-rings from the accumulator piston.





39. Cover the C-2 accumulator piston with a shop towel.
40. Using compressed air at low pressure 392 kPa (57 psi) push out the C-2 accumulator piston from the transaxle case.
41. Remove the accumulator spring from the transaxle case.





42. Remove the 2 O-rings from the accumulator piston.





43. Remove the 14 bolts.

44. Important: Remove the transaxle housing slowly so the differential gear does not drop out of the transaxle case.

Tap around the transaxle housing with a soft faced hammer to remove the transaxle housing from the transaxle case.





45. Remove the 2 bolts and transaxle housing oil separator from the transaxle housing.





46. Remove the retaining bolt.
47. Remove the bearing lock plate from the transaxle case.





48. Remove the bolt and differential gear lube apply tube from the transaxle housing.





49. Using a bearing puller, remove the front drive pinion roller bearing from the transaxle housing.





50. Important: If the end play is not within 0.37-1.29 mm (0.0146-0.0508 inch), replace the thrust roller bearing.

Using a dial indicator, measure the end play of the input shaft.





51. Remove the 7 oil pump assembly retaining bolts.
52. Remove the oil pump assembly from the transaxle case.





53. Remove the differential gear assembly from the transaxle case.





54. Using a screwdriver, remove the 2 O/D brake gaskets from the transaxle case.





55. Remove the input shaft assembly from the transaxle.





56. Remove the stator shaft thrust roller bearing from the input shaft assembly.





57. Remove the forward clutch hub thrust roller bearing from the forward clutch hub.





58. Remove the forward clutch hub sub-assembly from the transaxle case.





59. Remove the 11 transaxle rear cover retaining bolts.
60. Tap on the circumference of the transaxle cover with a soft faced hammer to remove the transaxle rear cover from the transaxle case.





61. Remove the 4 transaxle case gaskets.





62. Using a magnet, remove the rear clutch drum thrust roller bearing.





63. Remove the intermediate shaft assembly from the transaxle case.





64. Remove the 2nd coast and overdrive brake flange, two 2nd coast and overdrive brake discs and two 2nd coast and overdrive brake flanges from the transaxle.





65. Check the 2nd coast and overdrive brake discs, plates and flanges. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flanges.





66. Using a magnet, remove the C-2 hub thrust bearing race, thrust roller bearing race from the direct clutch hub.





67. Remove the direct clutch hub from the transaxle case.





68. Using a magnet, remove the rear planetary sun gear No.2 thrust bearing from the rear planetary sun gear assembly.





69. Remove the rear planetary sun gear assembly from the transaxle case.





70. Remove the rear planetary sun gear thrust roller bearing and thrust washer No. 1 from the rear planetary sun gear.





71. Hold the rear planetary sun gear (1) and turn the 1 way clutch. The 1 way clutch should turn freely clockwise (2) and should lock if turned counterclockwise (3).





72. Remove the 1 way clutch assembly and planetary carrier thrust washer No. 2 from the rear planetary sun gear.





73. Using a screwdriver, remove the 2nd coast and overdrive brake flange snap ring from the transaxle case.





74. Using a screwdriver, remove the 2nd brake disc snap ring.
75. Remove the flange, 3 discs and 3 plates from the transaxle case.





76. Check the 2nd brake discs, plates and flanges. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flanges.





77. Remove the 2nd brake piston sleeve from the transaxle case.





78. Install the 1 way clutch and thrust washer on the rear planetary sun gear.
79. Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely counterclockwise (1) and should lock counterclockwise (2).





80. Using a screwdriver, remove the rear planetary gear assembly snap ring.
81. Remove the rear planetary gear assembly from the transaxle case.