1 - 48
Transmission Disassemble
^ Tools Required
- DT 46451 (DW240-020) Brake/Clutch Spring Compressor
- DT 46454 (DW240-050) Overdrive Brake Adapter
- DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut
- DT 46457 (DW240-070) 1st and Reverse Brake Adapter
- DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter
- DT 46465 (DW240-170) Adapter Handle
- DT 46453 (DW260-021) Automatic Transaxle Overhaul Fixture
- DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket
Disassembly Procedure
1. Remove the transaxle assembly from the vehicle.
2. Install the transaxle assembly to the transaxle support stand using the DT 46453 (1).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the 2 bolts and nut and pull out the park/neutral position (PNP) switch.
6. Remove the 2 unions the transaxle case.
7. Remove the 2 O-rings from the unions.
8. Remove the screw plug from the transaxle case.
9. Remove the O-ring from the screw plug.
10. Remove the bolt and the input shaft speed (ISS) sensor.
11. Remove the breather plug.
12. Remove the O-ring from the breather plug.
13. Remove the bolt and the output shaft speed (OSS) sensor.
14. Remove the 18 bolts.
15. Remove the oil pan and gasket.
16. Remove the drain plug from the oil pan.
17. Remove the 3 bolts and oil strainer.
18. Remove the gasket from the oil strainer.
19. Remove the bolt and transmission fluid temperature sensor with the clamp.
20. Disconnect the 5 solenoid connectors.
^ Lock-up control solenoid (5)
^ Pressure control solenoid (1)
^ No. 2 shift solenoid (2)
^ No. 1 shift solenoid (3)
^ Timing solenoid (4)
21. Support the valve body assembly and remove the 14 bolts.
22. Disconnect the manual valve control rod from the manual valve lever, then remove the valve body assembly.
23. Remove the check valve and spring.
24. Remove the brake drum gasket.
25. Remove the apply gasket.
26. Notice:
Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice.
Important:
^ Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
^ Take care not to splash automatic transaxle fluid (ATF) when air-blowing.
Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the direct clutch accumulator piston and spring.
27. Remove the spring.
28. Remove the 2 O-rings (1) from the direct clutch accumulator piston.
29. Notice:
Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice.
Important:
^ Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
^ Take care not to splash ATF when air-blowing.
Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the forward clutch accumulator piston and spring.
30. Remove the spring.
31. Remove the 2 O-rings (1) from the forward clutch accumulator piston.
32. Notice:
Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice.
Important:
^ Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.
^ Take care not to splash ATF when air-blowing.
Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the over drive (O/D) and 2nd brake clutch accumulator piston and spring.
33. Remove the 2 O-rings (1) from the O/D and 2nd brake accumulator piston.
34. Remove the bolt and the transaxle wire from the transaxle case.
35. Remove the O-ring (1) from the transaxle wire.
36. Important:
Be careful not to drop the differential gear assembly when the transaxle housing is removed.
Remove the 16 bolts and tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
37. Using a dial indicator, measure the input shaft end play.
The end play is 0.3 - 0.9 mm (0.012 - 0.035 inch).
38. Remove the 6 bolts and oil pump.
39. Remove the differential gear assembly from the transaxle case.
40. Remove the apply gasket.
41. Remove the direct clutch assembly from the transaxle case.
42. Remove the thrust needle roller bearing from the direct clutch assembly.
43. Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case.
44. Remove the counter driven gear assembly from the transaxle case.
45. Remove the 9 bolts and tap on the circumference of the transaxle rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
46. Remove the 4 apply gaskets.
47. Remove 2nd coast and O/D brake flange (1), 2 discs (2), and 2 plates (3) from the transaxle case.