Part I
Transmission
Special tools, testers and auxiliary items required
• End Play Socket Set (8266A)
• Dial Indicator
• Oil Pump Puller (C-3752)
• Compressing Tool (5058A)
• Holder (9739)
• Button (6055)
• Puller Set (5048)
• Jaws (5048-5)
• Button (L 4539-2)
• Puller Set (C-293-PA)
• Adapter (9738)
• Plug (9678)
• Jaws (5048-3)
• Button (6055)
• Disc (6057)
• Compressor (5059A)
• Compressor bar (5058-3)
• Remover (6062A)
• Puller Adapter (9908)
• Remover (8913)
• Kukko Support (22/2)
• Remover (8912)
• Installer (5050A)
• Installer (6053)
• Driver Handle (C-4171)
• Gear Checking Plate (L-4432)
• Bolts (6260)
• Puller (L-4407A)
• Dial Indicator Rod (6268)
• Turning Torque Tool (9735)
• Installer (9730)
• Differential Bearing Torque Tool (C-4995A)
• End Play Tool (9951)
• Installer (6756)
• Staking Tool (9721)
• Seal Installer (MD998334)
Disassembly
- Remove the input speed sensor (1).
- Remove the output speed sensor (2).
- Remove the transfer shaft speed sensor (3).
- Remove fluid filter oil pan bolts (1).
- Remove the fluid filter oil pan (2).
- Remove the oil filter bolts (1).
- Remove the oil filter (2).
- Remove the oil filter seal (1).
• Keep the front sound dampener cover if replacing the unit.
- Remove the front sound dampener cover fasteners (1) and cover (2).
• Keep the top sound dampener cover if replacing the unit
- Remove the top sound damper cover (1).
- Remove the valve body oil pan bolts (2).
- Remove the pressure tap plug (2) from the valve body oil pan.
- Remove the valve body oil pan.
- Disconnect the range sensor electrical connector (1).
- Remove the detent spring bolt (3).
- Remove the detent spring (2).
- Remove valve body bolts (1).
- Remove valve body (1) from the oil transfer tubes and the manual valve (3) from detent lever.
- Remove the oil transfer tubes (2) from the case.
- Remove the six accumulators (1, 2, 3, 5, 6 and 7) from the case along with the accumulator return springs.
- Remove the 2/4 clutch oil supply seal (4) from the case.
- Remove the manual lever, transmission range sensor and seal. Refer to => [ Transmission Range Sensor ] Service and Repair.
- Measure the input shaft end play. Place the transaxle so the input shaft is vertical. Set up the end play socket set (8266A) (1 and 2) and the dial indicator (3). Check the end play, the reading should be within 0.13 to 0.64 mm (0.005 to 0.025 in). Record indicator reading for reference upon reassembly.
- Remove the front pump bolts (1).
Be sure input speed sensor is removed before removing oil pump.
- Install the oil pump puller (C-3752) (1) to the oil pump.
- Remove the oil pump (1) using the oil pump puller (C-3752) (2).
- Remove the oil pump gasket (2).
If a transaxle failure has occurred, the cooler bypass valve must be replaced. Do not reuse or attempt to clean the valve.
- Remove the cooler bypass valve (2).
• The tanged side (2) goes out.
- Remove the number one caged needle bearing (1).
- Remove the input clutch assembly (1).
- Remove the number four thrust plate (2).
- Remove the front sun gear assembly (1) and number four thrust washer (2).
- Remove the front carrier/rear annulus assembly (2) and the number six needle bearing (1).
- Remove the rear sun gear (2) and the number seven needle bearing (1).
• The number seven needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (2).
- Setup compressing tool (5058A) (1), and compress the 2/4 clutch return spring (4).
- Using a screwdriver (2) remove the snap ring (3).
• Verify that the compressing tool (5058A) is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the compressing tool (5058A) bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
• The 2/4 clutch piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
- Remove the 2/4 clutch retainer (1).
- Remove the 2/4 clutch return spring (1).
- Remove the 2/4 clutch pack (1 - clutch plates, four each) and (2 - clutch discs, four each). Tag the 2/4 clutch pack for reassembly identification.
• Tapered side goes up.
- Using a screwdriver (2), remove the tapered low/reverse snap ring (3).
• Flat side up.
- Remove the L/R reaction plate (1).
- Remove the one L/R clutch disc (1).
• Do not scratch the clutch plate.
- Using a screwdriver (1), remove the L/R reaction plate flat snap ring (2).
- Remove the low/reverse clutch pack (1 - clutch plates, five each) and (2 - clutch discs, five each).
- Remove the transfer gear cover bolts (2).
- Remove transfer gear cover (1).
- Remove the oil scavenger (2).
- Bend back the locking tabs (2) on the output transfer gear retaining strap (3).
- Remove the output transfer gear retaining strap bolts (1).
- Remove the output transfer gear retaining strap (3).
- Install the holder (9739) (2) onto the output transfer gear (3).
- Using a socket (1), remove the output transfer gear bolt.
- Grind the staked tabs (1) from the transfer gear (underdrive compounder side).
- Install the holder (9739) onto the transfer gear (underdrive compounder side) and remove the nut.
- Lift the transfer gear from the underdrive compounder shaft.
- Using puller (L-4407) (1) and button (6055) (3), remove the output shaft transfer gear (2) and select shim.
- Using puller set (5048) with jaws (5048-5) and button (L 4539-2) (1) remove the output gear (3) bearing cone.
- Using puller set (C-293-PA) (1), adapter (9738) (3) and plug (9678) , remove compounder transfer gear (2) bearing cone.
- Remove the rear carrier assembly (1) from the transaxle (2).
- Using puller set (5048) (1) with jaws (5048-3) and button (6055) , remove the rear carrier assembly (3) bearing cone.
- Assemble the disc (6057) (1), compressor (5059A) (2) and compressor bar (5058-3) (3).
- Using the assembled disc (6057) (3), compressor (5059A) (4) and compressor bar (5058-3) (5) compress the low/reverse spring (1).
• The snap ring (1) opening must be between the spring levers.
- Using snap ring pliers (2), remove the low/reverse piston return spring snap ring (1).
- Remove the assembled compressor tool and remove the low reverse piston return spring (1).
• The low/reverse clutch piston (1) has bonded seals (2 and 3) which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
- Remove the low/reverse clutch piston (1).
- Using a Torx driver (2), remove the low/reverse clutch piston retainer screws (3).
- Remove the low/reverse clutch piston retainer (1).
