Transaxle Disassembly
- Remove torque converter. Mount transaxle in a appropriate holding fixture. Place in vertical position and drain fluid.
- Place in horizontal position. Remove speedometer cover bolts, cover and seal. Discard seal. Lift speedometer drive gear assembly and bearing from case. Bearing sits on top of speedometer drive gear.
- Remove bolts from overdrive servo cover. Servo cover is under pressure and must be retained when removing bolts. Mark and remove cover, piston assembly and spring. Discard "O" ring from cover. Remove low-intermediate servo cover bolts. Mark and remove cover, piston assembly and spring. Remove and discard gasket.
- Install Step Plate Adapter (D80L-630-3) into right-hand output shaft opening; hold adapter in position with grease. Screw output shaft Seal Remover (T74P-6700-A) into metal seal and protector. Tighten screw on end of seal remover until metal seal protector is removed. Reinstall remover and repeat procedure to remove seal.
- Remove bolts from Transmission Range (TR) sensor and remove sensor. Remove dipstick tube and dipstick from case. Remove nine chain cover bolts from inside torque converter housing.
- Using a slide hammer and Seal Puller (1175-AC), remove converter oil seal from input shaft. Rotate transaxle to vertical position. Remove side cover bolts. Remove cover and discard gasket.
- Disconnect electrical connectors from Transmission Fluid Temperature (TFT) sensor and solenoids. Use both hands. DO NOT
pull on wires. Compress tabs on both sides of bulkhead connector from inside of chain cover and remove connector and wiring. See Figure
.CAUTION: DO NOT remove four bolts holding oil pump and valve body together. DO NOT remove six oil pump cover bolts.LEGEND FOR FIGURE 9
Item Description 1 Oil Level Thermostatic Element Retaining Collar 2 Pin 3 Oil Level Thermostatic Element 4 Oil Level Thermostatic Valve Plate 5 Drive Chain Assembly 6 Drive Sprocket Thrust Washer No. 1 7 Chain Cover Thrust Washer No. 3 8 Manual Valve Detent Valve Assy. 9 Transaxle Wiring Harness Assy. 10 Chain Cover Assembly 11 Chain Cover Gasket 12 Case Vent 13 Cooler Line Retainer 14 Cooler Line Fitting 15 Plug 16 Main Valve Body (Control Assy.) 17 Oil Pump Gasket 18 Oil Pump Body Separator Plate 19 Oil Pump Separator Body Gasket 20 Oil Pump Body 21 "O" Ring Seal 22 Electronic Pressure Control (EPC) Solenoid Valve 23 Oil Pump Body Ring 24 Oil Pump Ring Side Seal 25 Oil Pump Ring Side Gear Support 26 Oil Pump Cover & Sleeve Assembly 27 Oil Pump Bore Radial Seal Support 28 Oil Pump Bore Radial Seal 29 Oil Pump Rotor 30 Oil Pump Valve 31 Oil Pump Valve Support Ring 32 Shift Solenoid 33 Oil Pump Bore Spring 34 Transmission Fluid Temperature (TFT) Sensor 35 TCC Solenoid Screen 35 Torque Converter Clutch (TCC) Solenoid Valve 36 Valve Body Separator Plate Gasket 37 Valve Body Separator Plate 38 Valve Body Separator Plate-To-Chain Cover Gasket 39 Output Shaft "C" Clip 40 Differential Seal 41 Transmission Speed Sensor (TSS) 42 Transmission Speed Sensor (TSS) Seal 43 Valve Body Cover Gasket 44 Valve Body Cover LEGEND FOR FIGURE 10Item Description 1 Converter Housing Cover 2 Torque Converter 3 Torque Converter Hub Seal 4 Differential Seal 5 Stud 6 Case Assembly 7 Dip Stick 8 Dipstick Tube 9 Dipstick Tube Grommet 10 Overdrive Servo Piston Cover 11 Overdrive Servo Cover Seal 12 "E" Clip 13 Overdrive Servo Piston Retainer 14 Overdrive Servo Piston & Seal Assembly 15 Overdrive Servo Retainer & Spring Assembly 16 Overdrive Servo Piston Selective Rod 17 Overdrive Servo Piston Return Spring 18 Identification Tag 19 Transmission Range (TR) Sensor 20 Manual Control Shaft 21 Manual Control Shaft Seal 22 Pin 23 Manual Control Valve Actuating Rod 24 Inner Manual Valve Detent Lever 25 1-2 Accumulator Piston 26 1-2 Accumulator Piston Seal 27 1-2 Accumulator Springs 28 Accumulator Piston Shaft 29 2-3 Accumulator Piston 30 2-3 Accumulator Piston Seal 31 2-3 Accumulator Springs 32 Drive Accumulator Piston 33 Drive Accumulator Piston Seal 34 Drive Accumulator Springs 35 Reverse Clutch Locator Bolt 36 Reverse Clutch Locator Bolt Nut 37 Low/Intermediate Servo Cover 38 Low/Intermediate Servo Cover Gasket 39 Low/Intermediate Servo Cover Seal 40 Low/Intermediate Servo Piston 41 Low/Intermediate Servo Piston Seal 42 Low/Intermediate Servo Spring & Retainer 43 Low/Intermediate Servo Piston Selective Rod 44 Low/Intermediate Servo Return Spring 45 Parking Pawl Actuator Rod 46 Parking Pawl Return Spring 47 Parking Brake Pawl 48 Parking Pawl Actuator Bracket 49 Parking Pawl Shaft 50 Differential Speedometer Oil Transfer Tube 51 Servo Apply Oil Transfer Tube 52 Servo Release Oil Transfer Tube 53 Reverse Clutch Apply Transfer Tube 54 Seal 55 Tube Support Main Bracket 56 Tube Support Reverse Clutch Bracket 57 Rear Lube Oil Transfer Tube 58 Tube Support Differential Speedometer Bracket 59 Oil Filter Seal 60 Oil Filter 61 Oil Pan Gasket 62 Magnet 63 Oil Pan 64 Manual Control Lever 65 Low/Intermediate Circuit Screen 66 Speedometer Gear Cover 67 Speedometer Gear Cover Seal 68 Speedometer Thrust Bearing & Race 69 Speedometer Drive Gear 70 Speedometer Driven Gear & Shaft Assembly 71 Plug 72 Low/Intermediate Servo Return Spring Retainer LEGEND FOR FIGURE 11Item Description 1 Stator Support Assembly 2 Turbine Shaft 3 "O" Ring Seal 4 Oil Pump Shaft 5 Drive Sprocket Bearing 6 Drive Sprocket Thrust Washer No.2 7 Drive Sprocket 8 Snap Ring 9 Turbine Shaft Front Seal 10 Differential Carrier Thrust Bearing & Race Assy. No. 19 11 Differential Carrier Thrust Washer 12 Speedometer Drive Gear 13 Final Drive Ring Gear 14 Gear & Differential Case Assy. 15 Differential Side Gear 16 Differential Side Gear Thrust Washer 17 Axle Differential Pinion Thrust Washer 18 Differential Pinion Gear 19 Differential Pinion Shaft Pin 20 Differential Pinion Shaft 21 Final Drive Pinion 22 Final Drive Planetary Gear Thrust Washer 23 Final Drive Planetary Gear Needle Bearing 24 Final Drive Planetary Gear Spacer 25 Final Drive Planetary Gear 26 Final Drive Pinion Shaft 27 Final Drive Gear Front Thrust Bearing No.17 28 Snap Ring 29 Final Drive Sun Gear 30 Parking Gear 31 Output Shaft Bearing Selective Shim No.16 32 Rear Planetary Gear Support 33 Rear Lube Oil Transfer Tube Seal 34 Snap Ring 35 Rear Sun Gear Thrust Bearing & Race No.15 36 Sun Gear Thrust Race 37 Rear Sun Gear & Drum Assembly 38 Low-Intermediate Band 39 Ring Gear 40 Reverse Planetary 41 Planetary Center Thrust Bearing & Race Center No.13 42 Front Planetary 43 Front Planetary Gear Carrier Bearing Assembly 44 Selective Snap Ring 45 Reverse Clutch Pressure Plate 46 Reverse Clutch Friction Plate 47 Reverse Clutch Steel Plate 48 Reverse Clutch Pressure Spring 49 Reverse Clutch Support & Spring Assembly 50 Output Shaft 51 Reverse Clutch Piston 52 Reverse Clutch Piston Outer Seal 53 Reverse Clutch Piston Small Seal 54 Low & Reverse Clutch Hub 55 Reverse Clutch Assembly LEGEND FOR FIGURE 12Item Description 1 Front Sun Gear & Shell Assy. 2 Front Sun Gear Thrust Bearing No. 10 & No. 11 3 Intermediate Clutch Hub 4 Selective Snap Ring 5 Intermediate Clutch Pressure Plate 6 Intermediate Clutch Friction Plate 7 Intermediate Clutch Steel Plate 8 Intermediate Clutch Pressure Spring 9 Snap Ring 10 Intermediate Clutch Support & Spring Assembly 11 Intermediate Clutch Outer Seal 12 Intermediate Clutch Piston 13 Intermediate Clutch Inner Seal 14 Intermediate Clutch Assembly 15 Direct/Intermediate Clutch Cylinder 16 Direct/Intermediate Clutch Cylinder Bushing 17 Direct/Intermediate Clutch Hub Seal 18 Direct Clutch Piston 19 Direct Clutch Outer Seal 20 Direct Clutch Piston Ring 21 Direct Clutch Support & Spring Assembly 22 Direct Clutch Friction Plate 23 Direct Clutch Steel Plate 24 Pressure Plate 25 Direct Clutch Thrust Washer No. 7 26 Direct Clutch Assembly 27 Direct One-Way Clutch Outer Race 28 Direct One-Way Clutch Hub 29 Direct One-Way Clutch Inner ** Race & Bushing Assembly 30 Forward Clutch Cylinder 31 Forward Clutch Outer Seal 32 Forward Clutch Inner Seal 33 Forward Clutch Piston 34 Forward Clutch Support & Spring Assembly 35 Forward Clutch Pressure Spring 36 Forward Clutch Internal Friction Plate 37 Forward Clutch External Steel Plate 38 Forward Clutch Pressure Plate 39 Forward Clutch Thrust Washer No. 6 40 Low One-Way Clutch Outer Race 41 Low One-Way Clutch Assembly 42 Overdrive Drum Assembly 43 Direct Clutch Hub Bearing & Race Assembly No. 9 44 Driven Sprocket Support Thrust Washer No. 8 45 Overdrive Band 46 Forward Clutch Cylinder Seals 47 Front Support Thrust Washer No. 5 48 Driven Sprocket Support Assy. 49 Driven Sprocket Bearing 50 Driven Sprocket Thrust Washer No. 4 51 Driven Sprocket 52 Driven Sprocket Wheel Speed Sensor 53 Overdrive Band Strut 54 Forward Clutch Assembly - Using a 9 mm wrench on flats of manual shaft, rotate shaft clockwise to position manual linkage in low detent (manual valve all the way in). See Fig 1 . Mark and remove 22 oil pump and valve body bolts, noting length and location. See Figure .
- Rotate valve body clockwise and remove manual valve link from manual valve. Disconnect manual valve link from detent lever. Remove pump and valve body assembly.
- Pull oil pump drive shaft out of case and remove four Teflon seals from shaft. Discard seals.
- Place transaxle in vertical position. Remove and discard left output shaft circlip. Screw Seal Remover (T74P-6700-A) into metal seal protector. Tighten screw of seal remover until metal seal protector is removed. Repeat procedure to remove seal.
- Remove Transmission Speed Sensor (TSS) from chain cover. Mark and remove 16 chain cover bolts. Note length and location of bolts for reassembly reference. Chain cover is under spring pressure; remove carefully. See Fig 6 . Note location of accumulator springs and tag to ensure reassembly to original location. Mark and remove No. 1 (plastic) thrust washer from chain cover. Mark and remove No. 3 (metal) thrust washer from chain cover.
- Simultaneously lift both sprockets out with chain assembly. Remove cast iron sealing ring from input shaft sprocket. Mark and remove No. 2 and No. 4 thrust washers from drive and driven sprocket supports. Thrust washers may stick to bottom side of sprockets. Inspect drive sprocket support bearing. Using slide hammer puller, replace drive sprocket support bearing, if necessary.
- Using Pin Remover (D81P-3504-N), remove lockpin and three roll pins from manual shaft. Be careful not to damage machined surfaces. Slide shaft out and pry seal from case. See Fig 7 .
- Remove six Torx (T30) bolts attaching support to case. Remove driven sprocket support assembly. See Fig 8 . Remove five Teflon seals from support assembly. Mark and remove No. 5 selective thrust washer. Washer may stay on support assembly during removal.
- Using a wire hook, if necessary, remove No. 8 selective thrust washer and No. 9 needle bearing. Remove plastic overdrive band retainer and overdrive band. Remove filter screen. Clean filter with compressed air. Replace filter tube lip seal.
- Position transaxle with oil pan up. Remove oil pan and discard gasket. Remove reverse apply tube/oil filter bolt and bracket. Remove oil filter screen and discard lip seal.
- Remove transfer tube retaining bracket bolts and brackets. If necessary, use Tube Remover (T86P-70001-A) and a slide hammer to remove transfer tubes. Tubes are retained with Loctite. See Fig 9
.
NOTE: For complete transaxle disassembly, reverse apply tube MUST be removed prior to removing the reverse clutch or differential.
- Remove 2 parking rod bracket bolts. Remove parking rod by lifting to clear bracket and lower from case. Remove parking pawl shaft roll pin. Use magnet to remove parking pawl shaft. Remove parking pawl and return spring. Remove reverse clutch anchor pin lock nut and bolt.NOTE: It is necessary to modify Front Clutch Loading Tool (T86P-70389-A) for use on 3.2L models. Remove .02" (.5 mm) of material from hook end of tool.
- Place transaxle in horizontal position. Install Front Clutch Loading Tool (T86P-70389-A). Lift front sun gear and shell assembly out of case. Install hook portion of Front Clutch Loading Tool (T86P-70389-A) on inner diameter of reverse clutch cylinder. Grasp outer diameter with fingertips and slide clutch assembly out of case.
- Rotate transaxle to vertical position. Grasp front planetary shaft and lift out both front and rear planetary assemblies. Lift out low-intermediate drum and sun gear assembly. Remove low-intermediate band.
- Remove final drive assembly snap ring from case using a screwdriver inserted through side of case. Lift out final drive assembly using output shaft. See Fig 10 .
- Remove final drive ring gear from case. Remove No. 18 thrust washer and No. 19 needle bearing. Thrust washer may remain on final drive next to speedometer gear. Remove and discard rear lube tube seal using a 3/8" rod or drift. Tap seal towards inside of case. If case replacement is necessary, remove Torx bolts and converter support from old case at this time.