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 9 chain cover bolts from inside torque converter housing.
- Using a slide hammer and appropriate seal puller, remove converter oil seal from input shaft. Rotate transaxle to vertical position. Remove side cover bolts. Remove cover and discard gasket.
- Using both hands, disconnect electrical connectors from Transmission Fluid Temperature (TFT) sensor and solenoids. See Figure. DO NOT pull on wires. Compress tabs on both sides of bulkhead connector from inside of chain cover and remove connector and wiring.CAUTION: Do not remove 4 bolts holding oil pump and valve body together. Do not remove 6 oil pump cover bolts.
- 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 4 Teflon seals from shaft. Discard seals. Remove transmission pan. Remove and discard fluid filter. Loosen reverse clutch anchor pin nut and remove bolt. See Fig 7.
- 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 Turbine Shaft Speed (TSS) sensor 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 3 roll pins from manual shaft. Be careful not to damage machined surfaces. Slide shaft out and pry seal from case. See Fig 8.
- Remove driven sprocket support assembly. See Fig 9. Remove 5 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 low-intermediate circuit screen. See Fig 3. Clean filter with compressed air. Replace filter tube lip seal.NOTE: For complete transaxle disassembly, reverse clutch apply fluid transfer tube and rear lube fluid transfer tube MUST be removed prior to removing the reverse clutch or differential. All fluid tubes removed must be replaced during reassembly.
- Position transaxle with oil pan up. Remove reverse apply tube/oil filter bolt and bracket. 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 7.
- 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.
- Place transaxle in horizontal position. Install Front Clutch Loading Tool (T86P-70389-A). Install hook portion of tool on inner diameter of reverse clutch cylinder. See Fig 10. Lift front sun gear and shell assembly out of case. Grasp outer diameter with fingertips and slide clutch assembly out of case.
- Grasp front planetary shaft and lift out both front and rear planetary assemblies. Lift out rear 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 11.
- 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.