Transaxle Disassembly
NOTE:
For exploded view of transaxle, see Figure
.
- Remove torque converter. Mount transaxle in a holding fixture. Place in vertical position. Remove shipping plug and drain fluid.
- Place in horizontal position. Remove 2 governor cover bolts, cover and seal. Discard seal. Lift governor, speedometer drive gear assembly and bearing from case. Bearing sits on top of speedometer.
- Remove 3 bolts from overdrive servo cover. Mark and remove cover, piston assembly and spring. Discard "O" ring from cover. Remove 3 low-intermediate servo cover bolts. Mark and remove cover, piston assembly and spring. Remove and discard gasket.
- Install Shaft Protector (D80L-625-A) into right-hand output shaft opening. Screw output shaft Seal Remover (T74P-6700-A), into metal seal. Tighten screw on end of seal remover until metal seal protector is removed. Reinstall remover and repeat procedure to remove seal. See Fig 1 .
- Remove 2 neutral safety switch bolts and remove switch. Remove dipstick tube attaching bolt and pull tube from case. Remove 9 chain cover bolts from inside torque converter housing.
- Using a slide hammer and Seal Puller (1175-AC), remove converter oil seal. Remove 12 valve body cover bolts. Remove cover and discard gasket.
- Unplug 4 electrical connectors from pressure switches and solenoid. Use both hands. DO NOT pull on wires. Compress tabs on both sides of 5-pin bulkhead connector from inside of chain cover and remove connector and wiring. DO NOT pull on wiring, pull on connector. See Figure .
- 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). Mark and remove 22 oil pump and valve body bolts, noting length and location. See Figure
.CAUTION: DO NOT remove 2 bolts holding oil pump and valve body together. DO NOT remove the 6 oil pump cover bolts.
- Push in T.V. plunger. Pull pump and valve body assembly outward. 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.
- Remove 2 throttle valve bracket bolts and remove bracket. Pull oil pump drive shaft out of case and remove 4 Teflon seals from shaft. Discard seals. See Fig 2 .
- Place transaxle in vertical position. Remove and discard left-hand 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 and remove seal. See Fig 1 .
- Mark and remove 14 chain cover bolts. Note length and location of bolts. See Fig 2 . Carefully remove chain cover and discard gasket. 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 washers from chain cover.
- Simultaneously lift out both sprockets with chain assembly. Mark and remove No. 2 and No. 4 thrust washers from drive and driven sprocket supports. Inspect drive sprocket support bearing to determine if it needs replacing. If bearing is okay, remove 6 Torx (T-30), bolts attaching support to case.
- Using Pin Remover (D81P-3504-N), remove lockpin and 2 roll pins from manual shaft. Be careful not to damage any machined surfaces. Slide shaft out of case, then pry seal from case. See Fig 3 .
- Use a straightedge and note whether driven sprocket support machined bolt hole surface is above or below the case machined surface. See Fig 3 . Note for reassembly. Remove driven sprocket support assembly. Back out reverse clutch anchor bolt if necessary.
- Remove 5 Teflon seals from support assembly. Mark and remove No. 5 selective thrust washer. Using a wire hook remove No. 8 selective thrust washer and No. 9 needle bearing. Remove plastic overdrive band retainer and overdrive band.
- Install Clutch Pack Holder (T86P-70389-A). Lift front sun gear and shell assembly out of case. Remove 17 oil pan cover bolts. Remove cover and discard gasket. Remove reverse apply tube/oil filter bolt and bracket. Remove oil filter screen and discard 2 "O" rings.
- Remove tube retaining bracket bolts and brackets. If necessary, use Tube Remover (T86P-70001-A) and a slide hammer to remove lube tubes. Tubes are retained with Loctite. See Fig 4
.NOTE: For complete transaxle disassembly the reverse apply tube MUST be removed prior to removing the reverse clutch. The rear lube tube must also be removed and the seal replaced whenever the differential is removed.
- Remove 2 park rod abutment bolts. Remove park rod by lifting to clear abutment and lower from case. Remove park pawl shaft roll pin. Use magnet to remove park pawl shaft. Remove park pawl and return spring. Loosen 19 mm reverse anchor pin nut and remove 6 mm Allen head bolt.
- Place transaxle in horizontal position. Install Clutch Pack Holder (T86P-70389-A), on inner diameter of reverse clutch cylinder. Grasp outer diameter with finger tips and slide clutch assembly out of case.
- Place transaxle in vertical position. Grasp front planetary shaft and lift out both front and rear planetary assembly. 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 5 .
- Remove final drive ring gear, No. 8 thrust washer and No. 19 needle bearing. Remove and discard rear lube tube seal using a 3/8" rod or drift. Tap seal towards inside of case.