Transaxle Disassembly

NOTE: Whenever working with transmission, it is important that normal standards of cleanliness be observed. Complete transmission assembly should be thoroughly steam cleaned before beginning any disassembly. Disassemble only those parts which require repair or replacement. Compressed air is preferred for drying components and oil passages, however, nylon cloth may be used. Never use fluffy rags or cloths to wipe parts dry.

On 4WD transmissions: Remove rear engine mount and place transmission on work bench with oil pan facing down. Remove solenoid from extension housing by turning it by hand. Disconnect temperature switch lead wire from clip and remove temperature switch from left side of extension housing.
On 4WD transmissions: Remove 8 (8 mm) bolts and remove extension housing. Drain automatic transmission fluid from extension housing, being careful not to drop rear drive gear thrust plate and transfer drive gear assembly. Remove washer from bearing bore on upper side of intermediate housing.
On 4WD transmissions: Remove rear shaft assembly from extension housing, being careful not to damage oil seal. Remove seal ring. Using removal plates, remove ball bearing, washer and transfer driven gear from shaft.
On 4WD transmissions: Remove drum and ball bearing. Dissasemble transfer clutch assembly by removing snap ring and front pressure plate. Remove driven plates, drive plates and rear pressure plate.
NOTE: Automatic transmission and differential sections are not normally separated. If they must be separated, place transmission section on stand.
If transmission and differential sections are going to be separated: Drain any remaining automatic transmission fluid by placing transmission on a work bench with converter housing facing down. Remove oil pan. Remove valve body on 4WD transmissions.
Wrap vinyl tape around spline portion of drive pinion rear end in order not to damage oil seal on 4WD transmissions. Separate transmission and differential sections.
If complete transmission is being disassembled: Remove turbine and oil pump drive shafts by pulling straight out with pliers (wrapped with vinyl tape), using care not to damage shafts. Disconnect oil cooler pipe from transmission housing.
Remove lead wire clips by removing nuts securing transmission housing to final drive housing. Remove downshift solenoid, transfer solenoid and temperature switch lead wire clips. Disconnect vacuum pipe and ground cable. Remove oil supply pipe from transmission after draining fluid. DO NOT lose "O" ring on end of pipe.
Drain differential gear oil. Drain any remaining automatic transmission fluid by placing transmission on a work bench with converter housing facing down. Remove oil pan, downshift solenoid, vacuum diaphragm, diaphragm rod and "O" ring.
Remove servo apply and servo release tubes. Remove valve body. Remove transfer valve by separating bend portion of transfer tube clip from transfer pipe. Disconnect transfer tube and remove 2 bolts which secure transfer clutch body.
Remove oil pump assembly by tightening band adjustment screw until reverse clutch is lightly held. Remove bolts which secure transmission cover (intermediate housing on 4WD transmissions). Gently tap housing until oil pump assembly is removed. DO NOT lose thrust washer located on oil pump carrier.
NOTE: Note positions of thrust washers, toothed thrust washers and needle bearings to be removed in following steps. DO NOT lose any of these parts.
Move transfer drive shaft upward and remove transfer coupling from rear spline of drive pinion, then remove transfer drive shaft. Remove band servo piston and remove strut band. Remove brake band assembly, reverse clutch assembly and forward cluth assembly.
Remove connecting shell, remove center support assembly by using 2 (6 mm) bolts. Remove planetary input gears. Remove planetary gear assembly and low/reverse brake plates. Remove retaining plate. Remove planetary output gear.
If necessary, remove selector arm, manual plate and parking rod. Remove transmission housing by wrapping vinyl tape around splines of drive pinion to prevent damage to oil seal.
If necessary, remove nuts securing transmission housing to final drive housing. Separate transmission housing from final drive housing by gently tapping final drive housing. Remove parking pawl, parking pawl shaft and parking pawl support plate.