Automatic Transmission (Service Information): Disassembly

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Remove the speed sensors (1, 2 and 3).

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Remove bolts (1) at the oil filter pan (2).
Remove the oil filter pan (2).

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Remove the nuts (1) at the oil filter (2).
Remove the oil filter (2).

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Remove the oil filter seal (1) at the case.

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NOTE:
Keep the Front Sound Dampener Cover if replacing the unit.
If equipped, remove the fasteners (1) and the Front Sound Dampener Cover (2).

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NOTE:
Keep the Top Sound Dampener Cover if replacing the unit.
If equipped, remove the Top Sound Damper Cover (1).

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Remove bolts (2) at the valve body oil pan (1).

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Remove the pressure tap plug (2) at valve body pan.
Remove the valve body pan.

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Remove the electrical connector (1) at the range sensor (4).
Remove the bolt (3) holding the detent spring.
Remove the detent spring (2).

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Remove valve body bolts (1).

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Remove valve body (1) from oil transfer tubes and manual valve (3) from rooster comb.

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Remove oil transfer tubes (2) from the case.

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1 - UD ACCUMULATOR

5 - LC ACCUMULATOR

2 - 2/4 ACCUMULATOR

6 - DC ACCUMULATOR

3 - LR ACCUMULATOR

7 - OD ACCUMULATOR

4 - 2/4 CLUTCH OIL SUPPLY SEAL

Remove all six accumulators (1, 2, 3, 5, 6 and 7) from 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 (TRS) and seal. Refer to SENSOR, TRANSMISSION RANGE, REMOVAL .

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1 - END PLAY FIXTURES 8266A

2 - DIAL INDICATOR C-3339A
Measure input shaft end play. Place transaxle so input shaft is vertical. Set up (special tool #8266-7, Spline Tool, 32RH) (1, 2) and dial indicator (3). Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.) Record indicator reading for reference upon reassembly.

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Remove the front pump bolts (1).

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CAUTION:
Be sure input speed sensor is removed before removing oil pump.
Install (special tool #C-3752, Slide Hammers)or equivalent (1) on oil pump (2).

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Remove oil pump assembly (1).

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Remove oil pump gasket (2).

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CAUTION:
If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
Remove cooler bypass valve (2).

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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove number one needle bearing (1).

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1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER

Remove input clutch assembly (1).

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - 3 DABS OF PETROLATUM FOR RETENTION

Remove number four thrust plate (2).

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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove front sun gear assembly (1) and number four thrust washer (2).

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Remove front carrier/rear annulus assembly (2) and number six needle bearing (1).

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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

NOTE:
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) when put together.

Remove rear sun gear (2) and number seven needle bearing (1).

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1 - SPRING COMPRESSING 5058A

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE:

Verify that (special tool #5058A, Compressor, Spring) (1) is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the (special tool #5058A, Compressor, Spring) bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Setup the (special tool #5058A, Compressor, Spring) (1), Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).

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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING

NOTE:
The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Remove 2/4 clutch retainer (1).

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1 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch return spring (1).

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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove 2/4 clutch pack (1, 2). Tag 2/4 clutch pack for reassembly identification.

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1 - LOW/REVERSE CLUTCH REACTION PLATE

2 - SCREWDRIVER

3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

4 - OIL PAN FACE

5 - LONG TAB

Remove tapered snap ring (3).

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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove low/reverse reaction plate (1).

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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one low/reverse clutch disc (1).

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Remove low/reverse reaction plate snap ring (2).

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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)
Remove low/reverse clutch pack (1, 2). Tag the low/reverse clutch pack for reassembly identification .

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Remove transfer gear cover-to-case bolts (2).
Remove transfer gear cover (1).

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Remove the oil scavenger (2).

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Bend back the locking tabs (2) at the output transfer gear retaining strap (3).
Remove the bolts (1) at the output transfer gear retaining strap (3).
Remove the output transfer gear retaining strap (3).

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Install the (special tool #9739, Holder, Gear) (2) onto the output transfer gear (3).
Remove the output transfer gear bolt (1).

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Grind the staked tabs (1) from the transfer gear (underdrive compounder side).
Install the (special tool #9739, Holder, Gear) onto the transfer gear (underdrive compounder side) and remove the nut.
Lift the transfer gear (3) from the underdrive compounder shaft.

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Using (special tool #L-4407A, Puller, Gear) (1) and (special tool #6055, Thrust Button) (3) remove output shaft transfer gear (2) and select shim.

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1 - BEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2

2 - WRENCHES

3 - OUTPUT GEAR

Using (special tool #5048, Puller, Bearing) with (special tool #5048-5, Set, Collet Half) and (special tool #L-4539-2, Pad, Thrust) (1) remove output gear bearing cone.

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Using (special tool #C-293-PA, Puller, Press) (1), (special tool #9738, Blocks, Adapter) (3) and (special tool #9678, Press Plug) remove compounder transfer gear bearing cone.

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Remove rear carrier assembly (1) from transaxle (2).

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1 - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055

2 - WRENCHES

3 - REAR CARRIER ASSEMBLY

Remove rear carrier assembly (3) bearing cone using (special tool #5048, Puller, Bearing) (1) with (special tool #5048-3, Set, Collet Half) and (special tool #6055, Thrust Button).

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1 - SPRING COMPRESSOR DISC 6057

2 - SPRING COMPRESSOR 5059-A

3 - FORCING SCREW 5058A-3

Install (special tool #6057, Disc, Spring Compressor) (1), (special tool #5059-A, Compressor, Spring) (2) and (special tool #5058A-3, Screw, Forcing) (3).

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - SPRING COMPRESSOR DISC 6057

4 - SPRING COMPRESSOR 5059-A

5 - FORCING SCREW 5058A-3

Compress low/reverse spring using (special tool #5059-A, Compressor, Spring) (4).

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)

2 - SNAP RING PLIERS

3 - SPRING COMPRESSOR DISC 6057

Remove snap ring (1) at low/reverse piston return spring.

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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Remove low/reverse spring compressor tool and low reverse piston return spring (1).

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1 - LOW/REVERSE CLUTCH PISTON

2 - BONDED SEAL

3 - BONDED SEAL

NOTE:

The low/reverse clutch piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Remove low/reverse clutch piston (1).

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

Remove low/reverse piston retainer-to-case screws (3).

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer (1).

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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove low/reverse piston retainer-to-case gasket (2), gasket holes must line up (1).

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Using a hammer and suitable drift (2), drive out inner output bearing cup (1).

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Using (special tool #6062A, Puller, Bearing Cup) (1), remove outer output bearing cup (2).

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Remove the snap ring (1) at the underdrive compounder assembly (2).

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Remove bolts (1) at the compounder bearing retainer.

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Install (special tool #9908, Adapter, Puller) (2) to the compounder bearing retainer.

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Install (special tool #C-3752, Slide Hammers) (1) to (special tool #9908, Adapter, Puller) (2) and pull the underdrive compounder assembly from the case.

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NOTE:
Insure that the planetary gear set / output hub is removed as part of the underdrive compounder assembly.
Remove the underdrive compounder assembly (2).

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Remove the bolts (1) at the remote pinion cover (2).

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Remove the remote pinion (1) and the remote pinion cover (2) from the case.

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Remove the remote pinion cover (1) from the remote pinion (2).

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Using (special tool #8913, Remover, Bearing Cup) (2) and (special tool #8915, Brace) (1) remove the remote pinion cover bearing cup (4) and selective shim.

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Using (special tool #8912, Remover, Bearing) and (special tool #8915, Brace) (1, 2) pull remote pinion small bearing cup (3) from the case.

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Remove the differential output bearing cover bolts (1).
Remove differential output bearing cover (2).

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Remove the differential cover bolts (1).

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Remove the differential cover (1).
Remove the out seal (2), oil singer (3) and the small bearing cup (4).
Remove the large bearing cup.

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Remove the differential (2).

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Remove the set screw (1) for the park pawl shaft (2).

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Remove the snap ring (1) for the park guide assembly (2).

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Remove the park guide assembly (1).

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Remove the plug (1) to allow the park pawl shaft to be removed.

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Slide the shaft (1) out of the park pawl (3).

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Remove the park pawl shaft (1).

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Remove the park pawl (1) and the park pawl spring (2).