Overhaul - Automatic Transmission: Disassembly
NOTE:
If the transaxle is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII(R) Scan Tool (Refer to
STANDARD PROCEDURE
).
Before disassembling transaxle, move the shift lever clockwise as far as it will go and then remove the shift lever.
NOTE:
Tag all clutch pack assemblies, as they are removed, for reassembly identification.
CAUTION:
Do not intermix clutch discs or plates as the unit might then fail.
- Measure input shaft end play using Tool 8266. Set up Tool 8266 and a dial indicator as shown in (Fig 1 ). Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transaxle. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.
- Remove input and output speed sensors (Fig 2 ).
- Remove transaxle oil pan (Fig 3 ).
- Remove transaxle oil filter (Fig 4 ).
- Remove seven valve body-to-case bolts (Fig 5
).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
- Remove valve body from transaxle (Fig 6
).
NOTE: For valve body recondition procedure, (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -42LE/VALVE BODY - DISASSEMBLY ).
- Remove underdrive accumulator and spring (Fig 7 ) (Fig 9 ).
- Remove overdrive accumulator and springs (Fig 8
) (Fig 9
).
CAUTION: Tag the springs for the Overdrive Accumulator so that they are not confused with the springs in the Low/Reverse Accumulator.
- Remove the low/reverse accumulator snap ring (Fig 10 ).
- Remove the low/reverse accumulator plug (Fig 11 ).
- Remove low/reverse accumulator piston and springs (Fig 12 ) (Fig 13 ).
- Remove long stub shaft bearing snap ring (Fig 14 ).
- Remove long stub shaft and bearing from bell-housing using Tools 8420A and C-3752 (Fig 15 ).
- Remove oil pump-to-case bolts (Fig 16 ).
- Remove oil pump using C-3752 Pullers (Fig 17 ).
- Remove oil pump while pushing in on input shaft (Fig 18 ).
- Remove oil pump gasket (Fig 19
).
CAUTION: By-pass valve must be replaced if transmission failure occurs.
- Remove cooler by-pass valve (Fig 20 ).
- Remove #1 caged needle bearing (Fig 21 ).
- Remove input clutch assembly (Fig 22 ).
- Remove #4 thrust plate (Fig 23 ).
- Remove front sun gear assembly and #4 thrust washer (if still in place) (Fig 24 ).
- Remove front carrier/rear annulus and #6 needle bearing (Fig 25 ).
- Remove rear sun gear and #7 needle bearing (Fig 26
) (Fig 27
).
NOTE: The number seven needle bearing has three, antireversal 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 (Fig 27 ). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
- Install and load Tool 5058 to remove 2/4 clutch retainer snap ring (Fig 28 ).
- Remove 2/4 clutch retainer (Fig 29 ) (Fig 30 ).
- Remove 2/4 clutch return spring (Fig 31 ).
- Remove tapered snap ring (Fig 33 ).
- Remove low/reverse reaction plate (Fig 34 ).
- Remove one (1) low/reverse clutch disc to facilitate snap ring removal (Fig 35 ).
- Remove low/reverse reaction plate snap ring (Fig 36 ).
- Remove low/reverse clutch pack (Fig 37 ).
- Remove chain cover (Fig 38 ).
- Stand trans upright on bellhousing.
- Remove chain oiler (Fig 39
).
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
- Remove chain snubber (Fig 40 ).
- Remove transfer and output shaft sprocket snap rings and wave washers (Fig 41
) (Fig 42
).
CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, removal or installation will be difficult. Overspreading of the chain sprockets will also make sprocket removal difficult.
- Install Tool 6550 and apply a light amount of pressure to facilitate removal (Fig 43 ).
- Remove transfer chain and sprockets as an assembly (Fig 44 ).
- Remove output shaft sprocket spacer (Fig 45 ).
- Remove main sump baffle from transaxle case (Fig 46
).
CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
- Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown in (Fig 47 ) (Fig 48 ). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
- Using a small chisel, carefully open stakes on nut (Fig 49 ).
- Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut (Fig 50 ).
- Remove output shaft from case using a shop press (Fig 51
).
Use special tool 6596 with a shop press to remove front output shaft bearing cup (Fig 52 ).
- Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rearward (Fig 53 ).
- Remove rear carrier front bearing cone (Fig 54 ).
- Install and load compressor (Fig 55 ) as shown in (Fig 56 ).
- Remove snap ring (Fig 57 ).
- Remove low/reverse piston belleville spring (Fig 58 ).
- Remove park sprag pivot retaining screw (Fig 59 ).
- Drive out anchor shaft using suitable punch (Fig 60 ).
- Remove guide bracket pivot shaft (Fig 61 ). Inspect all components (Fig 62 ) for wear and replace if necessary.
- Remove low/reverse clutch piston (Fig 63 ).
- Remove low/reverse piston retainer screws (Fig 64 ).
- Remove low/reverse piston retainer (Fig 65 ).
- Remove low/reverse piston retainer gasket (Fig 66 ).