Automatic Transmission - Theory & Operation, & Disassembly & Assembly - 6f50 Ford Taurus X I

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

SOLENOID OPERATION CHART

SOLENOID OPERATION CHART

a Solenoid state will change if vehicle is moving forward with the selector lever in the NEUTRAL position.

b Turns on above 5 km/h (3 mph).

c Turns off above 5 km/h (3 mph).

CLUTCH APPLICATION CHART

CLUTCH APPLICATION CHART

LINE PRESSURE CHART

LINE PRESSURE CHART

a All pressures are approximate.

STALL SPEED CHART

STALL SPEED CHART

SHIFT SPEEDS

SHIFT SPEEDS

DIFFERENTIAL BEARING PRELOAD SHIM SELECTION CHART

DIFFERENTIAL BEARING PRELOAD SHIM SELECTION CHART

TRANSFER GEAR BEARING PRELOAD SHIM SELECTION CHART

TRANSFER GEAR BEARING PRELOAD SHIM SELECTION CHART

TORQUE SPECIFICATIONS TABLE

TORQUE SPECIFICATIONS TABLE

a Refer to the procedure in this article.

Scheme 25

This automatic transaxle is a 6-speed transaxle with electronic shift control. It is designed for operation in a transverse powertrain for Front Wheel Drive (FWD) and All-Wheel Drive (AWD) vehicles.

This transaxle has a 4-element torque converter design, which includes a Torque Converter Clutch (TCC) and a geartrain with 3 planetary gearsets.

The hydraulic control system of this transaxle uses a solenoid body with 7 electronically controlled solenoids for

1. Shift feel (through line pressure control and shift pressure control)
2. Shift scheduling and timing
3. TCC operation

Scheme 26

Scheme 27

When servicing the transaxle, use the identification tag located on top of the transaxle case.

Scheme 28

Scheme 29

Scheme 30

When servicing the solenoid body, use the identification tag located on top of the transaxle case.

Major Components

This transaxle has the following major components

1. Case with torque converter housing
2. Two drive clutches: Direct clutch Overdrive clutch
3. Four brake clutches: Forward clutch Low one-way clutch Low/reverse clutch Intermediate clutch
4. Three planetary gearsets: Front Center Rear
5. Final drive gearset: Transfer shaft drive gear Transfer shaft and gear assembly Differential ring gear
6. Differential
7. Pump and filter assembly
8. Main control: Valve body assembly Solenoid body assembly

Scheme 31

Gear Ratios

This transaxle has 6 forward speeds and reverse.

GEAR RATIO CHART

Torque Converter

The torque converter transmits and multiplies torque. The torque converter is a 4-element device

1. Impeller and cover assembly
2. Turbine
3. Reactor
4. Clutch and damper assembly

Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the impeller blades and pump.

The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft.

The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it rotates in the same direction as the impeller. This action assists in torque multiplication.

The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to rotate at higher vehicle speeds.

Scheme 32

The Torque Converter Clutch (TCC) connects the torque converter housing to the damper when the TCC is applied.

During TCC release, the direction that the transmission fluid flows through the torque converter allows the TCC to release. During TCC apply, the transmission fluid flows in the opposite direction to apply the TCC.

The PCM controls TCC operation using the TCC solenoid in the solenoid body. TCC solenoid operation provides the modulation of hydraulic pressure to change the position of the TCC control valve and TCC regulator apply valve which changes the pressure and transmission fluid direction in the torque converter.

The TCC can be applied in 3rd, 4th, 5th and 6th gears.

Scheme 33

Upshifts

Upshifting is controlled by the PCM. The PCM receives inputs from various engine or vehicle sensors and driver demands to control shift scheduling, shift feel and Torque Converter Clutch (TCC) operation.

The PCM has an adaptive learn strategy to electronically control the transaxle which will automatically adjust the shift feel through the life of the vehicle. The first few hundred miles of operation of the transaxle may have abrupt shifting. This is a normal operation. To reset the adaptive shift pressure strategy, use the scan tool to clear the transmission keep alive memory tables.

Downshifts

Under certain conditions, the transaxle will downshift automatically to a lower gear range (without moving the selector lever). There are 3 categories of automatic downshifts: coastdown, torque demand and forced or kickdown shifts.

Coastdown

The coastdown downshift occurs when the vehicle is coasting down to a stop.

Torque Demand

The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio. If applied, the transmission will disengage the TCC to provide added acceleration.

Kickdown

For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are subject to variations due to tire size, engine and transaxle calibration requirements.

Planetary Gearset

This transaxle has 3 planetary gearsets to provide operation in reverse and 6 forward speeds.

The gearsets are comprised of the following components

1. Front planetary sun gear (part of the front sun gear and shell assembly)
2. Front planetary carrier
3. Front planetary ring gear
4. Center planetary sun gear
5. Center planetary carrier
6. Center planetary ring gear
7. Rear planetary ring gear
8. Rear planetary carrier
9. Rear planetary sun gear and shell assembly

The front planetary sun gear is splined to the forward (1, 2, 3, 4) clutch and is held stationary in 1st, 2nd, 3rd and 4th gear.

The front planetary carrier is splined to the rear planetary ring gear and transfers power from the rear planetary gearset to the front planetary gearset in 2nd, 3rd, 5th and 6th gear and reverse. The front planetary carrier is splined to the transfer shaft drive gear. The front planetary carrier is the output component for the planetary gearset.

The front planetary ring gear is splined to the center planetary carrier and transfers power from the center planetary gearset to the front planetary gearset in 1st, 2nd, 3rd and 4th gear.

The center planetary sun gear is splined to the input shaft and is used as input to the planetary gearsets in 1st, 2nd, 3rd and 4th gear.

The center planetary ring gear is splined to the rear planetary carrier and transfers power from the center planetary gearset to the rear planetary gearset in 3rd gear, from the rear planetary gearset to the center planetary gearset in 4th gear and is held stationary by the low One-Way Clutch (OWC) and low/reverse clutch in 1st gear and reverse.

The rear planetary carrier is splined to the Overdrive (O/D) (4, 5, 6) clutch hub and transfers power from the input shaft to the rear planetary carrier in 4th, 5th and 6th gear.

The rear planetary sun gear and shell assembly is splined to both the intermediate (2, 6) clutch and the direct (3, 5, R) clutch. The rear planetary sun gear and shell assembly is held stationary by the intermediate (2, 6) clutch in 2nd and 6th gear and is driven by the direct (3, 5, R) clutch in 3rd and 5th gear and reverse.

Scheme 34

Scheme 35

Input Shaft

The input shaft is part of the direct/O/D clutch assembly and is splined to the torque converter turbine and the center planetary sun gear. The input shaft transfers power from the torque converter to the rear planetary gearset through the direct (3, 5, R) and O/D (4, 5, 6) clutches and the center planetary sun gear.

Scheme 36

Scheme 37

Front Planetary Carrier Hub (Output Hub)

The front planetary carrier hub is splined to the front planetary carrier and the transfer shaft drive gear. This allows torque to be transferred from the planetary gearset to the final drive gearset.

Scheme 38

Scheme 39

Final Drive Gearset

The final drive consists of a gearset that transfers and multiplies torque from the planetary gearsets to the differential.

The final drive consists of the following components

1. Transfer shaft drive gear
2. Transfer shaft and gear assembly
3. Differential assembly
4. Ring gear

The planetary gear set transfers power to the transfer shaft drive gear through the front planetary carrier hub. The transfer shaft drive gear is part of the stator support assembly. The transfer shaft drive gear turns the transfer shaft and gear assembly which multiplies torque through gear reduction and turns the differential ring gear.

Scheme 40

Scheme 41

Differential

The differential allows the halfshafts and wheels to rotate at different speeds during cornering and transfers power to the Power Transfer Unit (PTU) for All-Wheel Drive (AWD) vehicles.

The differential assembly consists of the following components

1. Differential case (part of the final drive carrier)
2. Two pinion gears supported by a pinion shaft
3. Two side gears supported by the differential case and halfshafts

When driving in a straight line, both front wheels rotate at relatively the same speed. This means both side gears are rotating at the same speed, as well, while both pinion gears revolve (but do not rotate) with the side gears. During cornering, the wheel on the outside of the turn is forced to rotate faster than the wheel on the inside of the turn. Since the side gears must now rotate at different speeds, the pinion gears rotate on the pinion shaft allowing the drive axles to rotate at different speeds while still transferring output torque.

Scheme 42

Scheme 43

Direct (3, 5, R) Clutch

The direct clutch is a drive clutch that transfers power from the direct/O/D hub and shaft assembly to the rear sun gear. The direct clutch is applied in 3rd and 5th gear and reverse.

Hydraulic pressure from the regulator valve in the valve body pushes the direct clutch piston against the direct clutch pack to apply the clutch. The input shaft transfers torque to the rear planetary sun gear as a result of the clutch being applied.

Scheme 44

Scheme 45

Overdrive (O/D) (4, 5, 6) Clutch

The O/D clutch is a drive clutch that transfers power from the direct/O/D hub and shaft assembly to the rear planetary carrier. The O/D clutch is applied in 4th, 5th and 6th gear.

Hydraulic pressure from the regulator valve in the valve body pushes the O/D clutch piston against the O/D clutch pack to apply the clutch. The input shaft transfers torque to the rear planetary sun gear as a result of the clutch being applied.

Scheme 46

Scheme 47

Forward (1, 2, 3, 4) Clutch

The forward clutch is a brake clutch that holds the front sun gear and shell assembly. The forward clutch is applied in 1st, 2nd, 3rd and 4th gear.

Hydraulic pressure from the regulator valve in the valve body pushes the forward clutch piston against the forward clutch pack to apply the clutch. The forward clutch pack is pushed against the low OWC when it is applied. The rear sun gear and shell assembly is held stationary to the transaxle case as a result of the clutch being applied.

Scheme 48

Scheme 49

Low/Reverse Clutch

The low/reverse clutch is a brake clutch that holds the low OWC which is splined to the rear planetary carrier. The low/reverse clutch is applied in manual LOW, REVERSE and 1st gear up to 5 km/h (3 mph).

Hydraulic pressure from the regulator valve, routed through the multiplex shift valve in the valve body, pushes the low/reverse clutch piston against the low/reverse clutch pack to apply the clutch. The rear planetary carrier is held stationary to the transaxle case as a result of the clutch being applied.

Scheme 50

Scheme 51

Intermediate (2, 6) Clutch

The intermediate clutch is a brake clutch that holds the rear sun and shell assembly. The intermediate clutch is applied in 2nd and 6th gear.

Hydraulic pressure from the regulator valve in the valve body pushes the intermediate clutch piston against the intermediate clutch pack to apply the clutch. The rear planetary sun gear is held stationary to the transaxle case as a result of the clutch being applied.

Scheme 52

Scheme 53

Low One-Way Clutch (OWC)

The low OWC is a brake clutch that holds the rear planetary carrier in one direction and allows it to freewheel in the opposite direction which eliminates engine braking in 1st gear when the transaxle is in DRIVE. The low OWC is used in 1st gear when the transaxle is in DRIVE.

Scheme 54

Scheme 55

External sealing

The torque converter housing has a lip-type seal that seals the torque converter hub. The manual lever shaft and halfshafts also use lip-type seals. AWD vehicles do not use a RH halfshaft seal, the transaxle is sealed by the PTU on the RH side.

The torque converter housing is sealed to the transaxle case with silicone sealant. The transaxle cover is sealed to the transaxle case with a reusable gasket.

The main control cover is sealed to the transaxle case and the solenoid body with reusable rubber gaskets and the Turbine Shaft Speed (TSS) sensor is sealed to the transaxle cover with an O-ring seal.

The transmission fluid filler tube is sealed to the main control cover with an O-ring seal that is serviced with the transmission fluid filler tube. The transmission fluid level indicator is sealed to the transmission fluid filler tube with an O-ring seal that is serviced with the transmission fluid level indicator.

The line pressure tap plug, transmission fluid drain plug and the lubrication circuit tap plug have pipe threads and seal when tightened to specification.

Scheme 56

Scheme 57

Lubrication

Transmission fluid enters the lubrication circuits after flowing through the transmission fluid cooler, mounted at the front of the vehicle. When the transmission fluid is not up to operating temperature a thermal bypass valve, mounted in line of the transmission fluid cooler tubes, allows the transmission fluid to bypass the transmission fluid cooler. Transmission fluid returns to the transaxle from the transmission fluid cooler tubes through the back transmission fluid cooler tube.

The transmission fluid enters 2 main lubrication circuits, the input shaft and final drive lubrication circuits, through the transaxle cover and flows through passages in the transaxle to lubricate the transaxle.

The transmission fluid in the input shaft circuit flows from the back of the input shaft toward the front of the input shaft and passes through ports in the input shaft to lubricate the planetary gearset, clutches, stator support and other components of the transaxle.

The transmission fluid in the final drive lubrication circuit flow from the rear cover to the transfer shaft and lubricates the transfer shaft bearings. The transmission fluid flows through the transfer shaft and feeds both of the differential bearings.

Scheme 58

Scheme 59

Park

The park gear is located on the transfer shaft and gear assembly. There are lugs around the outer diameter of the park gear to allow the park pawl to hold the park gear stationary to the transaxle case, which holds the differential in place and keeps the vehicle from moving.

When the manual control lever is rotated to the PARK position, the park lock works as follows

1. The Transmission Range (TR) sensor rotates the range detent plate which pushes the park pawl actuator rod towards the park pawl.
2. The actuator rod pivots the park pawl into the lugs on the park gear, locking the gear stationary to the transaxle case.

Scheme 60

Transmission Fluid Filter

The transmission fluid in the sump area at the bottom of the transaxle case flows through a transmission fluid filter to the pump assembly. The pump is bolted to the torque converter housing and is chain driven from a sprocket that is mounted on the stator support and turned by the torque converter.

Scheme 61

Transmission Fluid Level

The transmission fluid level is checked with the transaxle at normal operating temperature between 80°C and 93°C (175°F and 200°F).

The transmission fluid level indicator is part of the transmission fluid filler tube located on the main control cover.

The correct transmission fluid level is between the MIN and MAX in the cross hatches of the transmission fluid level indicator.

Scheme 62

Main Control

The hydraulic system has a main control assembly. The main control assembly consists of a valve body and a solenoid body. The valve body contains the hydraulic regulator and multiplex shift valves. The solenoid body contains the shift solenoids that control the hydraulic valves. The solenoid body is serviced as an assembly and can not be disassembled. The solenoid body is controlled by the PCM. The PCM has software stored in it specific to the solenoid body currently in the transaxle, called the solenoid body strategy. A new solenoid body strategy must be downloaded into the PCM anytime a new solenoid body is installed.

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

SOLENOID BODY HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 69

COVER PLATE HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 70

TRANSFER PLATE HYDRAULIC CIRCUIT IDENTIFICATION CHART (TOP SIDE)

Scheme 71

TRANSFER PLATE HYDRAULIC CIRCUIT IDENTIFICATION CHART (BOTTOM SIDE)

Scheme 72

CENTER SPACER PLATE HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 73

VALVE BODY HYDRAULIC CIRCUIT IDENTIFICATION CHART (TOP SIDE)

Scheme 74

VALVE BODY HYDRAULIC CIRCUIT IDENTIFICATION CHART (BOTTOM SIDE)

Scheme 75

LOWER SPACER PLATE HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 76

LOWER VALVE BODY HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 77

TRANSAXLE CASE HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 78

PUMP HYDRAULIC CIRCUIT IDENTIFICATION CHART

Scheme 79

Line Pressure Hydraulic Circuits

The PCM controls line pressure with the Line Pressure Control (LPC) solenoid. This effects shift feel and apply component operation.

When the engine is running, the pump supplies pressure to the pressure regulator valve, which is controlled by the LPC solenoid. The pressure regulator valve controls the line pressure.

The line pressure circuit supplies the manual valve. The manual valve directs the line pressure to either the REV/REV SUPPLY circuit when the manual lever is in the REVERSE position or the DRIVE 1 circuit when the manual lever is in the DRIVE or LOW position.

Scheme 80

Lubrication Hydraulic Circuits

Lubrication for the transaxle is supplied by the transmission fluid cooler return tube. Transmission fluid is sent to the transmission fluid cooler from the Torque Converter Clutch (TCC) control valve.

LINE pressure supplied to the pressure regulator valve is sent to the TCC control valve as CONV FD pressure. During TCC release, the TCC control valve sends the transmission fluid to the torque converter to release the clutch. The transmission fluid returns to the TCC control valve from the torque converter and is directed to the transmission fluid cooler on the COOLER FEED circuit.

Scheme 81

When the TCC clutch is applied the TCC solenoid applies pressure to the TCC control and regulator apply valves. The TCC control valve directs the CONV FD circuit to the COOLER FEED circuit.

For lubrication passage location and description, refer to Mechanical Components and Functions .

Scheme 82

Torque Converter Hydraulic Circuits

The PCM controls the TCC solenoid. The TCC solenoid applies hydraulic pressure to the TCC control and regulator apply valves through the TCC SOL SIG circuit. Regulated DRIVE 2 pressure from the multiplex shift valve is directed to the TCC control valve by the TCC regulator apply valve through the REG APPLY circuit. The TCC control valve directs pressure from the REG APPLY circuit to the TCC APPLY circuit to apply the clutch.

The transmission fluid returns to the TCC control valve through the TCC RELEASE hydraulic circuit. The TCC control valve opens the TCC RELEASE circuit to exhaust, so the TCC RELEASE circuit is not pressurized when the TCC is applied.

Scheme 83

When the TCC is released, The TCC solenoid does not apply hydraulic pressure to the TCC control or regulator apply valves. The TCC control valve, in this position, directs hydraulic pressure from the CONV FD circuit to the torque converter through the TCC RELEASE hydraulic circuit and it returns to the TCC control valve through the TCC APPLY circuit.

For torque converter description and function, refer to Torque Converter .

Scheme 84

Solenoid Hydraulic Circuits

LINE pressure from the pump is directed to the individual shift, TCC and LPC solenoids by the solenoid regulator valve on the SOL FEED circuit. The solenoids, controlled by the PCM, direct the fluid to the valves that they control.

The LPC solenoid sends varying pressure to the line pressure regulator valve to control line pressure.

In PARK position, Shift Solenoid D (SSD) directs pressure to the low/reverse/overdrive (4, 5, 6) regulator and boost valves through the SSD SIG hydraulic circuit. Shift Solenoid E (SSE) directs pressure to the multiplex shift valve to direct regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve to the low/reverse clutch.

Scheme 85

In REVERSE position, SSD directs pressure to the low/reverse/overdrive (4, 5, 6) regulator and boost valves through the SSD SIG hydraulic circuit. SSE directs pressure to the multiplex shift valve to direct regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve to the low/reverse clutch. Shift Solenoid B (SSB) directs pressure to the direct (3, 5, R) regulator and boost valves through the SSB SIG hydraulic circuit to apply the direct (3, 5, R) clutch.

Scheme 86

In NEUTRAL position, SSD directs pressure to the low/reverse/overdrive (4, 5, 6) regulator and boost valves through the SSD SIG hydraulic circuit. SSE directs pressure to the multiplex shift valve to direct regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve to the low/reverse clutch.

Scheme 87

In 1st gear, Shift Solenoid A (SSA) directs pressure to the forward (1, 2, 3, 4) clutch regulator and boost valves through the SSA SIG hydraulic circuit to apply the forward (1, 2, 3, 4) clutch. SSD directs pressure to the low/reverse/overdrive (4, 5, 6) regulator and boost valves through the SSD SIG hydraulic circuit only when vehicle speed is below 5 km/h (3 mph). SSE directs pressure to the multiplex shift valve to direct regulated pressure from the low/reverse/overdrive (4, 5, 6) regulator valve to the low/reverse clutch only when vehicle speed is below 5 km/h (3 mph).

Scheme 88

In 2nd gear, the forward (1, 2, 3, 4) clutch remains applied. Shift Solenoid C (SSC) directs pressure to the intermediate (2, 6) clutch regulator valve through the SSC SIG hydraulic circuit to apply the intermediate (2, 6) clutch.

Scheme 89

In 3rd gear, the forward (1, 2, 3, 4) clutch remains applied. SSC releases pressure to the intermediate (2, 6) clutch regulator valve. SSB directs pressure to the direct (3, 5, R) regulator and boost valves through the SSB SIG hydraulic circuit to apply the direct (3, 5, R) clutch.

Scheme 90

In 4th gear, the forward (1, 2, 3, 4) clutch remains applied. SSB releases pressure to the direct (3, 5, R) regulator and boost valves. SSD directs pressure to the low/reverse/overdrive (4, 5, 6) regulator and boost valves through the SSD SIG hydraulic circuit to apply the overdrive (4, 5, 6) clutch.

Scheme 91

In 5th gear, the overdrive (4, 5, 6) clutch remains applied. SSA releases pressure to the forward (1, 2, 3, 4) regulator and boost valves. SSB directs pressure to the direct (3, 5, R) regulator and boost valves through the SSB SIG hydraulic circuit to apply the direct (3, 5, R) clutch.

Scheme 92

In 6th gear, the overdrive (4, 5, 6) clutch remains applied. SSB releases pressure to the direct (3, 5, R) regulator and boost valves. SSC directs pressure to the intermediate (2, 6) clutch regulator valve through the SSC SIG hydraulic circuit to apply the intermediate (2, 6) clutch.

Scheme 93

Forward Clutch Hydraulic Circuits

When the forward (1, 2, 3, 4) clutch is applied in 1st (above 5 km/h [3 mph]), 2nd, 3rd, and 4th gear, LINE pressure from the pump is directed to the multiplex shift valve by the manual valve through the DRIVE 1 hydraulic circuit. The multiplex shift valve supplies the forward (1, 2, 3, 4) clutch regulator valve with pressure through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits. The forward (1, 2, 3, 4) clutch regulator valve directs regulated pressure to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit.

Scheme 94

When the forward (1, 2, 3, 4) clutch is applied in LOW position and 1st gear (below 5 km/h [3 mph]), LINE pressure from the pump is directed to the multiplex shift valve by the manual valve through the DRIVE 1 hydraulic circuit. The multiplex shift valve directs the pressure to the multiplex manual valve through the REV DRIVE B circuit. The multiplex manual valve directs the REV DRIVE B pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE B, CB26FD/CB1234FD and CB1234 SUP circuits. The forward (1, 2, 3, 4) clutch regulator valve directs regulated pressure to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit.

Scheme 95

When the forward (1, 2, 3, 4) clutch is released in 5th and 6th gear, DRIVE 2 pressure is directed to the forward (1, 2, 3, 4) clutch regulator valve. Solenoid pressure is not applied to the forward (1, 2, 3, 4) clutch regulator valve and the regulator valve blocks the DRIVE 2 circuit in this position.

Scheme 96

Direct (3, 5, R) Clutch Hydraulic Circuits

When the direct (3, 5, R) clutch is applied in REVERSE, LINE pressure from the pump is directed to the multiplex manual valve by the manual valve through the REV hydraulic circuit. The multiplex manual valve supplies the direct (3, 5, R) clutch regulator valve with pressure through the REV SUPPLY and C35R SUPPLY hydraulic circuits. The direct (3, 5, R) clutch regulator valve is controlled by SSB and directs regulated C35R SUPPLY pressure to the direct (3, 5, R) clutch through the C35R hydraulic circuit.

Scheme 97

When the direct (3, 5, R) clutch is applied in 3rd and 5th gear, LINE pressure from the pump is directed to the multiplex shift valve by the manual valve through the DRIVE 1 hydraulic circuit. The multiplex shift valve directs the pressure to the direct (3, 5, R) clutch regulator valve through the DRIVE 2/C35R SUPPLY circuits. The direct (3, 5, R) clutch regulator valve is controlled by SSB and directs regulated pressure to the direct (3, 5, R) clutch through the C35R hydraulic circuit.

Scheme 98

When the direct (3, 5, R) clutch is released in 1st, 2nd, 4th and 6th gear, C35R SUPPLY pressure is supplied to the direct (3, 5, R) clutch regulator valve. Solenoid pressure is not applied to the direct (3, 5, R) clutch regulator valve and the regulator valve blocks the C35R SUPPLY circuit in this position.

Scheme 99

Intermediate (2, 6) Clutch Hydraulic Circuits

When the intermediate (2, 6) clutch is applied in 2nd and 6th gear, LINE pressure from the pump is directed to the multiplex shift valve by the manual valve through the DRIVE 1 hydraulic circuit. The multiplex shift valve supplies the intermediate (2, 6) clutch regulator valve with pressure through the DRIVE 2 and CB26FD/CB1234FD hydraulic circuits. The intermediate (2, 6) clutch regulator valve is controlled by SSC and directs regulated pressure to the intermediate (2, 6) clutch through the CB26 hydraulic circuit. Regulated overdrive (4, 5, 6) clutch pressure is supplied to the intermediate (2, 6) clutch regulator valve in 6th gear to boost the SSC solenoid pressure.

Scheme 100

When the intermediate (2, 6) clutch is released in 1st, 3rd, 4th and 5th gear, CB26FD/CB1234FD pressure is supplied to the intermediate (2, 6) clutch regulator valve. Solenoid pressure is not applied to the intermediate (2, 6) clutch regulator valve and the regulator valve blocks the CB26FD/CB1234FD circuit in this position.

Scheme 101

Low/Reverse Clutch Hydraulic Circuits

When the low/reverse clutch is applied in REVERSE, LINE pressure from the pump is directed to the multiplex shift valve by the manual valve through the REV hydraulic circuit to move the valve. Line pressure is also supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve from the pump. The low/reverse/overdrive (4, 5, 6) clutch regulator valve is controlled by SSD and directs regulated pressure to the multiplex shift valve. The multiplex shift valve directs the regulated pressure to the low/reverse clutch through the CBLR SUPPLY circuit.

Scheme 102

When the low/reverse clutch is applied in PARK, LOW, or 1st gear below 5 km/h (3 mph), SSE pressure is supplied to the multiplex shift valve to move the valve. LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve from the pump. The low/reverse/overdrive (4, 5, 6) clutch regulator valve is controlled by SSD and directs regulated pressure to the multiplex shift valve. The multiplex shift valve directs the regulated pressure to the low/reverse clutch through the CBLR SUPPLY circuit.

Scheme 103

When the low/reverse clutch is released in 4th, 5th and 6th gear, LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve from the pump. The low/reverse/overdrive (4, 5, 6) clutch regulator valve is controlled by SSD and directs regulated pressure to the multiplex shift valve. The multiplex shift valve directs the regulated pressure to the multiplex manual valve and is then directed to the overdrive (4, 5, 6) clutch.

Scheme 104

When the low/reverse clutch is released in 1st (above 5 km/h [3 mph]), 2nd and 3rd gear, LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve. Solenoid pressure is not applied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve and the regulator valve blocks regulated LINE pressure to the multiplex shift valve assembly.

Scheme 105

Overdrive Clutch Hydraulic Circuits

When the overdrive clutch is applied in 4th, 5th and 6th gear, LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve from the pump. The low/reverse/overdrive (4, 5, 6) clutch regulator valve is controlled by SSD and directs regulated pressure to the multiplex shift valve through the CBLR/C456 SUPPLY hydraulic circuit. The multiplex shift valve directs the regulated pressure to the multiplex manual valve through the C456 SUPPLY hydraulic circuit. The multiplex manual valve directs the regulated pressure to the overdrive (4, 5, 6) clutch through the C456 hydraulic circuit. The C456 circuit also supplies pressure to the CB26 clutch regulator valve to boost the pressure from SSC in 6th gear.

Scheme 106

When the overdrive (4, 5, 6) clutch is released in PARK, REVERSE, NEUTRAL, 1st gear (below 5 km/h [3 mph]) and LOW position, LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve from the pump. The low/reverse/overdrive (4, 5, 6) clutch regulator valve is controlled by SSD and directs regulated pressure to the multiplex shift valve through the CBLR/C456 SUPPLY hydraulic circuit. The multiplex shift valve directs the regulated pressure to the low/reverse clutch through the CBLR SUPPLY hydraulic circuit.

Scheme 107

When the overdrive (4, 5, 6) clutch is released in 1st (above 5 km/h [3 mph]), 2nd and 3rd gear, LINE pressure is supplied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve. Solenoid pressure is not applied to the low/reverse/overdrive (4, 5, 6) clutch regulator valve and the regulator valve blocks regulated LINE pressure to the multiplex shift valve assembly.

Scheme 108

Electronic System Description

The PCM and its input/output network controls the following operations

1. Shift timing
2. Line pressure (shift feel)
3. Torque Converter Clutch (TCC)

The transaxle control is separate from the engine control strategy in the PCM, although some of the input signals are shared. When determining the best operating strategy for transaxle operation, the PCM uses input information from certain engine-related and driver-demand related sensors and switches.

In addition, the PCM receives input signals from certain transaxle-related sensors and switches. The PCM also uses these signals when determining transaxle operating strategy.

Using all of these input signals, the PCM can determine when the time and conditions are right for a shift, or when to apply or release the TCC. It will also determine the best line pressure needed to optimize shift engagement feel. To accomplish this, the PCM uses output solenoids to control transaxle operation.

The following provides a brief description of each of the sensors and actuators used to control transaxle operation.

Electronic Ignition (EI)

The Electronic Ignition (EI) system consists of the PCM, a Crankshaft Position (CKP) sensor and ignition coils. The CKP sensor sends a crankshaft position signal to the PCM. The PCM then sends the appropriate ignition signal to the ignition coils. The PCM also uses this signal as well as Wide Open Throttle (WOT) shift control, TCC control and electronic pressure control.

Accelerator Pedal Position (APP)

The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal. The APP detects the position of the accelerator pedal and inputs this information as a voltage to the PCM. The PCM uses APP sensor information to aid in determining line pressure, shift scheduling and TCC operation. Failure of this sensor will cause the transmission to operate at higher line pressure to avoid damage to the transmission. This higher line pressure causes harsh upshifts and harsh engagements.

Throttle Position (TP) Sensor

The Throttle Position (TP) sensor is a potentiometer mounted on the Throttle Body (TB). The TP sensor detects the position of the throttle plate and sends this information to the processor assembly as varying voltage signal.

The PCM uses the monitored voltage level of the TP sensor for control of Line Pressure Control (LPC), TCC operation and shift scheduling.

If a malfunction occurs in the TP sensor circuit, the processor will recognize that the TP sensor signal is out of specification. The processor will then operate the transaxle in a high capacity mode to prevent transaxle damage.

PCM

The PCM controls operation of the transaxle. Many input sensors provide information to the powertrain control module. The PCM then controls the actuators which affect transaxle operation.

Transmission Range (TR) Sensor

The Transmission Range (TR) sensor has a 6-pin connector. The TR sensor is located on the inside of the transaxle at the manual lever. The TR sensor sends a signal to the PCM to start the vehicle in PARK and NEUTRAL. The TR sensor opens/closes a set of 4 switches that are monitored by the PCM to determine the position of the manual lever (P, R, N, D, L).

Brake Pedal Position (BPP) Switch

The Brake Pedal Position (BPP) switch tells the PCM when the brakes are applied. The BPP switch closes when the brakes are applied and opens when they are released. The BPP signal is used for brake shift interlock actuation.

Turbine Shaft Speed (TSS) Sensor

This Turbine Shaft Speed (TSS) sensor is a Hall-effect pickup that sends a signal to the PCM that indicates transaxle turbine shaft input speed. The TSS sensor provides converter turbine speed information for TCC strategy. Also used in determining static LPC pressure settings.

Output Shaft Speed (OSS) Sensor

The Output Shaft Speed (OSS) sensor is a Hall-effect pickup, located on the transfer shaft drive gear, that sends a signal to the PCM to indicate transmission output speed. The OSS is used for TCC control and shift scheduling.

Solenoid Body

Note. If the solenoid body identification and strategy does not match the solenoid body information in the Powertrain Control Module (PCM), transaxle damage or driveability concerns can occur.

The solenoid body contains 7 solenoids, 5 shift solenoids (Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC), Shift Solenoid D (SSD) and Shift Solenoid E (SSE)). TCC solenoid and LPC solenoid. The Transmission Fluid Temperature (TFT) is also located in the solenoid body. The solenoid body is serviced as an assembly.

The solenoid body has a unique strategy data file that must be downloaded to the PCM. there is a 7-digit solenoid body identification and a 13-digit solenoid body strategy for each solenoid body. Anytime a new solenoid body is installed or the transaxle is installed, the scan tool must be used to get the solenoid body strategy data file and download it into the PCM.

If the PCM is replaced and the PCM data can not be inhaled or exhaled, the solenoid body identification and solenoid body strategy must be downloaded into the PCM.

Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC), Shift Solenoid D (SSD) and Shift Solenoid E (SSE)

Five shift solenoids are used for electronic shift scheduling. The 5 solenoids are located in the solenoid body. SSA, SSB, SSC and SSD are Variable Force Solenoid (VFS). SSE is an ON/OFF shift solenoid. Shift solenoids SSA, SSB, SSC, SSD and SSE provide selection of 1st through 6th gears and reverse by controlling the pressure of the shift valves. SSA and SSC are normally low-pressure solenoids. Pressure increases as the PCM activates the solenoid. SSB and SSD are normally high-pressure solenoids. Pressure decreases as the PCM activates the solenoid. SSE is normally closed and opens when the PCM activates the solenoid. The solenoids are activated by the PCM controlling current flow at the solenoid ground circuit, this is known as ground side switching.

Transmission Fluid Temperature (TFT) Sensor

This sensor is located in the transaxle solenoid body. It is a temperature-sensitive device called a thermistor. The resistance value of the TFT sensor will vary with temperature change. The PCM monitors the voltage across the TFT to determine the temperature of the transmission fluid.

The PCM uses this initial signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule allows delayed shifts when the TFT is cold to help warm the transmission fluid. The PCM also inhibits TCC operation at low transmission fluid temperatures and adjusts LPC pressures for temperature.

Line Pressure Control (LPC) Solenoid

The LPC solenoid is a VFS solenoid. The VFS-type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. It supplies the pressure which regulates transaxle line pressure. This is done by producing resisting forces to the main regulator and line modulator circuits. These 2 pressures control clutch application pressures.

The PCM has an adaptive learn strategy to electronically control the transaxle which will automatically adjust the shift feel. The first few hundred miles of operation of the transaxle may have abrupt shifting. This is a normal operation. If the battery has been disconnected for any reason it will need to be kept disconnected for approximately 20 minutes to reset the adaptive shift pressure strategy or use the scan tool to do the keep alive memory reset.

Torque Converter Clutch (TCC) Solenoid

The TCC solenoid is used in the transaxle control system to control the application, modulation and release of the torque converter clutch.

Mass Air Flow (MAF) Sensor

This sensor directly measures the mass of the air flowing into the engine. The sensor output is a DC (analog) signal ranging from about 0.5 volt to 5 volts by the PCM to calculate the injector pulse width for stoichiometry. The Mass Air Flow (MAF) sensor input is used for Electronic Pressure Control (EPC), shift and TCC control.

Intake Air Temperature (IAT) Sensor

The Intake Air Temperature (IAT) sensor provides the Sequential Multi-Port Fuel Injection (SFI) system mixture temperature information. The IAT sensor is used both as a density corrector for airflow calculation and to proportion cold enrichment fuel flow. The IAT sensor is part of the MAF sensor and is installed in the Air Cleaner (ACL) outlet tube. The IAT sensor is also used in determining LPC pressures.

A/C Clutch

An electromagnetic clutch is energized when the clutch cycling pressure switch closes. The switch is located on the suction accumulator/drier. The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor driveshaft. When the A/C is engaged, Electronic Pressure Control (EPC) pressure is adjusted to compensate for the additional load on the engine if the Electronic Throttle Control (ETC) signal is not available.

Cylinder Head Temperature (CHT) Sensor

The Cylinder Head Temperature (CHT) sensor is a thermistor device in which resistance changes with the temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. The CHT sensor is used to control TCC operation.

This transaxle uses a torque converter with the following elements

1. Impeller
2. Turbine
3. Reactor
4. Torque Converter Clutch (TCC)

For component information, refer to Torque Converter .

Planetary Gearsets

Operation of this transaxle involves the use of the following planetary gearsets

1. Front
2. Center
3. Rear

Apply Clutches

This transaxle uses the following clutches to operate the 3 planetary gearsets

1. Forward (1, 2, 3, 4) clutch
2. Low/reverse clutch
3. Low One-Way Clutch (OWC)
4. Direct (3, 5, R) clutch
5. Intermediate (2, 6) clutch
6. Overdrive (O/D) (4, 5, 6) clutch

For additional information about planetary gearsets or the apply clutches, refer to Mechanical Components and Functions .

Hydraulic System

The hydraulic system of this transaxle consists of the following components

1. Transmission fluid pump with filter
2. Transmission fluid filler tube with transmission fluid level indicator
3. Main control assembly (valve body and solenoid body)

For component information, refer to Hydraulic System .

Electronic Operation

The PCM controls the operation of the transaxle with the following solenoids

1. Line Pressure Control (LPC) solenoid
2. Shift Solenoid A (SSA)
3. Shift Solenoid B (SSB)
4. Shift Solenoid C (SSC)
5. Shift Solenoid D (SSD)
6. Shift Solenoid E (SSE)
7. TCC solenoid

For solenoid information, refer to Transaxle Electronic Control System .

Scheme 109

Mechanical Operation - Apply components

1. Park pawl engaged, holding the final drive assembly stationary
2. Low/reverse clutch applied

Planetary Gearset Operation - Front planetary gearset driven components

1. None

Center planetary gearset driven components

1. Sun gear

Rear planetary gearset driven components

1. None

Front planetary gearset held components

1. Planetary carrier assembly (splined to final drive assembly, held stationary by park pawl)

Center planetary gearset held components

1. Center ring gear (splined to rear planetary carrier)

Rear planetary gearset held components

1. Planetary carrier
2. Rear ring gear (splined to front carrier)

PARK POSITION CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 110

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) regulator valve to apply the low/reverse clutch.
3. SSE applies pressure to the multiplex shift valve to position the valve against the spring and direct regulated CBLR/C456 SUPPLY pressure to the low/reverse clutch.

Clutch hydraulic circuits

1. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
2. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
3. The multiplex shift valve directs the fluid to the low/reverse clutch through the CBLR hydraulic circuit.

For additional hydraulic circuit information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

PARK POSITION SOLENOID OPERATION CHART

Scheme 111

Scheme 112

Reverse Position

Mechanical Operation - Apply components

1. Low/reverse clutch applied
2. Direct (3, 5, R) clutch applied

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier

Center planetary gearset driven components

1. Sun gear (does not contribute to power flow)

Rear planetary gearset driven components

1. Sun gear

Front planetary gearset held components

1. None

Center planetary gearset held components

1. Center ring

Rear planetary gearset held components

1. Planetary carrier

REVERSE POSITION CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 113

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure is supplied to the manual valve by the pump through the LINE hydraulic circuit.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from theLPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC .
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSB applies pressure to the direct (3, 5, R) regulator valve to apply the direct clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) regulator valve to apply the low/reverse clutch.
4. SSE applies pressure to the multiplex shift valve to position the valve against the spring and direct regulated CBLR/C456 SUPPLY pressure to the low/reverse clutch.

Clutch hydraulic circuits

1. Line pressure supplied to the manual valve is directed to the multiplex shift valve and the multiplex manual valve through the REV hydraulic circuit.
2. The multiplex manual valve directs REV transmission fluid to the direct (3, 5, R) clutch regulator valve through the REV SUPPLY and C35R SUPPLY hydraulic circuits. The (3, 5, R) regulator valve is controlled by SSB and applies regulated C35R SUPPLY pressure to the direct (3, 5, R) clutch.
3. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
4. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
5. The multiplex shift valve directs the transmission fluid to the low/reverse clutch through the CBLR hydraulic circuit.

For additional hydraulic circuit information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

REVERSE POSITION SOLENOID OPERATION CHART

Scheme 114

Scheme 115

Neutral Position

Mechanical Operation - Apply components

1. Low/reverse clutch applied

Planetary Gearset Operation - Front planetary gearset driven components

1. None

Center planetary gearset driven components

1. Sun gear

Rear planetary gearset driven components

1. None

Front planetary gearset held components

1. None

Center planetary gearset held components

1. Ring gear

Rear planetary gearset held components

1. Planetary carrier

NEUTRAL POSITION CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 116

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) regulator valve to apply the low/reverse clutch.
3. SSE applies pressure to the multiplex shift valve to position the valve against the spring and direct regulated CBLR/C456 SUPPLY pressure to the low/reverse clutch.

Clutch hydraulic circuits

1. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
2. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
3. The multiplex shift valve directs the fluid to the low/reverse clutch through the CBLR hydraulic circuit.

For additional hydraulic circuit information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

NEUTRAL POSITION SOLENOID OPERATION CHART

Scheme 117

Scheme 118

1st Gear Above 5 km/h (3 mph)

Note. The transaxle operates differently in 1st gear above and below 5 km/h (3 mph). For transaxle operation below 5 km/h (3 mph), refer to Manual LOW Position and 1st Gear Below 5 km/h (3 mph) .

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Low one-way clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Ring gear
2. Planetary carrier

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier

Rear planetary gearset driven components

1. None

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. Ring gear

Rear planetary gearset held components

1. Rear planetary carrier (does not contribute to power flow)

1ST GEAR ABOVE 5 KM/H (3 MPH) CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 119

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through theLPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits.
3. The low/reverse/overdrive (4, 5, 6) clutch regulator valve directs DRIVE 2 pressure to the multiplex shift valve through the VALVE LATCH hydraulic circuit to latch the multiplex shift valve.
4. Regulated CB1234 SUP pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

1ST GEAR ABOVE 5 KM/H (3 MPH) SOLENOID OPERATION CHART

Scheme 120

Scheme 121

2nd Gear

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Intermediate (2, 6) clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier
2. Ring gear

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Rear planetary gearset driven components

1. Planetary carrier
2. Ring gear

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. Sun gear

2ND GEAR CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 122

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSC applies pressure to the intermediate (2, 6) clutch regulator valve to apply the intermediate clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch and the intermediate (2, 6) clutch regulator valves through the DRIVE 2 and CB26FD/CB1234FD hydraulic circuits. The CB26FD/CB1234FD circuit feeds the CB1234 SUP hydraulic circuit which feeds the forward (1, 2, 3, 4) clutch regulator valve.
3. The low/reverse/overdrive (4, 5, 6) clutch regulator valve directs DRIVE 2 pressure to the multiplex shift valve through the VALVE LATCH hydraulic circuit to latch the multiplex shift valve.
4. Regulated DRIVE 2 pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
5. Regulated DRIVE 2 pressure from the intermediate (2, 6) clutch regulator valve is directed to the intermediate (2, 6) clutch through the CB26 hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

2ND GEAR SOLENOID OPERATION CHART

Scheme 123

Scheme 124

3rd Gear Torque Converter Clutch (TCC) Released

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Direct (3, 5, R) clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier
2. Ring gear

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Rear planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

3RD GEAR CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 125

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSB applies pressure to the direct (3, 5, R) clutch regulator valve to apply the direct clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits. The DRIVE 2 hydraulic circuit also feeds the C35R SUPPLY hydraulic circuit which supplies the direct (3, 5, R) clutch regulator valve with pressure.
3. The low/reverse/overdrive (4, 5, 6) clutch regulator valve directs DRIVE 2 pressure to the multiplex shift valve through the VALVE LATCH hydraulic circuit to latch the multiplex shift valve.
4. Regulated CB1234 SUP pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
5. Regulated C35R SUPPLY pressure from the direct (3, 5, R) clutch regulator valve is directed to the direct (3, 5, R) clutch through the C35R hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

3RD GEAR (TCC RELEASED) SOLENOID OPERATION CHART

Scheme 126

Scheme 127

3rd Gear TCC Applied

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Direct (3, 5, R) clutch
3. TCC

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier
2. Ring gear

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Rear planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

3RD GEAR TCC APPLIED CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 128

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the TCC regulator apply valve through the DRIVE 2 hydraulic circuit.
3. When the TCC is applied, the TCC regulator apply valve directs regulated DRIVE 2 pressure to the TCC control valve through the REG APPLY hydraulic circuit. The TCC control valve directs DRIVE 2 pressure to the TCC APPLY hydraulic circuit to apply the TCC.
4. Transmission fluid from the TCC APPLY circuit returns to the TCC control valve unpressurized through the TCC RELEASE circuit and returns to the sump through the EXH port.

Cooler and lubrication hydraulic circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. The TCC control valve directs transmission fluid from the CONV FD circuit to the COOLER FEED circuit.
3. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSB applies pressure to the direct (3, 5, R) clutch regulator valve to apply the direct clutch.
4. The TCC solenoid applies pressure to the TCC control valve and the TCC regulator apply valve to apply the TCC.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits. The DRIVE 2 hydraulic circuit also feeds the C35R SUPPLY hydraulic circuit which supplies the direct (3, 5, R) clutch regulator valve with pressure.
3. The low/reverse/overdrive (4, 5, 6) clutch regulator valve directs DRIVE 2 pressure to the multiplex shift valve through the VALVE LATCH hydraulic circuit to latch the multiplex shift valve.
4. Regulated CB1234 SUP pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
5. Regulated C35R SUPPLY pressure from the direct (3, 5, R) clutch regulator valve is directed to the direct (3, 5, R) clutch through the C35R hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

3RD GEAR (TCC APPLIED) SOLENOID OPERATION CHART

Scheme 129

Scheme 130

4th Gear Torque Converter Clutch (TCC) Released

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Overdrive (O/D) (4, 5, 6) clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier
2. Ring gear

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Rear planetary gearset driven components

1. Planetary carrier

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

4TH GEAR CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 131

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the O/D clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits. The DRIVE 2 hydraulic circuit also feeds the CBLR/C456 clutch regulator valve.
3. Regulated CB1234 SUP pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
4. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
5. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
6. The multiplex shift valve directs the transmission fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
7. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the O/D (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
8. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

4TH GEAR (TCC RELEASED) SOLENOID OPERATION CHART

Scheme 132

Scheme 133

4th Gear Torque Converter Clutch (TCC) Applied

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. O/D (4, 5, 6) clutch
3. TCC

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier
2. Ring gear

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Rear planetary gearset driven components

1. Planetary carrier

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

4TH GEAR TCC APPLIED CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 134

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the TCC regulator apply valve through the DRIVE 2 hydraulic circuit.
3. When the TCC is applied, the TCC regulator apply valve directs regulated DRIVE 2 pressure to the TCC control valve through the REG APPLY hydraulic circuit. The TCC control valve directs DRIVE 2 pressure to the TCC APPLY hydraulic circuit to apply the TCC.
4. Transmission fluid from the TCC APPLY circuit returns to the TCC control valve unpressurized through the TCC RELEASE circuit and returns to the sump through the EXH port.

Cooler and lubrication hydraulic circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. The TCC control valve directs transmission fluid from the CONV FD circuit to the COOLER FEED circuit.
3. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the Overdrive (O/D) clutch.
4. The TCC solenoid applies pressure to the TCC control valve and the TCC regulator apply valve to apply the TCC.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the forward (1, 2, 3, 4) clutch regulator valve through the DRIVE 2, CB26FD/CB1234FD and CB1234 SUP hydraulic circuits. The DRIVE 2 hydraulic circuit also feeds the CBLR/C456 clutch regulator valve.
3. Regulated CB1234 SUP pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
4. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
5. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
6. The multiplex shift valve directs the fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
7. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the Overdrive (O/D) (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
8. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

4TH GEAR (TCC APPLIED) SOLENOID OPERATION CHART

Scheme 135

Scheme 136

5th Gear Torque Converter Clutch (TCC) Released

Mechanical Operation - Apply components

1. O/D (4, 5, 6) clutch
2. Direct (3, 5, R) clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier

Center planetary gearset driven components

1. Sun gear (does not contribute to power flow)

Rear planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Front planetary gearset held components

1. None

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

5TH GEAR CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 137

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSB applies pressure to the direct (3, 5, R) clutch regulator valve to apply the direct clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the O/D clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the C35R clutch regulator valve through the DRIVE 2 and C35R SUPPLY hydraulic circuits.
3. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
4. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
5. The multiplex shift valve directs the CBLR/C456 SUPPLY transmission fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
6. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the Overdrive (O/D) (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
7. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve.
8. Regulated C35R SUPPLY pressure from the direct (3, 5, R) clutch regulator valve is directed to the direct (3, 5, R) clutch through the C35R hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

5TH GEAR TCC RELEASED SOLENOID OPERATION CHART

Scheme 138

Scheme 139

5th Gear Torque Converter Clutch (TCC) Applied

Mechanical Operation - Apply components

1. O/D (4, 5, 6) clutch
2. Direct (3, 5, R) clutch
3. TCC

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier

Center planetary gearset driven components

1. Sun gear (does not contribute to power flow)

Rear planetary gearset driven components

1. Sun gear
2. Planetary carrier
3. Ring gear

Front planetary gearset held components

1. None

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. None

5TH GEAR TCC APPLIED CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 140

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the TCC regulator apply valve through the DRIVE 2 hydraulic circuit.
3. When the TCC is applied, the TCC regulator apply valve directs regulated DRIVE 2 pressure to the TCC control valve through the REG APPLY hydraulic circuit. The TCC control valve directs DRIVE 2 pressure to the TCC APPLY hydraulic circuit to apply the TCC.
4. Transmission fluid from the TCC APPLY circuit returns to the TCC control valve unpressurized through the TCC RELEASE circuit and returns to the sump through the EXH port.

Cooler and lubrication hydraulic circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. The TCC control valve directs transmission fluid from the CONV FD circuit to the COOLER FEED circuit.
3. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSB applies pressure to the direct (3, 5, R) clutch regulator valve to apply the direct clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the O/D clutch.
4. The TCC solenoid applies pressure to the TCC control valve and the TCC regulator apply valve to apply the TCC.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the C35R clutch regulator valve through the DRIVE 2 and C35R SUPPLY hydraulic circuits.
3. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
4. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
5. The multiplex shift valve directs the CBLR/C456 SUPPLY transmission fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
6. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the O/D (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
7. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve.
8. Regulated C35R SUPPLY pressure from the direct (3, 5, R) clutch regulator valve is directed to the direct (3, 5, R) clutch through the C35R hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

5TH GEAR TCC APPLIED SOLENOID OPERATION CHART

Scheme 141

Scheme 142

6th Gear Torque Converter Clutch (TCC) Released

Mechanical Operation - Apply components

1. O/D (4, 5, 6) clutch
2. Intermediate (2, 6) clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier

Center planetary gearset driven components

1. Sun gear (does not contribute to power flow)
2. Ring gear (does not contribute to power flow)

Rear planetary gearset driven components

1. Planetary carrier
2. Ring gear

Front planetary gearset held components

1. None

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. Sun gear

6TH GEAR CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 143

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSC applies pressure to the intermediate (2, 6) clutch regulator valve to apply the direct (2, 6) clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the O/D clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the intermediate (2, 6) clutch regulator valve through the DRIVE 2 and CB26FD/CB1234FD hydraulic circuits.
3. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
4. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
5. The multiplex shift valve directs the CBLR/C456 SUPPLY transmission fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
6. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the O/D (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
7. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve to boost the SSC SIG circuit.
8. Regulated CB26FD/CB1234FD pressure from the intermediate (2, 6) clutch regulator valve is directed to the intermediate (2, 6) clutch through the CB26 hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

6TH GEAR TCC RELEASED SOLENOID OPERATION CHART

Scheme 144

Scheme 145

6th Gear Torque Converter Clutch (TCC) Applied

Mechanical Operation - Apply components

1. O/D (4, 5, 6) clutch
2. Intermediate (2, 6) clutch
3. TCC

Planetary Gearset Operation - Front planetary gearset driven components

1. Planetary carrier

Center planetary gearset driven components

1. Sun gear (does not contribute to power flow)
2. Ring gear (does not contribute to power flow)

Rear planetary gearset driven components

1. Planetary carrier
2. Ring gear

Front planetary gearset held components

1. None

Center planetary gearset held components

1. None

Rear planetary gearset held components

1. Sun gear

6TH GEAR TCC APPLIED CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 146

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the TCC regulator apply valve through the DRIVE 2 hydraulic circuit.
3. When the TCC is applied, the TCC regulator apply valve directs regulated DRIVE 2 pressure to the TCC control valve through the REG APPLY hydraulic circuit. The TCC control valve directs DRIVE 2 pressure to the TCC APPLY hydraulic circuit to apply the TCC.
4. Transmission fluid from the TCC APPLY circuit returns to the TCC control valve unpressurized through the TCC RELEASE circuit and returns to the sump through the EXH port.

Cooler and lubrication hydraulic circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. The TCC control valve directs transmission fluid from the CONV FD circuit to the COOLER FEED circuit.
3. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSC applies pressure to the intermediate (2, 6) clutch regulator valve to apply the direct (2, 6) clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) clutch regulator valve to apply the O/D clutch.
4. The TCC solenoid applies pressure to the TCC control valve and the TCC regulator apply valve to apply the TCC.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the intermediate (2, 6) clutch regulator valve through the DRIVE 2 and CB26FD/CB1234FD hydraulic circuits.
3. Line pressure from the pump is supplied to the low/reverse/overdrive (4, 5, 6) regulator valve.
4. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
5. The multiplex shift valve directs the CBLR/C456 SUPPLY transmission fluid to the multiplex manual valve through the C456 SUPPLY hydraulic circuit.
6. The multiplex manual valve directs pressure from the C456 SUPPLY circuit to the O/D (4, 5, 6) clutch through the C456 hydraulic circuit to apply the clutch.
7. The C456 hydraulic circuit supplies pressure to the VALVE LATCH circuit to latch the multiplex shift valve and also supplies pressure to the intermediate (2, 6) clutch regulator valve to boost the SSC SIG circuit.
8. Regulated CB26FD/CB1234FD pressure from the intermediate (2, 6) clutch regulator valve is directed to the intermediate (2, 6) clutch through the CB26 hydraulic circuit to apply the clutch.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

6TH GEAR TCC APPLIED SOLENOID OPERATION CHART

Scheme 147

Scheme 148

Manual LOW Position and 1st Gear Below 5 km/h (3 mph)

Note. The transaxle operates differently in first gear above and below 5 km/h (3 mph). For transaxle operation above 5 km/h (3 mph), refer to 1st Gear Above 5 km/h (3 mph) .

Mechanical Operation - Apply components

1. Forward (1, 2, 3, 4) clutch
2. Low/reverse clutch
3. Low one-way clutch

Planetary Gearset Operation - Front planetary gearset driven components

1. Ring gear
2. Planetary carrier

Center planetary gearset driven components

1. Sun gear
2. Planetary carrier

Rear planetary gearset driven components

1. None

Front planetary gearset held components

1. Sun gear

Center planetary gearset held components

1. Ring gear

Rear planetary gearset held components

1. Rear planetary carrier (does not contribute to power flow)

MANUAL LOW POSITION AND 1ST GEAR BELOW 5 KM/H (3 MPH) CLUTCH APPLICATION CHART

For component information, refer to Mechanical Components and Functions .

Scheme 149

Hydraulic Operation - Line pressure hydraulic circuits

1. Line pressure from the pump is supplied to the manual valve.
2. Line pressure is regulated by the pressure regulator valve.
3. The pressure regulator valve is controlled by varying pressure from the LPC solenoid through the LPC circuit.

Torque converter circuits

1. Regulated line pressure from the pressure regulator valve is directed to the TCC control valve through the CONV FD hydraulic circuit.
2. When the TCC is released, CONV FD pressure is directed to the TCC RELEASE circuit by the TCC control valve. Pressure from the TCC RELEASE circuit releases the TCC.
3. Transmission fluid from the TCC RELEASE returns to the TCC control valve through the TCC APPLY circuit.

Cooler and lubrication hydraulic circuits

1. The TCC control valve directs transmission fluid from the TCC APPLY circuit (return circuit from the torque converter when the TCC is released) to the COOLER FEED circuit.
2. In the COOLER FEED circuit, transmission fluid flows through the transmission fluid cooler or the thermal bypass valve to the LUBE circuit.

Solenoid hydraulic circuits

1. The LPC solenoid applies varying pressure to the pressure control valve through the LPC hydraulic circuit. The LPC solenoid regulates line pressure by controlling the position of the pressure regulator valve.
2. SSA applies pressure to the forward (1, 2, 3, 4) clutch regulator valve to apply the forward clutch.
3. SSD applies pressure to the low/reverse/overdrive (4, 5, 6) regulator valve to apply the low/reverse clutch.
4. SSE applies pressure to the multiplex shift valve to position the valve against the spring and direct regulated CBLR/C456 SUPPLY pressure to the low/reverse clutch.

Clutch hydraulic circuits

1. Line pressure from the manual valve is directed to the multiplex shift valve through the DRIVE 1 hydraulic circuit.
2. The multiplex shift valve directs DRIVE 1 pressure to the multiplex manual valve through the REV DRIVE B circuit.
3. The multiplex manual valve directs REV DRIVE B pressure to the DRIVE 2/DRIVE B shuttle ball where it enters the CB26FD/CB1234FD circuit.
4. The CB26FD/CB1234FD circuit feeds the forward (1, 2, 3, 4) clutch through the CB1234 SUP circuit.
5. Regulated DRIVE 2 pressure from the forward (1, 2, 3, 4) clutch regulator valve is directed to the forward (1, 2, 3, 4) clutch through the CB1234 hydraulic circuit to apply the clutch.
6. Regulated line pressure from the low/reverse/overdrive (4, 5, 6) regulator valve is sent to the multiplex shift valve assembly through the CBLR/C456 SUPPLY hydraulic circuit.
7. The multiplex shift valve directs the transmission fluid to the low/reverse clutch through the CBLR hydraulic circuit.

For additional hydraulic circuit and information, refer to Hydraulic Circuits .

Electrical Operation - Solenoid operation

MANUAL LOW POSITION AND 1ST GEAR BELOW 5 KM/H (3 MPH) SOLENOID OPERATION CHART

Scheme 150

Transaxle

Special Tools Illustration Tool Name Tool Number 2-6 Spring Compressor 307-584 (includes 307-584/1 and 307-584/2) Compressor, Forward Clutch Spring 307-574 (includes 307-574/1 and 307-574/2) Differential Bearing Cup Remover 307-586 Holding Fixture 307-580 Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C) Transfer Gear Bearing Race Remover 307-577

Scheme 151

Scheme 152

All vehicles

1. Using the Holding Fixture 307-580, install the transaxle onto the bench.
2. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter.
3. Remove the torque converter from the transaxle.
4. Remove the nut and the manual lever.
5. Remove the 14 bolts and the main control cover.
6. Slide the Transmission Range (TR) sensor electrical connector lock tab over to unlock the connector.
7. Disconnect the TR sensor electrical connector.
8. Disconnect the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensor electrical connectors. TSS sensor. OSS sensor.
9. Remove the OSS sensor wire from the retainer.
10. Remove the 11 bolts and the solenoid body.
11. Remove the 10 main control valve body bolts and the valve body.
12. Using a suitable tool, remove and discard the TR sensor locking pin.
13. Remove the TR sensor. Slide the TR sensor out of the transaxle case. Rotate the TR sensor detent plate until it rests against the transaxle case. Remove the park pawl actuator rod from the detent lever and remove the TR sensor.
14. Using a suitable tool, remove the manual lever shaft seal.
15. Using a suitable tool, remove the forward clutch feed seal.
16. Remove the bolt and the OSS sensor.
17. Remove the 10 cover assembly bolts.
18. Remove the cover assembly and carefully route the TSS sensor wiring harness and electrical connector out of the transaxle case.
19. Remove the cover assembly gasket.
20. Remove the No. 1 cover assembly thrust bearing.
21. Remove the overdrive/direct clutch hub and turbine shaft assembly.
22. Remove No. 3 rear sun gear thrust bearing.
23. Remove the intermediate clutch shell and sun gear assembly.
24. Remove the intermediate clutch assembly.
25. Remove the low/reverse clutch assembly.
26. Remove the rear planetary carrier and center ring gear assembly.
27. Remove the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
28. Remove the center planetary sun gear.
29. Remove the center planetary carrier and front ring gear assembly.
30. Remove the No. 7 center sun gear and the No. 8 front/center planetary gear assembly thrust bearings.
31. Remove the front planetary carrier and rear ring gear assembly.
32. Remove the front planetary sun gear and shell assembly.
33. Remove the No. 10 front sun gear thrust bearing.
34. Remove the front planetary carrier hub assembly.
35. Remove the No. 11 support assembly thrust bearing.
36. Remove the low OWC snap ring.
37. Remove the low OWC.
38. Remove the forward clutch assembly.
39. Using the 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2) and the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) compress the forward clutch piston return spring.
40. Remove the forward clutch piston return spring snap ring.
41. Remove Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2).
42. Remove the forward clutch piston return spring.
43. Using a suitable tool, remove and discard the forward clutch piston.
44. Remove the 19 torque converter housing bolts.
45. Using a suitable tool, carefully pry the torque converter housing off the transaxle case just enough to break the seal of the silicone and remove the torque converter housing from the transaxle case.
46. Remove the transaxle lube tube.
47. Remove the differential and ring gear assembly.
48. Remove the transfer shaft and gear assembly.
49. Remove the pump-to-case seal.
50. Remove the 2 bolts and the oil reservoir.
51. Using a suitable tool, remove the reservoir O-ring seal.
52. Inspect the transaxle case side transfer shaft bearing cup for damage.
53. If the transaxle case side transfer shaft bearing cup is damaged, install Transfer Gear Bearing Race Remover 307-577 on the bearing cup.
54. Install Front Wheel Hub Remover/Installer 204-069.
55. Using a wrench, turn the nut on Front Wheel Hub Remover/Installer 204-069 to remove the transfer shaft bearing cup from the transaxle case.
56. If the transaxle case side transfer shaft bearing cup was removed, using a suitable tool, punch a hole in the fluid dam.
57. If the transfer shaft bearing cup was removed, using a suitable dent puller, remove the fluid dam from the transaxle case.
58. Using a suitable tool, remove the halfshaft seal from the transaxle case.
59. Inspect the transaxle case side differential bearing cup for damage.
60. If the transaxle case side differential bearing cup is damaged, install the Differential Bearing Cup Remover 307-586 on the bearing cup. Position the Differential Bearing Cup Remover 307-586 in the transaxle case with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the transaxle case. Expand the Differential Bearing Cup Remover 307-586 by hand. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the transaxle case, tighten the nut.
61. Using a suitable press, press the differential bearing cup out of the transaxle case.
62. Remove the park pawl actuator rod.
63. Remove the 2 bolts and the park pawl pin retainer.
64. Remove the park pawl spring.
65. Remove the park pawl pin and the park pawl.
66. Using a magnet, remove the park pawl abutment pins and the abutment.
67. Remove the bolt and the fluid baffle from the torque converter housing.
68. Remove the 10 stator support assembly bolts.
69. Remove the stator support assembly.
70. Remove the 3 bolts and the fluid pump and filter assembly.
71. Remove the fluid pump sprocket and chain assembly.
72. Remove the fluid pump drive sprocket and driven sprocket thrust washers.
73. Install the Transfer Gear Bearing Race Remover 307-577 on the bearing cup.
74. Install Front Wheel Hub Remover/Installer 204-069.
75. Using a wrench, turn the nut on Front Wheel Hub Remover/Installer 204-069 to remove the transfer shaft bearing cup from the torque converter housing.
76. Remove the preload shim.
77. Using a suitable tool, punch a hole in the fluid dam.
78. If the transfer shaft bearing cup was removed, using a suitable dent puller, remove the fluid dam from the torque converter housing.
79. Using a suitable tool, remove the halfshaft seal from the torque converter housing.
80. Install the Differential Bearing Cup Remover 307-586 on the bearing cup. Position the Differential Bearing Cup Remover 307-586 in the torque converter housing with the tabs on the Differential Bearing Cup Remover 307-586 aligned with the slots in the transaxle case. Expand the Differential Bearing Cup Remover 307-586 by hand. While holding the Differential Bearing Cup Remover 307-586 in the expanded position with the tabs in the slots of the transaxle case, tighten the nut.
81. Using a suitable press, press the differential bearing cup out of the torque converter housing.
82. Remove the differential bearing preload shim.
83. Using a suitable dent puller, remove the torque converter hub seal from the torque converter housing.

Transfer Shaft and Gear

Special Tools Illustration Tool Name Tool Number Differential Bearing Installer and Guide 307-587 (includes 307-587/1, 307-587/2 and 307-587/3) Puller, Bearing 205-D064 (D84L-1123-A) or equivalent

Scheme 153

1. Inspect the transfer shaft bearings for damage or excessive wear. Install new if necessary.
2. Install the Bearing Puller 205-D064 on the bearing.
3. Using a suitable press, remove bearings from the transfer shaft assembly.
4. Inspect the transfer shaft assembly for damage. Inspect the park pawl wheel for damage and install new, if necessary. Inspect the transfer shaft and transfer shaft input gear for damage and install new, if necessary.

1. Install the park pawl wheel on the transfer shaft.
2. Using the Differential Bearing Installer and Guide 307-587 (307-587/2 and 307-587/3) and a press, install new transfer shaft bearings on the transfer shaft assembly.

Differential Gear Assembly

Special Tools Illustration Tool Name Tool Number Differential Bearing Installer and Guide 307-587 (includes 307-587/1, 307-587/2 and 307-587/3) Puller, Bearing 205-D064 (D84L-1123-A) or equivalent Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C) Step Plate 205-D015 (D80L-630-4) or equivalent Step Plate 205-D019 (D80L-630-8) or equivalent

All vehicles

1. Inspect the differential bearings for damage or excessive wear. Install new bearings if necessary.
2. Using Step Plate 205-D019, Bearing Puller 205-D064 and Front Wheel Hub Remover/Installer 204-069, remove the right differential carrier bearing from the differential assembly.
3. Using Step Plate 205-D015, Bearing Puller 205-D064 and Front Wheel Hub Remover/Installer 204-069, remove the right differential carrier bearing from the differential assembly.
4. Using Step Plate 205-D015, Bearing Puller 205-D064 and Front Wheel Hub Remover/Installer 204-069, remove the left differential carrier bearing from the differential assembly.
5. Inspect the differential assembly and the ring gear for damage and install new if necessary.

1. Using Differential Bearing Installer and Guide 307-587 (307-587/1 and 307-587/2), press new differential carrier bearings on the differential assembly.

Pump and Filter Assembly

Material

1. Remove and discard the fluid filter. Pull the filter out of the bore of the fluid pump. Discard the fluid filter. If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.
2. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.

1. Flush the pump with clean transmission fluid. Rotate the pump shaft by hand to clean the old transmission fluid out of the pump.
2. Install the fluid filter seal in the fluid pump.
3. Install the fluid filter in the fluid pump.

Pump Chain and Sprocket

1. Clean and inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary. Check the drive chain for wear, damage, stretching or tightness of the chain links. Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.

Stator Support and Gear Assembly

Special Tools Illustration Tool Name Tool Number Collet, 7/8 Inch to 1 Inch 303-D020 (D80L-100-R) or equivalent Slide Hammer 100-001 (T50T-100-A) Support Seal Installer 307-585 Support Solid Seal Installer (Single Seal) 307-579 (includes 307-579/1, 307-579/2 and 307-579/3)

Scheme 154

Scheme 155

1. Remove and discard the stator support assembly seal.
2. Install 7/8 Inch to 1 Inch Collet 303-D020 on the input shaft seal.
3. Assemble Slide Hammer 100-001 and 7/8 Inch to 1 Inch Collet 303-D020 and remove and discard the input shaft seal.
4. Remove the drive sprocket thrust washer.
5. Using a suitable tool, remove the stator support-to-torque converter seal.
6. Remove the 4 bolts and the stator support feed tube.
7. Remove and discard the gasket for the feed tube assembly.
8. Clean and inspect the stator support assembly for damage and install new, if necessary.

1. Install the Support Solid Seal Installer 307-579/3 on the stator support assembly.
2. Install a new seal on Support Solid Seal Installer 307-579/3.
3. Install the Support Solid Seal Installer 307-579/2 on the Support Solid Seal Installer 307-579/3 and slide the seal in to the groove on the stator support assembly.
4. Remove the Support Solid Seal Installer 307-579 (includes 307-579/2 and 307-579/3) from the stator support assembly.
5. Install the Support Solid Seal Installer 307-579/1 on the stator support assembly to size the seal.
6. Install a new gasket on the stator support assembly.
7. Position the feed tube assembly in place and install the bolts hand tight.
8. Tighten the 2 Torx head bolts. Tighten to 7 Nm (62 lb-in).
9. Tighten the 2 hex head bolts. Tighten to 12 Nm (106 lb-in).
10. Install a new input shaft seal on the Support Seal Installer 307-585.
11. Using the Support Seal Installer 307-585, install the input shaft seal.
12. Remove the Support Seal Installer 307-579/1 from the stator support assembly.
13. Install the drive sprocket thrust washer.
14. Install a new stator support assembly seal.

Scheme 156

1. Remove the 6 bolts and the cover assembly.
2. Remove the 5 bolts and the transfer plate assembly.
3. Remove and discard the valve body separator plate.
4. Remove the 7 check balls from the valve body.
5. Remove the lower valve body assembly.
6. Remove and discard the lower valve body separator plate and gasket.
7. Remove the manual valve from the valve body.
8. Remove the individual valves and springs from the main control valve body and lower valve body by removing the retaining clips. See the Valve Body and Lower Valve Body illustrations for valve and spring locations. Clean valves, springs, main control valve body and lower valve body.

1. Install the valve body valves, springs and retaining clips in the main control valve body and lower valve body. See the Valve Body and Lower Valve Body illustrations for valve and spring locations.
2. Install the manual valve in the valve body.
3. Position a new lower valve body separator plate and gasket on the main control valve body.
4. Position the lower valve body on the main control valve body.
5. Install the 7 check balls.
6. Install a new valve body separator plate and gasket.
7. Install the transfer plate assembly and hand tighten the 5 bolts. 63 mm (2.48 in) bolts 35 mm (1.37 in) bolts
8. Tighten the 5 bolts. Tighten to 12 Nm (106 lb-in).
9. Install the cover assembly and hand tighten the 6 bolts. 63 mm (2.48 in) bolts 35 mm (1.37 in) bolts
10. Tighten the 6 bolts. Tighten to 12 Nm (106 lb-in).

Solenoid Body Assembly

1. Remove the solenoid body filter assembly by pulling it straight up from the alignment tabs. Discard the filter.
2. Remove and discard the solenoid body assembly electrical connector seal.
3. Clean and inspect the solenoid body assembly for damage and install new if necessary.

1. Install a new solenoid body assembly electrical connector seal.
2. Install a new solenoid body filter assembly by pushing it straight down onto the alignment tabs.

Planetary Gear Assembly

1. Clean and inspect the rear planetary sun gear and shell assembly for damage or wear and install new, as necessary. Gear teeth Shell-to-clutch pack surfaces Thrust bearing surfaces
2. Clean and inspect the rear planetary gear carrier assembly for damage or wear and install new, as necessary. Pinion gear teeth Pinion gear surfaces Pinion gear bearings Spline teeth Thrust bearing Thrust bearing surfaces Ring gear teeth
3. Clean and inspect the center planetary sun gear for damage or wear and install new, as necessary. Sun gear teeth Spline teeth
4. Clean and inspect the center planetary gear carrier assembly for damage or wear and install new, as necessary. Pinion gear teeth Pinion gear surfaces Pinion gear bearings Thrust bearing surfaces Ring gear teeth
5. Clean and inspect the front planetary gear carrier assembly for damage or wear and install new, if necessary. Spline teeth Thrust bearing surfaces Ring gear teeth Shell-to-clutch pack surfaces Pinion gear teeth Pinion gear surfaces Pinion gear bearings Thrust bearing
6. Clean and inspect the front planetary sun gear and shell assembly for damage or wear and install new, if necessary. Sun gear teeth Shell-to-clutch pack surfaces Bearing surfaces
7. Clean and inspect the front planetary carrier hub for damage or wear and install new, if necessary. Spline teeth Thrust bearing surfaces Hub-to-stator support surfaces

Low One-Way Clutch

1. Clean and inspect the low One-Way Clutch (OWC) for cracks and damaged splines. The internal splined section should rotate counterclockwise and lock when rotated clockwise. If any damage is found or the clutch does not rotate or lock, install a new low OWC.
2. Inspect the forward clutch surface for damage. If the surface is burned or worn excessively, install a new OWC.

Overdrive/Direct Clutch Assembly

Special Tools Illustration Tool Name Tool Number 2-6 Spring Compressor 307-584 (includes 307-584/1 and 307-584/2) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Overdrive Clutch and Balance Piston Service Set 307-589 (includes 307-589/1 and 307-589/2)

1. Remove the overdrive clutch snap ring.
2. Remove the overdrive clutch hub and clutch assembly.
3. Remove the bottom overdrive clutch steel plate.
4. Remove the No. 2 rear sun gear thrust bearing.
5. Install the Overdrive Clutch and Balance Piston Service Set 307-589/1 and 2-6 Spring Compressor 307-584/2 on the balance piston. Using a press, compress the overdrive piston return spring.
6. With the overdrive piston return spring compressed, remove the balance piston snap ring.
7. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/1 and the 2-6 Spring Compressor 307-584/2.
8. Remove and discard the balance piston.
9. Remove the overdrive piston return spring.
10. Position the overdrive/direct clutch assembly in the rear cover.
11. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.
12. Remove the overdrive/direct clutch assembly from the rear cover.
13. Remove and discard the overdrive clutch piston inner seal.
14. Remove and discard the overdrive clutch piston outer seals from the piston.
15. Install the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Remove the snap ring.
16. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2.
17. Remove the direct clutch cylinder.
18. Remove the rear direct clutch piston seal.
19. Remove and discard the direct clutch piston.
20. Remove the direct clutch piston return spring.
21. Remove and discard the direct clutch piston seals.
22. Remove the direct clutch snap ring.
23. Remove the direct clutch pressure plate, clutch assembly and wave spring.
24. Clean and inspect the overdrive/direct clutch hub and shaft assembly for damage. Install new, if necessary.

1. Install the direct clutch wave spring.
2. Lubricate the direct clutch pack in clean automatic transmission fluid.
3. Install the direct clutch assembly and pressure plate.
4. Install the direct clutch snap ring.
5. Install new direct clutch piston seals and lubricate the seals with petroleum jelly.
6. Install the direct clutch piston return spring.
7. Lubricate a new direct clutch piston with petroleum jelly and install the piston.
8. Install a new rear direct clutch piston seal and lubricate it with petroleum jelly.
9. Install the direct clutch cylinder.
10. Install the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring and install the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Install the snap ring.
11. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/2 and the 2-6 Spring Compressor 307-584/2 .
12. Install new seals on the overdrive clutch piston and lubricate the seals with petroleum jelly.
13. Install a new overdrive clutch piston inner seal and lubricate the seal with petroleum jelly.
14. Install the overdrive clutch piston in the overdrive/direct clutch hub and shaft assembly and push the overdrive clutch piston in the cylinder by hand using Overdrive Clutch and Balance Piston Service Set 307-589/1.
15. Install the overdrive clutch piston return spring.
16. Lubricate the seals on a new balance piston.
17. Install the new balance piston and install the Overdrive Clutch and Balance Piston Service Set 307-589/1 and 2-6 Spring Compressor 307-584/2 on the balance piston.
18. Using a press, compress the overdrive clutch piston return spring and install the snap ring.
19. Remove the Overdrive Clutch and Balance Piston Service Set 307-589/1 and the 2-6 Spring Compressor 307-584/2 from the balance piston.
20. Install the No. 2 rear sun gear thrust bearing.
21. Install the overdrive clutch hub.
22. Lubricate the overdrive clutch pack in clean automatic transmission fluid.
23. Install the overdrive clutch pack assembly and the pressure plate.
24. Install the overdrive clutch pack snap ring.
25. Position the overdrive/direct clutch assembly in the cover assembly, install the Dial Indicator Gauge with Holding Fixture 100-002 or a suitable dial indicator and position the plunger on the overdrive clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the overdrive clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 1.13 mm (0.044 in) and 2.28 mm (0.090 in). If the clearance is out of range, check the overdrive clutch pack for correct installation. If the overdrive clutch pack is correctly installed, install a new overdrive clutch pack.
26. Position the Dial Indicator Gauge with Holding Fixture 100-002 on the direct clutch pressure plate. Apply 483 kPa (70 psi) of air pressure to the direct clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.98 mm (0.039 in) and 2.34 mm (0.092 in). If the clearance is out of range, check the direct clutch pack for correct installation. If the direct clutch pack is correctly installed, install a new direct clutch pack.

Cover Assembly

Special Tools Illustration Tool Name Tool Number 2-6 Spring Compressor 307-584 (includes 307-584/1 and 307-584/2) Input Shaft Support Seal Installer (Back Plate, Multiple Rings) 307-578 (includes 307-578/1, 307-578/2 and 307-578/3) Reverse Clutch Piston And Retaining Ring Set 307-588 (includes 307-588/1, 307-588/2 and 307-588/3)

Scheme 157

1. Remove the bolt and the Turbine Shaft Speed (TSS) sensor.
2. Using the 2-6 Spring Compressor 307-584/1 and 307-584/2, compress the intermediate clutch return spring, using a press and remove the snap ring.
3. Remove the 2-6 Spring Compressor 307-584/1 and 307-584/2.
4. Remove the intermediate clutch return spring.
5. Remove and discard the intermediate clutch piston.
6. Install the 2-6 Spring Compressor 307-584/2 and the Reverse Clutch Piston And Retaining Ring Set 307-588/3, using a press, compress the low/reverse clutch return spring and remove the snap ring.
7. Remove the 2-6 Spring Compressor 307-584/2 and the Reverse Clutch Piston And Retaining Ring Set 307-588/3.
8. Remove the low/reverse clutch return spring.
9. Remove and discard the low/reverse clutch piston.
10. Using a suitable tool, remove and discard the 4 Teflon® seals.
11. Clean and inspect the cover for damage. Install a new cover if damaged.

1. Install the Input Shaft Support Seal Installer 307-578/3 on the cover and adjust the Input Shaft Support Seal Installer to align the bottom edge of the Input Shaft Support Seal Installer with the top edge of the bottom Teflon® seal groove.
2. Install a new Teflon® seal on the Input Shaft Support Seal Installer 307-578/3.
3. Install the Input Shaft Support Seal Installer 307-578/2 over 307-578/3. Using the Input Shaft Support Seal Installer 307-578/2, slide the Teflon® seal over the cover and into the groove.
4. Remove the Input Shaft Support Seal Installer 307-578. Repeat Steps 1, 2, 3 and 4 for the other 3 Teflon® seals.
5. Install the Input Shaft Support Seal Installer 307-578/1 on the cover to size the 4 Teflon® seals.
6. Install the Reverse Clutch Piston And Retaining Ring Set 307-588/1 and 307-588/2.
7. Lubricate the sealing surfaces of the low/reverse piston with petroleum jelly and position the low/reverse piston in the cover. Lubricate the seals. Position the low/reverse piston in the cover so that the semicircles in the piston are aligned with the indentation in the cover.
8. Make sure the low/reverse piston bleed hole and semicircle area are aligned with the indentation in the cover and the intermediate cylinder fill hole. Low/reverse piston bleed hole Low/reverse piston semicircle area Cover indentation Intermediate cylinder fill hole
9. Position the low/reverse piston in the cover, make sure that the piston bleed hole stays aligned with the indentation in the cover and push the piston in the cylinder using the Reverse Clutch Piston And Retaining Ring Set 307-588/3.
10. Remove the Reverse Clutch Piston And Retaining Ring Set 307-588/1 and 307-588/2.
11. Install the low/reverse piston return spring with the tabs facing down.
12. Install the 2-6 Spring Compressor 307-584/2 and the Reverse Clutch Piston And Retaining Ring Set 307-588/3.
13. Compress the low/reverse piston return spring, install the snap ring and remove the 2-6 Spring Compressor 307-584/2 and the Reverse Clutch Piston And Retaining Ring Set 307-588/3.
14. Lubricate the sealing surfaces on the intermediate clutch piston with petroleum jelly.
15. Install the intermediate clutch piston.
16. Install the intermediate clutch piston return spring.
17. Install the 2-6 Spring Compressor 307-584/1 and 307-584/2. Using a press, compress the intermediate clutch piston return spring, install the snap ring and remove the 2-6 Spring Compressor 307-584/1 and 307-584/2.
18. Remove the Input Shaft Support Seal Installer 307-578/1.
19. Lubricate the O-ring seal on the TSS sensor with clean transmission fluid and install the TSS sensor in the cover and install the bolt. Tighten to 12 Nm (106 lb-in).

Special Tools Illustration Tool Name Tool Number 2-6 Spring Compressor 307-584 (includes 307-584/1 and 307-584/2) Bearing Cup Installer 307-576 Compressor, Forward Clutch Spring 307-574 (includes 307-574/1 and 307-574/2) Converter Seal Installer 307-575 Cover Axle Seal Installer 307-582A Depth Micrometer 303-D075 (D92P-4201-A) or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Drawbar (Heavy Duty Threaded) 204-029 (T77F-1176) Handle 205-153 (T80T-4000-W) Installer, Transfer Gear Bearing 307-541 Manual Lever Retaining Pin Installer 307-592 Manual Lever Seal Installer 307-581 Oil Dam Seal Installer 307-583 Shim Gauge, Differential/Transfer Gear Bearing 307-591 (includes 307-591/1, 307-591/2 and 307-591/3)

Scheme 158

Scheme 159

Scheme 160

Material

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

All vehicles

1. If the transfer shaft fluid dam and bearing race were removed during disassembly, assemble the Handle 205-153 and the Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the special tool.
2. Using the Handle 205-153 and the Oil Dam Seal Installer 307-583, install the transfer shaft fluid dam in the transaxle case.
3. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the transaxle case.
4. Using the Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the transaxle case.
5. If removed, install a new differential bearing race on the Bearing Cup Installer 307-576.
6. Using the Bearing Cup Installer 307-576, Transfer Gear Bearing Installer 307-541 and Drawbar 204-029, press the differential bearing cup in the transaxle case.
7. Install the park pawl abutment and the pins.
8. Install the park pawl and the pin.
9. Install the park pawl spring.
10. Install the park pawl pin retainer and the 2 bolts. Tighten to 12 Nm (106 lb-in).
11. Slide the park pawl over and install the park pawl actuator rod.
12. Lubricate a new manual shaft seal and the Manual Lever Seal Installer 307-581 with petroleum jelly and install the seal on the Manual Lever Seal Installer 307-581.
13. Using the Manual Lever Seal Installer 307-581, install the manual lever shaft seal in the transaxle case.
14. Install the Transmission Range (TR) sensor. Position the park pawl actuating rod in the TR sensor detent plate. Install the TR sensor in the transaxle case.
15. Install a new TR sensor locking pin in the transaxle case.
16. Using the Manual Lever Retaining Pin Installer 307-592, drive the TR sensor locking pin into the transaxle case.
17. Install a new O-ring seal on the reservoir. Lubricate the seal with clean transmission fluid.
18. Install the transmission fluid reservoir and the 2 bolts. Tighten to 12 Nm (106 lb-in).
19. Install a new pump-to-case seal.
20. Install the transfer shaft and gear assembly.
21. Tilt the transfer shaft and gear assembly over and install the differential assembly.
22. Install the differential and transfer shaft bearing cups on the bearings.
23. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 and 307-591/2) on the differential and transfer shaft bearing cups.
24. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (studs) in the transaxle case to align the torque converter housing.
25. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) on the studs to space the torque converter housing from the transaxle case.
26. Place the torque converter housing on the Differential/Transfer Gear Bearing Shim Gauge 307-591/3.
27. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (remaining 4 spacers, bolts and washers). Tighten to 24 Nm (18 lb-ft).
28. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts and washers) on the studs. Tighten to 24 Nm (18 lb-ft).
29. Rotate the transfer shaft and the differential several times to seat the bearings.
30. Using a feeler gauge, measure and record the smallest and largest preload gap on the Differential/Transfer Gear Bearing Shim Gauge 307-591/1 placed on the differential assembly. Add the 2 measurements and divide by 2. This is the thickness of the differential bearing preload shim. For additional information, refer to Specifications in this article for the differential bearing preload shim part number.
31. Using a feeler gauge, measure and record the smallest and largest preload gap on Differential/Transfer Gear Bearing Shim Gauge 307-591/2 placed on the transfer shaft assembly. Add the 2 measurements and divide by 2. This is the thickness of the transfer shaft bearing preload shim. For additional information, refer to Specifications in this article for the transfer gear bearing preload shim part number.
32. Remove the torque converter housing and the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.
33. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) from the transaxle case.
34. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 studs) from the transaxle case.
35. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/1 and 307-591/2 from the differential and transfer shaft assemblies.
36. Remove the differential and transfer shaft bearing cups.
37. Install a new torque converter hub seal on the Converter Seal Installer 307-575.
38. Using the Converter Seal Installer 307-575 and a dead blow hammer, install the torque converter hub seal in the torque converter housing.
39. Assemble the Handle 205-153 on the Cover Axle Seal Installer 307-582A and install a new RH halfshaft seal on Cover Axle Seal Installer 307-582A.
40. Use the Handle 205-153 and the Cover Axle Seal Installer 307-582A. Install the RH halfshaft seal in the torque converter housing.
41. Assemble the Handle 205-153 and the Oil Dam Seal Installer 307-583 and install a new transfer shaft fluid dam on the Oil Dam Seal Installer 307-583.
42. Using the Handle 205-153 and the Oil Dam Seal Installer 307-583, install the fluid dam in the torque converter housing.
43. Inspect the transfer shaft fluid dam to be sure it is seated evenly into the torque converter housing.
44. Install the transfer shaft preload shim in the torque converter housing.
45. Using the Bearing Cup Installer 307-576, press the transfer shaft bearing cup in the torque converter housing.
46. Install the differential bearing preload shim in the torque converter housing.
47. Install a new differential bearing race on the Bearing Cup Installer 307-576.
48. Using the Bearing Cup Installer 307-576, Transfer Gear Bearing Installer 307-541 and the Drawbar 204-029, press the differential bearing cup in the torque converter housing.
49. Install the pump drive sprocket and driven sprocket thrust washers.
50. Install the pump sprocket and chain assembly.
51. Position the pump and filter assembly in place and install the 3 bolts. Tighten to 12 Nm (106 lb-in).
52. Position the stator support assembly in place on the torque converter housing.
53. Install the stator support bolts. Tighten in the sequence shown. Tighten to 41 Nm (30 lb-ft).
54. Position the differential carrier baffle in place and install the bolt. Tighten to 12 Nm (106 lb-in).
55. Lubricate the ends of the transaxle fluid tube with petroleum jelly and install it in the transaxle.
56. Apply a bead of silicone sealant to the machined surface of the transaxle case.
57. Install the torque converter housing on top of the transaxle case and install the bolts.
58. Tighten the bolts in the sequence shown. Tighten to 24 Nm (18 lb-ft).
59. Assemble the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install a new halfshaft seal on Cover Axle Seal Installer 307-582A.
60. Using the Handle 205-153 and the Cover Axle Seal Installer 307-582A, install the halfshaft seal in the transaxle case.
61. Lubricate the forward clutch piston seals with petroleum jelly.
62. Position the forward clutch piston in place in the transaxle case.
63. Using the 2-6 Spring Compressor 307-584/1, push the forward clutch piston down into the bore.
64. Install the forward clutch piston return spring with the tabs facing downward.
65. Install the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2) and compress the forward clutch piston return spring.
66. Install the forward clutch piston return spring snap ring. Install the snap ring. The snap ring gap should be at the top of the transaxle case.
67. Remove the Forward Clutch Spring Compressor 307-574 (307-574/1 and 307-574/2) and the 2-6 Spring Compressor 307-584 (307-584/1 and 307-584/2).
68. Install the forward clutch wave spring.
69. Lubricate the forward clutch pack in clean automatic transmission fluid.
70. Install the forward clutch pack assembly. Position the forward clutch pack assembly in the case. Make sure the alignment tab on the clutch pack is positioned in the correct location.
71. Install the low OWC.
72. Install the low OWC snap ring.
73. Compare the position of the low OWC snap ring gap with the tab on the low/reverse clutch pressure plate to be sure that the gap is in the right position.
74. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transaxle case and position the plunger on a top friction disc tab.
75. Install a new forward clutch feed seal.
76. Apply 483 kPa (70 psi) of air pressure to the forward clutch piston port while recording the clutch pack clearance on the Dial Indicator. The clearance should be between 0.85 mm (0.033 in) and 2.41 mm (0.095 in). If the clearance is out of range, check the forward clutch pack and low OWC for correct installation. If the forward clutch pack and low OWC is correctly installed, install a new forward clutch pack.
77. Remove the Dial Indicator Gauge with Holding Fixture 100-002 from the transaxle case.
78. Install the No. 11 stator support thrust bearing.
79. Install the front planetary carrier hub.
80. Install the No. 10 front sun gear thrust bearing.
81. Install the front sun gear and shell assembly.
82. Install the front carrier and rear ring gear assembly.
83. Install the No. 8 front/center planetary gear assembly and the No. 7 center sun gear thrust bearings.
84. Install the center planetary carrier and front ring gear assembly.
85. Install the center planetary sun gear.
86. Install the No. 6 center sun gear and the No. 5 center/rear planetary thrust bearings.
87. Install the rear planetary gear carrier assembly.
88. Install the low/reverse clutch pressure plate. Make sure the tab on the bottom of the pressure plate fits in the gap of the low OWC snap ring. Install the low/reverse clutch pressure plate.
89. Measure the depth of the low/reverse clutch pressure plate where the tab fits into the gap of the low OWC snap ring and directly across from it. If the pressure plate is seated correctly, the depth should be the same. If the depths are different, rotate the snap ring so that the gap fits around the tab on the pressure plate.
90. Lubricate the low/reverse clutch pack with clean automatic transmission fluid.
91. Install the low/reverse clutch pack.
92. Install the low/reverse pressure plate.
93. Using a suitable straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to the low/reverse pressure plate.
94. Using the same straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the low/reverse clutch piston to the cover assembly deck surface.
95. Subtract measurement B from measurement A and add 1.6 mm (0.063 in), to compensate for the thickness of the gasket, to get the low/reverse clutch clearance. The clearance should be between 1.01 mm (0.040 in) and 2.47 mm (0.1 in). If the clearance is out of range, check the low/reverse clutch pack for correct installation. If the low/reverse clutch pack is correctly installed, install a new low/reverse clutch pack. Description Reading Measurement A Measurement B Subtract measurement B from measurement A and add 1.6 mm (0.063 in) to get the low/reverse clutch clearance.
96. Install the intermediate clutch pressure plate.
97. Lubricate the intermediate clutch pack assembly in clean automatic transmission fluid.
98. Install the intermediate clutch pack assembly.
99. Install the intermediate clutch pack wave spring.
100. Using a suitable straightedge and the Depth Micrometer 303-D075, measure and record as measurement A, the distance from the transaxle case deck surface to a low point on the intermediate clutch wave spring.
101. Using the straightedge and the Depth Micrometer 303-D075, measure and record as measurement B, the distance from the intermediate clutch piston to the cover assembly deck surface.
102. Subtract measurement B from measurement A and add 1.6 mm (0.063 in), to compensate for the thickness of the gasket, to get the intermediate clutch clearance. The clearance should be between 0.90 mm (0.035 in) and 2.24 mm (0.088 in). If the clearance is out of range, check the intermediate clutch pack for correct installation. If the intermediate clutch pack is correctly installed, install a new intermediate clutch pack. Description Reading Measurement A Measurement B Subtract measurement B from measurement A and add 1.6 mm (0.063 in) to get the intermediate clutch clearance.
103. Install the rear sun gear and shell assembly.
104. Install the No. 3 rear sun gear thrust bearing.
105. Install the overdrive/direct clutch hub and turbine shaft assembly.
106. Install the No. 1 cover assembly thrust bearing.
107. Install the cover assembly gasket.
108. Route the Turbine Shaft Speed (TSS) sensor harness through the transaxle case to the valve body area and install the cover assembly.
109. Install the cover assembly bolts and tighten the bolts in the sequence shown. Tighten to 12 Nm (106 lb-in).
110. Install the Output Shaft Speed (OSS) sensor and the bolt. Tighten to 12 Nm (106 lb-in).
111. Position the TSS, OSS and TR sensor wiring harnesses aside, align the manual pin in the manual valve, install the main control valve body and loosely install the bolts. Manual pin. Manual valve.
112. Install the main control valve body bolts. Tighten the bolts in the sequence shown. Tighten to 12 Nm (106 lb-in).
113. Install the solenoid body bolts hand tight. 42 mm (1.65 in) bolt 63 mm (2.48 in) bolts 80 mm (3.14 in) bolts 95 mm (3.74 in) bolts
114. Tighten the solenoid body bolts in the sequence shown. Tighten to 12 Nm (106 lb-in).
115. Route the OSS sensor wiring harness into the retainer.
116. Connect the TSS and OSS sensor electrical connectors.
117. Connect the TR sensor electrical connector and slide the lock tab to the LOCK position.
118. Inspect the transaxle main control cover seal for damage and install new if necessary.
119. Install the transaxle main control cover and install the bolts. Bolt location Studbolt location
120. Tighten the main control cover bolts in the sequence shown. Tighten to 12 Nm (106 lb-in).
121. Install the manual lever and the nut. Tighten to 18 Nm (159 lb-in).
122. Install two 10 mm x 1.50 bolts into the torque converter 6 to 8 turns to assist in handling the torque converter and install the torque converter in the transaxle.
123. Remove the bolts from the torque converter.

See also:
• Mechanical Components and Functions
• Torque Converter
• Hydraulic System
• Manual LOW Position and 1st Gear Below 5 km/h (3 mph)
• 1st Gear Above 5 km/h (3 mph)