Automatic Transaxle - Overhaul [CD4E]: Overhaul Mazda Tribute I

Solenoid Valve Body Assembly

The solenoid valve body assembly contains the transaxle fluid temperature sensor (TFT) sensor, as well as five PCM controlled output devices

1. Electronic pressure control (EPC) solenoid.
2. Shift solenoid 1 (SS1).
3. Shift solenoid 2 (SS2).
4. 3-2 timing/coast clutch solenoid (3-2 T/CCS).
5. Torque converter clutch (TCC) solenoid.

Shift Solenoid Assembly (SS1, SS2)

Shift solenoids A and B provide gear selection of first through fourth gears by providing ON/OFF pressure control to the shift valves.

Disassembly Note

Note. Clean the transaxle assembly to prevent the entry of dirt when reassembling.

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1. Inspect transaxle during disassembly.
2. Remove the special tool. CAUTION: Do not tilt the torque converter when removing it. This can damage the torque converter hub. NOTE: The torque converter is filled with fluid. Position it on a table so that fluid will drain out of the torque converter into a drain pan.
3. Using the special tool, remove the torque converter.
4. Remove the output shaft speed (OSS) sensor.
5. Remove the turbine shaft speed (TSS) sensor. Remove the bolt. Remove the TSS sensor.
6. Remove and discard the TSS and OSS sensor O-ring seals.
7. Remove the transaxle range (TR) sensor. Remove the bolts. Remove the TR sensor from the manual valve detent lever shaft.
8. Using the special tool, secure the transaxle to the bench.
9. Position the drain pan under the transaxle, remove the drain plug, and drain the transaxle fluid.
10. Remove the pump assembly driveshaft.
11. Using the special tools, remove and discard the torque converter impeller hub seal.
12. Using the special tools, remove the left-hand differential seals.
13. Using the special tools, remove the right-hand differential seals.
14. Remove the transaxle fluid filler tube bolt.
15. Remove the transaxle fluid filler tube.
16. Remove and discard the transaxle filler tube grommet. NOTE: Remove the bolts in the indicated sequence.
17. Remove the main control cover bolts, and cover.
18. Remove and discard the gasket.
19. Inspect the fitting of the main control cover vent tube for blockage. NOTE: Remove the bolts in the indicated sequence.
20. Remove the main control valve body bolts.
21. Disconnect the manual valve link from the manual valve when lifting the main control valve body from the case. CAUTION: Do not pull on solenoid body electrical connector wires, or use a hammer on the electrical connector.
22. Remove the solenoid body electrical connector. Release the retaining tabs and push the connector through the transaxle case.
23. Support the manual valve and remove the main control.
24. Remove the thermostatic fluid level control valve bracket. Remove the bolt. Remove the bracket.
25. Remove the thermostatic fluid level control valve.
26. Using the special tool, remove the forward clutch circuit filter (if equipped). WARNING: The servo and servo cover are under high spring force. Use caution when removing servo cover. Failure to follow these instructions can result in personal injury. CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case can occur. Use only snap ring pliers to remove the retaining ring.
27. Using the special tool, remove the servo assembly. Install the special tool. Compress the servo assembly by tightening the bolt. Remove the retaining ring.
28. Remove the servo cover assembly.
29. Remove the intermediate and overdrive servo piston and return spring. NOTE: If the bonded seal is damaged, install a new servo assembly.
30. Inspect the intermediate and overdrive servo assembly and bore for damage or wear. Servo cover with bonded seal. Cushion spring. Servo apply rod. Servo return spring. Case servo bore. NOTE: Position the transaxle with the torque converter housing facing upward.
31. Remove the 20 bolts. NOTE: Place the torque converter housing on the engine flange side after removal to prevent damage to the lube tube.
32. Separate the torque converter housing from the transaxle case. Remove and discard the transaxle split flange gasket.
33. Remove the differential bearing and shim. Remove the No. 15 differential bearing. Remove the No. 14 differential bearing shim.
34. Remove the final drive carrier and differential assembly.
35. Remove the No. 13 driven sprocket thrust bearing.
36. Unclip and remove the chain pan cover. NOTE: The driven sprocket thrust washer may adhere to the converter housing.
37. Remove the No. 10 driven sprocket thrust washer from the reverse/overdrive ring gear assembly.
38. Remove the chain drive, reverse/overdrive ring gear, and driven sprocket assembly.
39. Separate the drive chain assembly from the driven sprocket assembly and reverse/overdrive ring gear assembly. NOTE: Inspect the magnet located on the chain pan for excessive metal particles.
40. Remove the chain pan (with the magnet retained) from the transaxle case.
41. Assemble the special tools.
42. Using the special tools, remove and discard fluid filter recirculating regulator exhaust seal.
43. Remove the fluid filter and seal assembly. Discard the fluid filter. Discard the fluid filter seal.
44. Remove the No. 12 driven sprocket bearing.
45. Remove the No. 11 driven sprocket shim (selective fit).
46. Disconnect the parking lever actuating rod from the parking cam actuator lever assembly.
47. Disconnect the parking lever actuation rod from the manual valve detent lever, and remove the parking lever actuation rod. NOTE: The thrust bearing may adhere to the reverse/overdrive sprocket.
48. Remove the No. 9 reverse/overdrive ring gear thrust bearing. NOTE: The thrust bearing is part of the reverse/overdrive carrier assembly.
49. Remove the reverse/overdrive carrier assembly with captured No. 8 thrust bearing.
50. Remove the reverse/overdrive sun gear and shell assembly. NOTE: The thrust bearing may adhere to the reverse/overdrive sun gear and shell.
51. Remove the reverse/overdrive sun gear and No. 7 shell thrust bearing.
52. Remove the low/intermediate ring gear assembly. NOTE: The low/intermediate carrier thrust bearing may adhere to the low/intermediate ring gear.
53. Remove the No. 6 low/intermediate carrier thrust bearing.
54. Remove the low/intermediate carrier assembly.
55. Remove the No. 5 low/intermediate sun gear thrust bearing and tag for installation.
56. Remove the forward one-way clutch and low/intermediate sun gear. NOTE: The turbine shaft thrust bearing may adhere to the forward one-way clutch and low/intermediate sun gear.
57. Remove the No. 4 turbine shaft thrust bearing.
58. Remove the turbine shaft assembly.
59. Remove the forward/coast/direct cylinder assembly and reverse clutch drum assembly from the transaxle.
60. Remove the forward/coast/direct clutch cylinder from the reverse clutch drum assembly. NOTE: The pump support thrust bearing assembly may adhere to the reverse clutch drum assembly.
61. Remove the No. 1 pump support thrust bearing and tag for installation.
62. Remove the low one-way clutch retaining ring.
63. Remove the low one-way clutch thrust plate. NOTE: The low one-way clutch assembly should be removed as an assembly.
64. Remove the low one-way clutch assembly.
65. Remove the low/reverse clutch wave spring.
66. Remove the low/reverse clutch plates. Inspect the friction plates for partially stripped, broken or bent spline teeth, burnt, worn or flaked-off friction material, and warped or bent friction discs. Inspect the steel plates for heat discoloration or warpage.
67. Remove the low/reverse clutch return spring retaining ring.
68. Remove the low/reverse clutch return spring assembly. NOTE: Rotate the low/reverse clutch piston while pulling upward.
69. Remove the low/reverse clutch piston. NOTE: Position the transaxle so the pump assembly is facing upward.
70. Remove the pump assembly bolts.
71. Using the special tools, remove the pump assembly. Install the special tool. Assemble the special tools. Using the special tools, remove the pump assembly.
72. Remove the intermediate and overdrive band assembly from the case. Inspect the intermediate and overdrive band assembly for damage and wear.

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1. Using the special tools, remove the No. 16 reverse/overdrive ring gear bearing, as necessary.
2. Using the special tools, remove the No. 17 stator support bearing, as necessary.

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1. Position the No. 16 reverse/overdrive ring gear bearing on the special tools. Position the bearing with the part number facing toward the handle of the special tool. NOTE: The identification stamping of the bearing goes to the outboard side of the reverse/overdrive ring gear.
2. Using the special tools, install the No. 16 reverse/overdrive ring gear bearing.
3. Position the No. 17 stator support bearing on the special tools. Position the bearing with the part number facing toward the handle of the special tool. NOTE: The identification stamping of the bearing goes to the outboard side of the reverse/overdrive ring gear.
4. Using the special tools, install the No. 17 stator support bearing into the stator support sprocket.

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Note. If damage is detected during the checking procedure, a new differential should be installed.

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1. Inspect the differential: Differential housing Differential bearing shim Differential housing bearing Pinion shaft roll pin Pinion shaft Pinion thrust washer Pinion gear Side gear thrust washer Differential side gear CAUTION: Do not disassemble the planet carrier. NOTE: If the measurement exceeds specification, install a new complete final drive carrier. If the measurement is within specification, continue with the diagnostic procedure.
2. Measure the final drive planet gear end play with a feeler gauge. NOTE: Do not remove the final drive pinion shaft retaining ring.
3. Remove the differential pinion shaft. Remove the pinion shaft roll pin. Remove the differential pinion shaft.
4. Remove the pinion gears and thrust washers. Turn the differential pinion gears 90 degrees and remove.
5. Remove the differential side gears and differential side gear thrust washers.
6. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
7. Inspect the differential parts for damage and wear. Gear teeth. Thrust washer surface. Thrust bearing surface. Pinion shaft.
8. Inspect the final drive planet and carrier. Pinion gear teeth. Thrust bearing surfaces. Bushing surfaces.

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1. Install the differential side gears and thrust washers.
2. Install the differential pinion gears and thrust washers. Rotate the differential pinion gears 90 degrees.
3. Install the differential pinion shaft. Push the pinion shaft in place. Install the roll pin.

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1. Remove the coast clutch hub retaining ring.
2. Remove the coast clutch hub.
3. Remove the forward one-way clutch outer race and sprag assembly with end caps. NOTE: Orientation of end caps to sprag assembly. New design end caps are the same thickness and interchangeable (but not reversible). NOTE: Not all transaxles contain this style sprag assembly.
4. Remove the forward one-way clutch end caps from the sprag assembly.
5. Remove the forward one-way clutch retainer.
6. Remove the retaining ring down over the gear. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
7. Clean all parts thoroughly in clean solvent and blow dry with moisture-free compressed air.
8. Inspect the forward one-way clutch parts for damage and wear. Outer race. Sprag assembly and end caps. Inner race and low-intermediate sun gear assembly. Lube holes. Coast clutch hub.

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1. Install the retaining ring. NOTE: The tabs on the retainer face downward.
2. Install the forward one-way clutch retainer.
3. Install the forward one-way clutch end caps onto the sprag assembly. CAUTION: The thicker end cap of the one-way clutch must face toward the lube groove (down).
4. Install the sprag assembly and end caps in the outer race. NOTE: Lube grooves face upward (away from the sun gear).
5. Rotate the outer race and sprag assembly (with end caps) over and install it on the forward one-way clutch inner race.
6. Install the coast clutch hub. NOTE: The ends of the retaining ring should point toward the coast clutch hub. NOTE: Make sure the retaining ring is fully seated upon installation.
7. Install the coast clutch hub retaining ring.
8. Check the operation of the forward one-way clutch with the low/intermediate sun gear facing upward. Hold the outer race firmly. Rotate the low/intermediate sun gear clockwise. The low/intermediate sun gear should rotate with a slight drag without attempting to rotate the outer race. Rotate the low/intermediate sun gear counterclockwise. The low/intermediate sun gear should rotate the outer race.

Note. Support the assembly of the forward/coast/direct clutch cylinder assembly and reverse clutch drum assembly on a block of wood so that the reverse clutch hub faces upward. This will ease the reverse clutch hub retaining ring removal.

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1. Remove the reverse clutch hub retaining ring.
2. Remove the reverse clutch hub.
3. Remove the reverse clutch drum assembly.
4. Remove the direct clutch hub and shell from the forward/coast/direct clutch cylinder.
5. Remove and discard the two reverse clutch cylinder seals from the forward/coast/direct clutch cylinder assembly. NOTE: Observe the tab orientation of the No. 2 direct clutch thrust washer during disassembly for correct installation.
6. Remove the No. 2 direct clutch thrust washer from the forward/coast/direct clutch cylinder.
7. Remove and discard the forward/coast/direct clutch cylinder hub seal ring.

Assembly Note

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1. Install the No. 2 direct clutch thrust washer on the forward/coast/direct clutch cylinder with the tabs facing downward.
2. Install the two reverse clutch cylinder seals. NOTE: Make sure that the reverse clutch cylinder seals are overlapped correctly.
3. Position the reverse clutch cylinder seals. Correct installation. Incorrect installation.
4. Support the forward/coast/direct clutch cylinder assembly on a block of wood so that the direct clutch faces upward.
5. Install the direct clutch hub and shell on the forward/coast/direct clutch cylinder.
6. Install the reverse clutch drum assembly.
7. Install the reverse clutch hub.
8. Support the reverse clutch drum on a block of wood while installing the reverse clutch hub retaining ring.
9. Install the forward/coast/direct clutch cylinder hub seal.
10. Leave special tool attached until the forward/coast/direct clutch cylinder is installed into the transaxle housing.

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1. Remove the direct clutch pressure plate retaining ring.
2. Disassemble the direct clutch pack. Remove the direct clutch pressure plate. Remove the direct clutch steel plates. Remove the direct clutch friction plates. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions may result in personal injury. CAUTION: Do not compress the direct clutch return springs completely.
3. Remove the direct clutch spring retaining ring. Using the special tool, compress the direct clutch return springs. Remove the direct clutch return spring retaining ring.
4. Remove the direct clutch return spring assembly.
5. Remove the direct clutch piston assembly.
6. Remove and discard the direct clutch piston outer lip seal.
7. Remove and discard the direct clutch piston inner lip seal from the forward/coast/direct clutch cylinder assembly.
8. Remove the forward clutch pressure plate retaining ring.
9. Remove the forward and coast clutch plates. Forward clutch pressure plate. Forward clutch external spline clutch plates (steel). Coast clutch internal spline clutch plates (friction). Coast clutch external spline clutch plates (steel). Coast clutch pressure plate. Forward clutch internal spline clutch plates (friction). Forward clutch wave spring. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury. CAUTION: Do not compress the return springs completely.
10. Remove the forward/coast clutch return spring retaining ring. Using the special tool, compress the return spring. Remove the retaining ring.
11. Remove the forward/coast clutch return spring assembly.
12. Remove the forward and coast clutch pistons.
13. Using the special tool, remove and discard the forward clutch piston inner seal from the forward/coast/direct clutch cylinder assembly.
14. Remove and discard the forward clutch piston outer lip seal.
15. Separate the coast clutch piston assembly from the forward clutch piston assembly. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury. NOTE: Do not clean the clutch plates in a vapor degreaser or in any other type of detergent solution.
16. Clean all parts thoroughly in a clean solvent and blow dry with moisture-free regulated compressed air. Clean the steel clutch plates with a lint-free cloth. Soak the new clutch plates in the specified transaxle fluid for 30 minutes before assembly.
17. Inspect the parts for damage or wear. Spline teeth. Clutch plates. Seals. Bushing. Check balls in pistons. Piston bore. Passages and lubrication holes in the forward/coast/direct clutch cylinder.

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1. Soak the internal spline clutch plates in clean MERCON(R) Automatic Transaxle Fluid (ATF) for 30 minutes before assembly.
2. Install the forward clutch piston inner seal on the forward/coast/direct clutch cylinder assembly.
3. Install the forward clutch piston outer lip seal on the forward clutch piston assembly.
4. Install the forward clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
5. Install the coast clutch piston assembly onto the special tool.
6. Using the special tool, install the coast clutch piston into the forward clutch piston assembly.
7. Install the forward/coast clutch return spring assembly. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury.
8. Install the forward/coast clutch return spring retaining ring. Using the special tool, compress the return spring. Install the forward/coast clutch retaining ring.
9. Install the forward and coast clutch plates in the sequence shown. Coast clutch external spline clutch plates (steel). Coast clutch internal spline clutch plates (friction). Coast clutch pressure plate. Forward clutch wave spring. Forward clutch internal spline clutch plates (friction). Forward clutch external spline clutch plates (steel). Forward clutch pressure plate.
10. Install the forward clutch pressure plate retaining ring.
11. Using a feeler gauge, measure the clearance between the forward clutch pressure plate and the forward clutch pressure plate retaining ring. Take a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within specification, select and install the proper thickness retaining ring to obtain the standard clearance. Retaining ring sizes: 1.43-1.53 mm (0.056-0.060 in) 1.59-1.69 mm (0.062-0.066 in) 1.75-1.85 mm (0.069-0.073 in) 1.92-2.02 mm (0.75-0.079 in)
12. Install the direct clutch piston inner lip seal on the direct clutch cylinder assembly.
13. Install the direct clutch piston outer seal on the direct clutch piston assembly. NOTE: Position the lip seal facing down.
14. Install the direct clutch piston assembly in the forward/coast/direct clutch cylinder assembly.
15. Install the direct clutch return spring assembly. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury. CAUTION: Do not compress the direct clutch return springs completely.
16. Install the direct clutch return spring retaining ring. Using the special tool, compress the direct clutch return springs. Install the direct clutch return spring retaining ring. NOTE: Quantity of plates are model dependent.
17. Install the direct clutch plates. Install the direct clutch external spline (steel) clutch plates. Install the direct clutch internal spline (friction) clutch plates. Install the direct clutch pressure plate.
18. Install the direct clutch pressure plate retaining ring.
19. Measure the direct clutch clearance as follows: Install the special tool. Zero the dial on the direct clutch pressure plate. Pull the direct clutch pressure plate upward, and record the reading.
20. Make a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within the specification, select and install, using the special tool, the correct thickness direct clutch pressure plate retainer snap ring to obtain the standard clearance. Retaining ring sizes: 1.28-1.38 mm (0.050-0.054 in) 1.39-1.49 mm (0.054-0.058 in) 1.52-1.62 mm (0.059-0.063 in) 1.65-1.75 mm (0.064-0.069 in)

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1. Inspect the low one-way clutch components: Low one-way clutch inner race. Roller assembly. Low one-way clutch outer race. Outer race groove. Inner race groove.
2. Position the low one-way clutch so the inner and outer race grooves are facing upward.
3. Remove the inner race.
4. Remove the roller assembly. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
5. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
6. Inspect the low one-way clutch parts for damage and wear. Outer race. Sprag assembly. Inner race. Lubrication holes.

Note. Outer tabs of the roller assembly must face up.

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1. Install the roller assembly into the outer race with the groove facing up. NOTE: To aid in inner race installation, rotate the inner race clockwise during installation.
2. Install the inner race with the grooves facing up.
3. Check the operation of the one-way clutch as follows: Hold the outer race. Rotate the inner race clockwise. It should rotate with a slight drag without attempting to rotate the outer race. Rotate the inner race counterclockwise. The inner race should rotate the outer race.

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1. Remove and discard the low/reverse clutch piston outer seal on the low/reverse clutch piston.
2. Remove and discard the low/reverse clutch piston inner seal on the low/reverse clutch piston.

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1. Install the low/reverse clutch piston outer seal on the low/reverse clutch piston.
2. Install the low/reverse clutch piston inner seal on the low/reverse clutch piston.

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1. Remove the manual valve. CAUTION: Do not attempt to remove the solenoid valve body wiring cover.
2. Remove the two solenoid valve body bolts and the solenoid valve body.
3. Remove and discard the solenoid valve body gasket.
4. Remove the three pressure tap plate bolts and the pressure tap plate.
5. Remove and discard the pressure plate tap gasket.
6. Remove the control valve body to transfer plate bolts, and remove the manual valve detent spring assembly.
7. Remove the accumulator body-to-transfer plate bolts.
8. Separate the accumulator body from the main control valve body. Remove the accumulator body assembly. Remove and discard the accumulator body separator gasket. Remove the accumulator body separator plate. Remove and discard the accumulator body separator gasket. Remove the main control valve body.
9. Separate the transfer plate from the main control valve body. Remove the main control valve body. Remove and discard the valve body separator plate gasket. Remove the valve body separator plate. Remove and discard the valve body separator plate gasket. Remove the transfer plate.
10. Remove the intermediate and overdrive accumulator valve plug retaining plate from the accumulator body assembly.
11. Remove the intermediate and overdrive accumulator valve plug.
12. Remove and discard the intermediate and overdrive accumulator plug seal. CAUTION: Remove, note location and clean one valve at a time to avoid incorrect installation.
13. As necessary, disassemble the parts of the accumulator body and main control valve body assemblies. Lubricate and reassemble the parts as soon as possible to avoid accidental damage or incorrect installation.

Note. Clean the main control valve body and accumulator body assembly of the main control in cleaning solvent. Blow dry with moisture-free regulated compressed air. The solenoid valve body should not be cleaned in cleaning solvent. It may be blown clean with compressed air or wiped clean with a lint-free cloth.

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1. Install a new intermediate and overdrive accumulator plug seal and coat with petroleum jelly. CAUTION: Do not install the intermediate and overdrive accumulator valve plug and seal too far into the bore and damage the seal. Only push the intermediate and overdrive accumulator valve plug until it is flush with the accumulator body assembly.
2. Install the intermediate and overdrive accumulator valve plug.
3. Install the intermediate and overdrive accumulator valve plug retaining plate.
4. Install the special tool.
5. Using the special tool, install the valve body separator plate gaskets and valve body separator plate. Install a new valve body separator plate gasket. Install the valve body separator plate. Install a new valve body separator plate gasket.
6. Using the special tool, install the main control valve body.
7. Using the special tool, install the accumulator body separator plate and gaskets. Install a new accumulator body separator plate gasket. Install the accumulator body separator plate. Install a new accumulator body separator plate gasket.
8. Using the special tool, install the accumulator body assembly.
9. Starting with the bolts in the middle and working outward, install the accumulator body transfer plate.
10. Starting with the bolts in the middle and working outward, install the main control valve body to transfer plate. Install the manual valve detent spring. Install the control valve body to transfer plate bolts.
11. Install a new pressure tap plate gasket.
12. Install the pressure tap plate and bolts. NOTE: Match the solenoid valve body gasket to passages.
13. Install the solenoid valve body. Install the solenoid valve body gasket. Install the solenoid valve body. Install the two solenoid valve body bolts. Remove the special tool.
14. Install the manual valve.

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1. Remove and discard the final drive lube tube.
2. Using the special tool, remove and discard the final drive lube tube seal.
3. Remove the parking pawl ratcheting spring.
4. Remove the manual control lever outer assembly.
5. Remove the manual control lever shaft assembly.
6. Remove the parking pawl shaft retainer and bolt.
7. Remove the parking pawl shaft.
8. Remove the parking pawl assembly. Remove the parking pawl. Remove the parking pawl return spring. CAUTION: Do not damage the transaxle case bore during seal removal.
9. Remove and discard the manual control lever seal.
10. Remove the manual valve actuator rod (manual valve link). CAUTION: Do not damage the transaxle case sealing surface.
11. Remove and discard the manual valve detent lever shaft retaining pin. CAUTION: Do not damage the transaxle case sealing surface. NOTE: There are two retaining pins, one on either side of the manual valve detent lever.
12. Remove the manual valve detent lever shaft retaining pin.
13. Remove the manual valve detent lever and shaft assembly. Pull the manual valve detent lever and manual valve detent lever shaft from the transaxle case. Lift the manual valve detent lever from the transaxle case. CAUTION: Do not damage the seal bore in the case during seal removal.
14. Remove and discard the manual control seal.
15. If the case is being replaced, remove the line pressure port plug.
16. If a new case is being installed, remove and discard the cooler tube fitting. NOTE: A new driven sprocket bearing No. 18 can be installed once before an installation of the transaxle case becomes necessary. If a new No. 18 driven sprocket bearing was installed previously and a second installation is required, a new transaxle case must be installed.
17. As necessary, remove the No. 18 driven sprocket bearing assembly from transaxle case. Install the special tool into the transaxle. Position the special tool. Remove the bearing.
18. Using the special tools, remove the No. 18 driven sprocket bearing assembly. Position the special tool. Position the special tool. Remove the No. 18 driven sprocket bearing. WARNING: In order to avoid injury, eye protection should be worn when cleaning components with compressed air. Failure to follow these instructions can result in personal injury.
19. Clean all components with a suitable solvent and use moisture-free compressed air to dry all parts and clean fluid passages. Check the following before assembling: Final drive lubrication tube for damage. Manual control linkage for damage or wear. Case mating surfaces for nicks or deformation. Bearing wear. Support area wear.

Note. A new driven sprocket bearing No. 18 can be installed once before an installation of the transaxle case becomes necessary. If the No. 18 driven sprocket bearing was installed previously and a second installation is required, a new transaxle case must be installed.

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1. As necessary, install the No. 18 driven sprocket bearing into the transaxle case. Position the special tool. Position the special tool. Install new bearing. CAUTION: Do not lubricate the outer surface of the No. 18 driven sprocket bearing assembly. NOTE: The No. 18 driven sprocket bearing must be installed with the lettering on the needle bearing surface facing toward the needle bearing replace.
2. Using the special tools, install the No. 18 driven sprocket bearing assembly by pressing it into the transaxle case. Install the bearing on the special tool. Position the special tool. Install the No. 18 driven sprocket bearing.
3. Install the cooler tube fitting.
4. Install the line pressure port plug.
5. Using the special tool, install a new manual control lever seal.
6. Using the special tool, install a new manual control seal.
7. Install the manual valve detent lever assembly and the manual valve detent lever shaft assembly. Position the manual valve detent lever into the transaxle case. Install the manual valve detent lever shaft into the transaxle case and lever.
8. Install a new manual shaft retaining pin. CAUTION: Do not allow the manual shaft retaining pin to contact the transaxle case.
9. Install a new manual valve detent lever shaft retaining pin. Verify that the manual valve detent lever shaft rotates without binding.
10. Install the manual valve actuator rod (manual valve link).
11. Install the parking pawl assembly. Install the parking pawl return spring. Install the parking pawl.
12. Install the parking pawl shaft.
13. Install the parking pawl shaft retainer and bolt. NOTE: Lubricate the manual control lever inner shaft prior to installation.
14. Install the manual control lever shaft assembly. NOTE: Verify that the actuating cam rotates freely.
15. Install the parking pawl ratcheting spring. NOTE: Hand-tighten the manual control lever bolt, it will be torqued after linkage adjustment.
16. Install the manual control lever outer assembly and bolt.
17. Using the special tool, install a new final drive lube tube seal.
18. Install the final drive lube tube into the seal.
19. Using the special tool, install the final drive lube tube into the case.

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

1. Remove and discard the seven pump support seal rings from the pump support.
2. Remove the six pump support bolts.
3. Separate the pump support and body assembly. Remove the pump support. Remove the pump body separator plate gasket. Remove the pump body separator plate. Remove the pump body.
4. Remove and discard the pump seal.
5. Remove the pump drive gear assembly. Pump drive gear insert. Pump drive gear. Pump driven gear. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury.
6. Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
7. Inspect the pump body and gears for damage and wear. Driven gear teeth. Drive gear teeth. Gear bore. Crescent. Lubrication passages and holes.
8. Inspect the pump support apply circuit passages and lubrication passages. Rear lube (from cooler TC circuit). Reverse clutch (RC). Direct clutch (DC). Forward clutch (FC). Coast clutch (CC). Converter clutch bypass (CBY).

Note. The identification dot on the pump driven gear must face downward.

Scheme 846

Scheme 847

Scheme 848

Scheme 849

Scheme 850

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

1. Install the pump driven gear.
2. Install the pump drive gear assembly. Install the pump drive gear. Install the pump drive gear insert.
3. Using the special tool, measure the clearance between each gear and the pump body face. If the clearance exceeds specification, install a new pump assembly.
4. Install the special tool.
5. Align the pump support assembly. Fill the pump gear cavity with MERCON(R) Multi-Purpose (ATF) Transaxle Fluid to the top of the gears. Align the pump guide screws. Install the pump body. Install the pump body separator plate. Install the pump body separator plate gasket onto the pump body. Install the pump support. NOTE: Install the four pump support bolts in the pump support holes, and remove the special tool. Then install the last two bolts.
6. Install the six pump support bolts. NOTE: Make sure that the white stripe on the pump seal is visible around the pump body circumference.
7. Install the pump seal on the pump body. NOTE: Make sure the pump support seal rings are overlapped correctly.
8. Install the seven pump support seal rings.
9. Measure the pump rotational torque. Install the pump drive shaft. Measure the pump rotational torque. Remove the pump drive shaft. If rotational torque exceeds the specification, disassemble and inspect the pump assembly for contamination or incorrect end clearance.
10. Install the No. 1 pump support thrust bearing. Lubricate the seal rings with MERCON(R) Multi-Purpose (ATF) Transaxle Fluid.
11. Install the forward/coast/direct clutch cylinder and reverse clutch drum on the pump support.
12. Check the following passages of the forward/coast/direct clutch cylinder and reverse clutch drum with moisture-free compressed air, regulated to 276 kPa (40 psi). Reverse clutch passage. Forward clutch passage. Direct clutch passage. Coast clutch passage. Converter bypass (located on the bottom).

Scheme 856

Scheme 857

Scheme 858

Scheme 859

Scheme 860

Scheme 861

1. Remove the reverse clutch pressure plate retainer snap ring.
2. Remove the reverse clutch plates. Pressure plate. Friction plate. Steel plate. Inspect for damage or wear. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury. CAUTION: Do not compress the reverse clutch return springs completely.
3. Remove the retaining ring. Using the special tool, compress the reverse clutch return springs.
4. Remove the reverse clutch return spring assembly.
5. Remove the reverse clutch piston assembly. WARNING: Air pressure must not exceed 138 kPa (20 psi). Wear safety glasses when using compressed air. Failure to follow these instructions can result in personal injury. NOTE: Do not clean the clutch plates in a vapor degreaser or with any other type of detergent solution. Clean all parts thoroughly in a clean solvent and blow dry with moisture-free regulated compressed air.
6. Clean the friction steel plates with a lint-free cloth.
7. Inspect the parts for damage and wear: Clutch plates. Piston and seals. Bushings. Check ball in drum. Drum outer surface band contact area. Piston bore.

Scheme 862

Scheme 863

Scheme 864

Scheme 865

Scheme 866

Scheme 867

1. Before assembly, soak the internal spline clutch plates in clean MERCON(R) Automatic Transaxle Fluid (ATF) for 30 minutes.
2. Using the special tool, install the reverse clutch piston assembly with integral seals.
3. Install the reverse clutch return spring assembly. WARNING: Use caution when releasing tool pressure on the clutch piston springs. Failure to follow these instructions can result in personal injury. CAUTION: Do not compress the reverse clutch return springs completely.
4. Install the reverse clutch retaining ring. Using the special tool, compress the reverse clutch return springs.
5. Install the reverse clutch plates. Install the steel plates. Install the friction plates. Install the reverse clutch pressure plate.
6. Install the reverse clutch pressure plate retainer snap ring (selective fit).
7. Measure the clearance between the reverse clutch pressure plate and the reverse clutch pressure plate retainer snap ring with a feeler gauge. Take a second measurement on the opposite side. Average the two measurements to get the clearance. If the clearance is not within the specifications, select and install the correct thickness retaining ring to obtain the specified clearance. Retaining ring sizes: 1.39-1.49 mm (0.054-0.058 in) 1.53-1.63 mm (0.060-0.064 in) 1.68-1.78 mm (0.066-0.070 in)

Scheme 868

Scheme 869

Scheme 870

Scheme 871

Scheme 872

Scheme 873

Scheme 874

Scheme 875

Scheme 876

Scheme 877

1. Inspect the low/intermediate sun gear assembly for damage. Gear teeth. Thrust bearing surfaces. Journal surface.
2. Inspect the low/intermediate carrier assembly. Pinion gear teeth. Spline teeth. Pinion gear surfaces. Bushing surfaces. Pinion gear bearings.
3. Inspect the low/intermediate carrier assembly end play. Use a feeler gauge to measure end play. If end play is out of specification, install a new assembly.
4. Inspect the low/intermediate ring gear. Gear teeth. Spline teeth. Thrust bearing surfaces. Journal surface. Lug teeth.
5. Inspect the reverse/overdrive sun gear and shell assembly for damage or wear. Gear teeth. Lug teeth. Thrust bearing surfaces. Bushing surface.
6. Inspect the reverse/overdrive carrier assembly. Pinion gear teeth. Clutch plate spline teeth. Pinion gear bearings. Thrust bearing surfaces. Bushing surfaces. No. 8 thrust bearing captured between the pinions and carrier.
7. Inspect the reverse/overdrive carrier assembly end play. Use feeler gauge to measure end play. If end play is out of specification, install a new assembly.
8. Inspect the reverse/overdrive ring gear. Gear teeth. Spline teeth. Drive sprocket teeth. Thrust bearing surfaces. Journal surface. Bearings.
9. Inspect the driven sprocket assembly. Gear teeth. Parking gear lug teeth. Driven sprocket teeth. Thrust bearing surfaces. Bearing surfaces. Rivets. Bushing surfaces. Lubrication holes.
10. Inspect the drive chain. Check the drive chain for wear, stretching, or tightness of the chain links. The chain must move freely.