TSB : Transaxle Assembly: Disassembly

Details

With final drive housing/transaxle assembly removed from vehicle, clean outside case thoroughly and disassemble in a clean area. When cleaning and wiping parts, use nylon cloth or paper towels. Common shop rags will leave lint that can interfere with transaxle operation. Mount assembly on repair fixture (VW851 and VW309). Drain ATF from transaxle. CAUTION: When removing/installing torque converter, do not rock or tilt converter. This could damage the converter oil seal, stator one-way clutch or other components in torque converter hub. Withdraw torque converter from final drive housing using a twisting motion. Set converter aside and cover hub opening. Remove governor cover and gasket. Pull governor from final drive housing. Use a clockwise twisting motion to disengage governor drive gear from gear on transaxle annulus gear. Turn transaxle/final drive assembly so gear oil cannot leak. Remove nuts from 1 3/4" (44 mm) transaxle-to-final drive studs. Separate transaxle from final drive. Drain gear oil from final drive if unit is to be repaired. Withdraw 12.56" (319 mm) long pump shaft and 10.44" (265.1 mm), long turbine shaft from transaxle (check turbine shaft rings for wear and proper seating). NOTE: Once transaxle and final drive assemblies are separated, keep out dirt by covering open end of transaxle when final drive is being worked on or both ends of final drive as transaxle is being repaired. Detach screws retaining separation plate in transaxle case. Remove plate and discard gasket. With- draw annulus gear assembly (governor drive gear/Reverse planetary ring gear) from case. See Fig 1 . Withdraw needle bearing and thrust washer from top of reverse (front) planetary gear set (some models may have thrust washer in place of needle bearing). Using screwdriver, pry out large circlip retaining one-way clutch assembly in case. Fabricate 2 hooks from 3/16" welding rod. Using hooks, lift one-way clutch, internally and externally splined 1st/Reverse gear brake discs (3 fiber and 3 steel) and the reverse planetary gear set from case. See Fig 2 . Remove thrust washer(s). Withdraw apply shell (with internally splined washer), forward (rear) planetary gear set (with sun gear), needle bearing (some models may have thrust washer in place of needle bearing) and forward clutch as an assembly. NOTE: When removing forward clutch assembly, ensure 2 thrust washers and thrust bearing which oil pump rides against are not lost or damaged. Remove forward clutch-to-Direct/Reverse clutch thrust washer and radial-roller thrust bearing (some models may have thrust washer in place of bearing). Push 2nd gear brake band servo piston assembly down into transaxle case. Remove retaining circlip. Withdraw servo assembly (cover, piston and spring) from case. If servo assembly sticks, tap cover with rubber mallet until piston pops out under spring pressure. On opposite side of case, loosen lock nut for 2nd gear brake band adjusting screw. Detach screw (with lock nut) and withdraw push rod. Remove Direct/Reverse clutch from case. From inside case, withdraw 2nd gear brake band. Remove 5 bolts from 1st/reverse gear brake spring plate. Withdraw plate and springs. Pull 1st/ Reverse apply shell, brake piston and AT oil pump assembly from case. Position transaxle case on bench with oil pan facing upward. Remove pan mount bolts. Withdraw pan and gasket. Remove oil strainer screws from valve body. NOTE: An inspection of any foreign matter in the oil pan can indicate the type of problems to look for while disassembling transaxle. Remove hex-head mount bolts from valve body. Lift valve body from case. Use care not to lose manual valve. Withdraw accumulator spring and piston from case. If necessary for parts replacement, disassemble parking lock, kickdown and manual valve linkage. See Figure . Fig 1: Exploded View Of Automatic Transaxle Assembly Fig 2: Removing One-Way Clutch From Case