Disassembly - Transmission

Special Service Tools / General Equipment

	307-163 (T86P-70043-A) Remover, Stator Housing Bearing TKIT-1986-LM TKIT-1986-F
	307-586 Differential Bearing Cup Remover TKIT-2006UF-FLM TKIT-2006UF-RYAD
	307-741 Spring Compressor, Clutch F
	307-821 Motor Rotor Remover/Installer
	308-001 (T58L-101-B) Guide Bearing Remover
Hydraulic Press
Puller
Strike with a fist
Wood block

1. 1
   Remove the vent assembly.

   

2. 2
   Remove the damper housing bolts and studs.

   

3. 3
   Using a pry bar, pry the damper housing at the indicated locations to remove the housing.

   

4. 4
   Remove the output shaft gear assembly and the traction motor drive gear assembly.

   

5. 5
   Replace the output shaft and gear assembly and install new bearing rings if the bearings are damaged.

   

6. 6
   Replace the output shaft and gear assembly and install new bearings if the bearings are damaged.

   

7. 7
   Using a pry bar and a wooden block, remove the final drive input gear assembly.
   Use common equipment: wooden block

   

8. 8
   Replace the final drive input gear assembly if the bearings are damaged.

   

9. 9
   Remove the differential case gear assembly.

   

10. 10
    Inspect the differential bearing for damage and replace if necessary.

    

11. 11
    Using the special service tools, remove the transaxle output shaft gear side bearing cup.
    Use special service tool: 308-001 (T58L-101-B) Guide Bearing Remover, 307-163 (T86P-70043-A) Stator Housing Bearing Remover.

    

12. 12
    Remove and discard the left axle seal.
    Use common equipment: slide hammer

    

13. 13
    1. 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.
       Use special service tool: 307-586 Differential Bearing Remover.

    2. Expand the differential bearing cup remover 307-586 by hand.

    3. Hold the differential bearing cup remover 307-586 in the expanded position with the tabs in the transaxle case slots, and tighten the nut.

    

14. 14
    Using a hammer and a drift, remove the differential bearing cup.
    Use special service tool: 307-586 Differential Bearing Remover.

    

15. 15
    Remove the clips and the transmission fluid pan baffle.

    

16. 16
    Remove the clips and the transmission fluid manifold plate.

    

17. 17
    Remove the clip and the transmission fluid manifold plate.

    

18. 18
    Remove and discard the right axle seal.
    Use common equipment: slide hammer

    

19. 19
    Remove and discard the input shaft seal.
    Use common equipment: slide hammer

    

20. 20
    Remove the transaxle output shaft gear side bearing cup from the damper housing.
    Use special service tool: 308-001 (T58L-101-B) Guide Bearing Remover, 307-163 (T86P-70043-A) Stator Housing Bearing Remover.

    

21. 21
    Remove the output shaft preload adjustment shim.

    

22. 22
    1. Position the differential bearing cup remover 307-586 in the damper housing with the tabs on the differential bearing cup remover 307-586 aligned with the slots in the damper housing.
       Use special service tool: 307-586 Differential Bearing Remover.

    2. Expand the differential bearing cup remover 307-586 by hand.

    3. Hold the differential bearing cup remover 307-586 in the expanded position with the tabs in the damper housing slots, and tighten the nut.

    

23. 23
    Using a hammer and a drift, remove the differential side bearing cup from the damper housing.
    Use special service tool: 307-586 Differential Bearing Remover.

    

24. 24
    Remove the differential adjustment shim.

    

25. 25
    Remove the traction motor drive gear rear bearing from the traction motor drive gear.
    Use common equipment: puller
    Use common equipment: hydraulic press

    

26. 26
    Remove the traction motor drive gear front bearing from the traction motor drive gear.
    Use common equipment: puller
    Use common equipment: hydraulic press

    

27. 27
    Remove the transaxle high-voltage terminals.
    Refer to: Transaxle High-Voltage Terminals (307-01B Automatic Transmission - Automatic Transmission - HF45, Disassembly and Assembly of Sub-Assemblies).
28. 28
    • Disconnect the traction motor stator electrical connector.

    • Disconnect the generator/starter stator electrical connector.

    • Disconnect the wiring harness retainer.

    

29. 29
    Position the transmission case on wooden blocks so that the transmission input shaft does not contact the bench surface.

    

30. 30
    Remove the transmission case cover.
    Refer to: Transmission Case Cover (307-01B Automatic Transmission/Transaxle - Automatic Transmission/Transaxle - HF45, Removal and Installation).
31. 31
    Using a straightedge, measure and record the distance between the traction motor rotor and the transmission case surface. Then measure and record the distance between the generator/starter rotor and the transmission case surface for reassembly.

    

32. 32
    Mark the traction motor stator and the generator/starter stator to the transmission case as a reference for correct installation.

    

33. 33
    Remove the traction motor stator bolts.

    

34. 34
    Install the special tool to the traction motor stator windings.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

35. 35
    Install the special tool into the traction motor rotor slot holes and turn counterclockwise until the special tool is secured.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

36. 36
    Install the pin into the special tool until it is fully seated in the rotor.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

37. 37
    Install the special tools, thread the tension bolt into the special tool and tighten the wing nuts.
    Use special service tools: 307-741 Spring Compressor, Clutch F, 307-821 Motor Rotor Remover/Installer.

    

38. 38

    NOTICE: The rotors are magnetized. Place them only on a non-metallic tray.

    • Remove the traction motor rotor by turning the nut on the drawbar.

    • When the rotor begins to move out of the stator, lift the special tool to remove the rotor.

    

39. 39
    Remove the generator/starter stator bolts.

    

40. 40
    Install the special tool to the generator/starter stator windings.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

41. 41
    Install the special tool into the generator/starter rotor slots and turn counterclockwise until the special tool is secured.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

42. 42
    Install the pin into the special tool until it is fully seated in the rotor.
    Use special service tool: 307-821 Motor Rotor Remover/Installer.

    

43. 43
    Install the special tools, thread the tension bolt into the special tool and tighten the wing nuts.
    Use special service tools: 307-741 Spring Compressor, Clutch F, 307-821 Motor Rotor Remover/Installer.

    

44. 44

    NOTICE: The rotors are magnetized. Place the rotors only on a non-metallic tray. Do not allow the traction rotor and the generator/starter rotor to contact each other, as damage may occur.

    • Remove the generator/starter rotor by turning the nut on the drawbar clockwise.

    • When the rotor begins to move out of the stator, lift the special tool to remove the rotor.

    

45. 45
    1. If equipped, cut and discard the tie strap.

    2. Disconnect the park lock actuator.

    

46. 46

    NOTICE: When removing the stator, be careful not to bend or break the stator wires.

    NOTICE: After removing the stator, lay the stator on its side, otherwise damage to the windings may occur.

    Remove the generator/starter stator.

    

47. 47
    Remove the planetary carrier support cover bolts, disconnect the generator/starter resolver and remove the support cover.

    

48. 48
    Remove the thrust washer from the planetary carrier support cover.

    

49. 49
    Remove the pump drive gear.

    

50. 50
    Remove the sun gear.

    

51. 51
    Remove the sun gear thrust bearing.

    

52. 52
    Remove the planetary carrier assembly.

    

53. 53
    Remove the ring gear.

    

54. 54

    NOTICE: When removing the stator, be careful not to bend or break the stator wires.

    NOTICE: After removing the stator, lay the stator on its side, otherwise damage to the windings may occur.

    Turn the transmission case on its side and remove the traction motor stator.

    

55. 55
    Using a metal scribe, mark the traction motor resolver and the transmission case as a reference for correct installation.

    

56. 56
    Remove the traction motor resolver bolts.

    

57. 57
    Disconnect and remove the traction motor resolver.

    

58. 58
    Disconnect the park lock actuator.

    

59. 59
    Remove the park lock bolts and the park lock actuator.

    

60. 60
    Turn the transmission case over and position it on wooden blocks.

    

61. 61
    Remove the wiring harness bolts.

    

62. 62
    Disconnect the wiring harness bulkhead connector and remove the wiring harness from the transmission case.

    

63. 63
    Inspect the wiring harness bulkhead seal for damage. Replace if necessary.

    

64. 64
    Remove the bolts and the fluid pump and filter assembly.

    

65. 65
    1. Remove the park pawl shaft.

    2. Remove the park lock actuator guide bolts.

    3. Remove the park lock actuator guide and the park pawl.