Page 1905 of 2585
(38) Using tool L-4407A, remove transfer shaft
gear (Fig. 54).
(39) Remove transfer gear shim (select) (Fig. 55). (40) Remove bearing cup retainer (Fig. 56).
(41) Remove transfer gear bearing cone using
setup shown in (Fig. 57).
Fig. 54 Remove Transfer Shaft Gear
1 - SPECIAL TOOL L4407-6
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A
Fig. 55 Remove Transfer Shaft Gear and (Select) Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
Fig. 56 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER
Fig. 57 Remove Transfer Gear Bearing Cone
1 - WRENCHES
2 - TOOL 5048 WITH JAWS TOOL 5048±4 AND BUTTON TOOL
L-4539±2
3 - TRANSFER SHAFT GEAR
21s - 44 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1906 of 2585
(42) Remove transfer shaft bearing cup from
retainer using Tool 6062 (Fig. 58).
(43) Using Tool 6051, remove transfer shaft bear-
ing snap ring (Fig. 59). (44) Using tool 5049A, remove transfer shaft from
transaxle (Fig. 60).
(45) Slip bearing cup retainer and oil baffle off of
shaft (Fig. 61).
Fig. 58 Remove Transfer Shaft Bearing Cup
1 - WRENCHES
2 - TOOL 6062
3 - TRANSFER SHAFT BEARING CUP RETAINER
Fig. 59 Remove Transfer Shaft Bearing Snap Ring
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT
Fig. 60 Remove Transfer Shaft
1 - SPECIAL TOOL 5049±A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR
Fig. 61 Bearing Cup Removed
1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
RS 40TE AUTOMATIC TRANSAXLE21s-45
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1907 of 2585
(46) Using tool P-334, press transfer shaft bearing
cone off of shaft (Fig. 62).
(47) Bend output gear retaining strap ears flat to
allow bolt removal. (48) Remove output shaft stirrup strap bolts (Fig.
63).
(49) Remove stirrup and strap (Fig. 64).
(50) Using Tool 6259 (Fig. 65), remove output shaft
gear-to-shaft bolt and washer (Fig. 66).
Fig. 62 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
Fig. 63 Remove Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 64 Remove Stirrup Strap
1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 65 Remove Output Gear Bolt
1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 66 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
21s - 46 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1908 of 2585
(51) Using Tool L4407A, and button 6055, remove
output gear from shaft (Fig. 67).
(52) Remove output gear bearing shim (select)
(Fig. 68). (53) Using setup as shown in (Fig. 69), remove
output gear bearing cone.
(54) Remove rear carrier assembly from transaxle
(Fig. 70).
Fig. 67 Remove Output Gear
1 - OUTPUT GEAR
2 - BUTTON TOOL 6055
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407±6
Fig. 68 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
Fig. 69 Remove Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±5 AND BUTTON L-4539±2
2 - WRENCHES
3 - OUTPUT GEAR
Fig. 70 Remove Rear Carrier Assembly
1 - REAR CARRIER ASSEMBLY
RS 40TE AUTOMATIC TRANSAXLE21s-47
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1909 of 2585
(55) Remove rear carrier assembly bearing cone
using setup shown in (Fig. 71).
(56) Install low/reverse spring compressor tool as
shown in (Fig. 72) (Fig. 73). (57) Compress low/reverse piston return spring
and remove snap ring (Fig. 74).
Fig. 71 Remove Rear Carrier Bearing Cone
1 - TOOL 5048 WITH JAWS 5048±3 AND BUTTON 6055
2 - WRENCHES
3 - REAR CARRIER ASSEMBLY
Fig. 72 Low/Reverse Spring Compressor Tool
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 5058±3
Fig. 73 Compressor Tool in Use
1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058±3
Fig. 74 Install Snap Ring
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
2 - SNAP RING PLIERS
3 - TOOL 6057
21s - 48 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1910 of 2585

(58) Remove low/reverse spring compressor tool
and low reverse piston return spring (Fig. 75).
(59) Using a suitable punch , drive out park guide
bracket pivot shaft plug (Fig. 76). (60) Using ordinary pliers, remove pivot shaft and
guide bracket assembly (Fig. 77).
(61) Inspect guide bracket components for exces-
sive wear and replace if necessary (Fig. 78).
NOTE: The Low/Reverse Clutch Piston has bonded
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
Fig. 75 Low/Reverse Piston
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
Fig. 76 Remove Anchor Shaft and Plug
1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 77 Pivot Shaft and Guide Bracket
1 - ANTIRACHET SPRING
2 - GUIDE BRACKET
3 - PIVOT SHAFT
4-PAWL
Fig. 78 Guide Bracket Disassembled
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5-PAWL
6 - STEPPED SPACER
RS 40TE AUTOMATIC TRANSAXLE21s-49
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1911 of 2585
(62) Remove low/reverse clutch piston (Fig. 79).
(63) Remove low/reverse piston retainer-to-case
screws (Fig. 80). (64) Remove low/reverse piston retainer (Fig. 81).
(65) Remove low/reverse piston retainer-to-case
gasket (Fig. 82).
Fig. 79 Remove Low/Reverse Clutch Piston
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL
Fig. 80 Remove Piston Retainer-to-Case Screws
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 81 Remove Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 82 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
21s - 50 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)
Page 1912 of 2585

(66) Using a hammer and suitable drift, drive out
inner output bearing cup (Fig. 83).
(67) Using tool 6062, remove outer output bearing
cup (Fig. 84).
ASSEMBLY
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch and/or
seal replacement), the TCM/PCM Quick Learn proce-
dure must be performed. (Refer t o 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install both output bearing cups using Tool
5050 (Fig. 85).
(2) Install low/reverse piston retainer gasket (Fig.
86). Make sure gasket holes line up with case.
Fig. 83 Remove Output Bearing Inner Cup
1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
Fig. 84 Remove Output Bearing Outer
1 - TOOL 6062
Fig. 85 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
Fig. 86 Install Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
RS 40TE AUTOMATIC TRANSAXLE21s-51
40TE AUTOMATIC TRANSAXLE (Continued)