AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A01W36J

      Using a screwdriver, remove the transmission breather hose sub-assembly from the transaxle case sub-assembly.

    2. B001NXQE11
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

      Using a screwdriver, remove the No. 1 breather plug from the breather plug hose.

    3. Using a screwdriver, remove the No. 2 breather plug from the breather plug hose.

    4. Using a screwdriver, remove the O-ring from the No. 2 breather plug.

  2. REMOVE TRANSMISSION CONTROL SHAFT LEVER


    1. B001OEQ

      Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.

  3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B001NUW

      Remove the 2 bolts and park/neutral position switch assembly from the transaxle case sub-assembly.

      Note

      Before removing the park/neutral position switch assembly, remove any dirt or rust on the installation portion of the manual valve lever shaft sub-assembly. Be sure to remove the park/ neutral position switch assembly straight along the manual valve lever shaft sub-assembly while being careful not to deform the plate spring that supports the manual valve lever shaft sub-assembly. If the plate spring is deformed, the park/neutral position switch assembly cannot be reinstalled correctly.

  4. REMOVE OIL COOLER TUBE UNION (OUTLET)


    1. A01W2LV

      Remove the oil cooler tube union (outlet) from the transaxle case sub-assembly.

    2. Remove the O-ring from the oil cooler tube union (outlet).

  5. REMOVE OIL COOLER TUBE UNION (INLET)


    1. A01VZOQ

      Remove the oil cooler tube union (inlet) from the transaxle case sub-assembly.

    2. Remove the O-ring from the oil cooler tube union (inlet).

  6. REMOVE NO. 1 TRANSAXLE CASE PLUG


    1. B001OK7

      Remove the 3 No. 1 transaxle case plugs from the transaxle case sub-assembly.

    2. Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs.

  7. REMOVE NO. 2 TRANSAXLE CASE PLUG


    1. B001NQA

      Using a 6 mm hexagon socket wrench, remove the 3 No. 2 transaxle case plugs from the transaxle housing.

    2. Remove the 3 gaskets from the 3 No. 2 transaxle case plugs.

  8. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. B001OAQE03
      Text in Illustration
      *a Wooden Block

      Support the automatic transaxle assembly with wooden blocks.

  9. REMOVE OVERFLOW PLUG


    1. A01W3CT

      Using a 6 mm hexagon socket wrench, remove the overflow plug from the automatic transaxle oil pan sub-assembly.

    2. Remove the gasket from the overflow plug.

  10. REMOVE NO. 1 TRANSMISSION OIL FILLER TUBE


    1. A01VZIU

      Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle oil pan sub-assembly.

  11. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01W0D9

      Remove the 19 bolts and automatic transaxle oil pan sub-assembly from the transaxle case sub-assembly.

      Note

      Some fluid will remain in the automatic transaxle oil pan sub-assembly. Remove all the bolts and carefully remove the automatic transaxle oil pan sub-assembly.

  12. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET


    1. Remove the automatic transaxle oil pan gasket.

  13. REMOVE TRANSMISSION OIL CLEANER MAGNET


    1. B001OKOE02
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

      Remove the 4 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.

  14. INSPECT TRANSMISSION OIL CLEANER MAGNET

    Click here

  15. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A01W1F5

      Remove the 2 bolts and valve body oil strainer assembly from the transmission valve body assembly.

    2. B001O4QE04
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the valve body oil strainer assembly.

  16. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01W4PP

      Remove the 11 bolts and transmission valve body assembly from the transaxle case sub-assembly.

      Note

      When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case sub-assembly to interfere with each other.

  17. REMOVE NO. 1 GOVERNOR APPLY GASKET


    1. A01W3K0

      Remove the 2 No. 1 governor apply gaskets from the transaxle case sub-assembly.

  18. INSPECT INPUT SHAFT END PLAY

    Click here

  19. REMOVE REFILL PLUG


    1. B001NQH

      Remove the refill plug from the rear transaxle cover sub-assembly.

    2. Remove the gasket from the refill plug.

  20. REMOVE REAR TRANSAXLE COVER PLUG


    1. A01W5OK

      Remove the 3 rear transaxle cover plugs from the rear transaxle cover sub-assembly.

    2. Using a screwdriver, remove the 3 O-rings from the 3 rear transaxle cover plugs.

  21. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01W3UX

      Remove the 14 bolts from the rear transaxle cover sub-assembly.

    2. Using a brass bar and a hammer, tap on the circumference of the rear transaxle cover sub-assembly to remove the rear transaxle cover sub-assembly from the transaxle case sub-assembly.

    3. B001OAC

      Using a screwdriver, remove the 3 O-rings from the transaxle case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    4. B001OIVE06
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

      Remove the thrust needle roller bearing and thrust bearing race from the rear transaxle cover sub-assembly.

    5. B001OKHE05
      Text in Illustration
      *1 Oil Seal Ring

      Using a screwdriver, remove the 2 oil seal rings from the rear transaxle cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    6. A01W1ZY

      Using a T30 "TORX" socket wrench, remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly.

    7. B001NOQE12
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly.

      SST
      09319-60020

  22. REMOVE REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. B001NRUE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

      Remove the rear multiple disc clutch assembly from the transaxle case sub-assembly.

    2. Remove the thrust needle roller bearing from the transaxle case sub-assembly.

    3. B001OCGE05
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

      Using a screwdriver, remove the O-ring from the rear multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    4. Using a screwdriver, remove the oil seal ring from the rear multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  23. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. B001O50E02
      Text in Illustration
      *1 Snap Ring

      Using 2 screwdrivers and a hammer, remove the snap ring from the rear multiple disc clutch assembly.

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

    2. B001O0BE02
      Text in Illustration
      *1 Rear Planetary Sun Gear Assembly

      Remove the rear planetary sun gear assembly from the rear multiple disc clutch assembly.

    3. B001O8BE07
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

      Remove the thrust needle roller bearing and thrust bearing race from the rear multiple disc clutch assembly.

  24. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  25. REMOVE TRANSAXLE HOUSING


    1. B001O29

      Remove the 20 bolts from the transaxle housing.

    2. Using a brass bar and a hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case sub-assembly.

  26. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)


    1. B001NTLE03

      Using SST, remove the differential drive pinion tapered roller bearing RH (outer race) and shim from the transaxle housing.

      SST
      09308-00010

  27. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01W55E

      Remove the bolt, clamp and differential gear lube apply tube from the transaxle housing.

  28. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. A01W3GH

      Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.

  29. REMOVE FRONT OIL PUMP ASSEMBLY


    1. B001O30E06
      Text in Illustration
      *1 Gasket

      Remove the gasket from the front oil pump assembly.

    2. Remove the 7 bolts and front oil pump assembly from the transaxle case sub-assembly.

    3. A01W4Q0

      Remove the O-ring from the front oil pump assembly.

    4. B001NRME02
      Text in Illustration
      *1 Thrust Bearing Race

      Remove the thrust bearing race from the underdrive planetary gear assembly.

    5. B001OABE04
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 O-ring

      Remove the thrust needle roller bearing from the counter drive gear nut.

    6. Remove the O-ring from the transaxle case sub-assembly.

  30. REMOVE NO. 3 BRAKE DISC


    1. A01W0CW

      Using a screwdriver, remove the snap ring from the front oil pump assembly.

    2. B001NY5E02
      Text in Illustration
      *1 No. 3 Brake Flange
      *2 No. 3 Brake Plate
      *3 No. 3 Brake Disc

      Remove the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates from the front oil pump assembly.

  31. INSPECT NO. 3 BRAKE DISC

    Click here

  32. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01W4WB

      Remove the underdrive planetary gear assembly from the front oil pump assembly.

  33. REMOVE NO. 3 BRAKE HUB


    1. B001OAJ

      Remove the No. 3 brake hub from the underdrive planetary gear assembly.

    2. B001O0EE09
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

      Remove the thrust needle roller bearing and thrust bearing race from the underdrive planetary gear assembly.

  34. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B001OPXE06
      Text in Illustration
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

      While expanding the snap ring with snap ring pliers, remove the planetary sun gear sub-assembly from the underdrive planetary gear assembly.

    2. Remove the snap ring from the underdrive planetary gear assembly.

  35. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click here

  36. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  37. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A01W4MG

      Remove the input shaft sub-assembly from the front oil pump assembly.

    2. B001OLPE02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

      Remove the thrust needle roller bearing and thrust bearing race from the input shaft sub-assembly.

    3. Using a screwdriver, remove the 3 oil seal rings from the input shaft sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  38. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. B001ONNE02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

      Remove the underdrive planetary sun gear from the front oil pump assembly.

    2. Remove the thrust needle roller bearing from the front oil pump assembly.

  39. REMOVE NO. 1 BRAKE DISC


    1. B001NTOE02
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

      Using a screwdriver, remove the 2 snap rings and brake snap ring stopper from the front oil pump assembly.

    2. B001O3TE01
      Text in Illustration
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

      Remove the No. 1 brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates from the front oil pump assembly.

  40. INSPECT NO. 1 BRAKE DISC

    Click here

  41. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A01W125

      Remove the 3 2nd brake piston return spring sub-assemblies from the front oil pump assembly.

  42. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    Click here

  43. REMOVE NO. 1 BRAKE PISTON


    1. A01VZ6F

      While holding the front oil pump assembly by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the front oil pump assembly to remove the No. 1 brake piston.

    2. B001OCPE01
      Text in Illustration
      *1 O-ring

      Using a screwdriver, remove the 2 O-rings from the No. 1 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

  44. REMOVE FRONT DIFFERENTIAL CASE


    1. A01VZXX

      Remove the front differential case from the transaxle case sub-assembly.

  45. REMOVE COUNTER DRIVE GEAR NUT


    1. B001OJCE04

      Using SST and a hammer, unstake the front planetary gear assembly.

      SST
      09930-00010
    2. B001OG8E04

      Turn the manual valve lever shaft sub-assembly counterclockwise to set it to the P position as shown in the illustration.

    3. B001OI1E03

      Using SST, remove the counter drive gear nut from the front planetary gear assembly.

      SST
      09387-00130
    4. B001OFVE02

      Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.

  46. REMOVE COUNTER DRIVEN GEAR


    1. A01W27A

      Remove the counter driven gear from the transaxle case sub-assembly.

  47. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)


    1. B001NX6E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the differential drive pinion tapered roller bearing RH (inner race) from the counter driven gear.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00320 )

  48. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (INNER RACE)

    Tech Tips

    If removing the differential drive pinion tapered roller bearing LH (inner race), replace the counter driven gear with a new one.

  49. REMOVE PAWL SHAFT CLAMP


    1. A01W552

      Remove the bolt and pawl shaft clamp from the transaxle case sub-assembly.

  50. REMOVE NO. 1 TRANSMISSION CASE PLATE


    1. A01W25V

      Remove the bolt and No. 1 transmission case plate from the transaxle case sub-assembly.

  51. REMOVE PAWL STOPPER PLATE


    1. A01W3ES

      Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.

  52. REMOVE PARKING LOCK SLEEVE


    1. A01VZXW

      Remove the parking lock sleeve from the transaxle case sub-assembly.

  53. REMOVE PARKING LOCK PAWL


    1. B001NMUE02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

      Remove the spring, parking lock pawl pin, parking lock pawl shaft and parking lock pawl from the transaxle case sub-assembly.

  54. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. B001NPIE03

      Using SST, remove the differential drive pinion tapered roller bearing LH (outer race) from the transaxle case sub-assembly.

      SST
      09308-00010

  55. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. B001OEY

      Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.

    2. B001OD7E08
      Text in Illustration
      *1 One-way Clutch Assembly with Planetary Ring Gear
      *2 Thrust Needle Roller Bearing

      Remove the one-way clutch assembly with planetary ring gear from the transaxle case sub-assembly.

    3. Remove the thrust needle roller bearing from the front planetary gear assembly.

    4. B001OORE02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

      Remove the one-way clutch assembly from the planetary ring gear.

    5. Remove the outer race retainer from the one-way clutch assembly.

  56. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  57. REMOVE PLANETARY RING GEAR FLANGE


    1. B001OM5E06
      Text in Illustration
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

      Using a screwdriver, remove the snap ring from the planetary ring gear.

    2. Remove the planetary ring gear flange from the planetary ring gear.

  58. REMOVE NO. 2 BRAKE DISC


    1. B001OP6

      Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.

    2. B001OBHE02
      Text in Illustration
      *1 No. 2 Brake Flange
      *2 No. 2 Brake Plate
      *3 No. 2 Brake Disc

      Remove the No. 2 brake flange, 4 No. 2 brake discs and 4 No. 2 brake plates from the transaxle case sub-assembly.

  59. INSPECT NO. 2 BRAKE DISC

    Click here

  60. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. B001ONF

      Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.

    2. B001O7M

      Remove the 1st and reverse brake return spring sub-assembly from the transaxle case sub-assembly.

  61. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

    Click here

  62. REMOVE NO. 2 BRAKE PISTON


    1. B001OCL

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the ATF hole to remove the No. 2 brake piston from the transaxle case sub-assembly.

    2. A01W2JV

      Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

  63. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B001NV0E01

      Using SST and a press, remove the front planetary gear assembly from the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00580 )
      09950-70010   ( 09951-07100 )

  64. REMOVE COUNTER DRIVE GEAR


    1. B001OKIE01

      Using SST and a press, remove the counter drive gear with bearing inner race (front side) from the transaxle case sub-assembly.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

    2. Remove the bearing inner race (rear side).

    3. A01W2Z0

      As shown in the illustration, tighten 2 service bolts evenly to make a clearance of approximately 5.0 mm (0.197 in.) between the counter drive gear and bearing inner race (front side).

    4. B001OP2E03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the bearing inner race (front side) from the counter drive gear.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60020   ( 09951-00710 )

  65. REMOVE NO. 3 BRAKE PISTON


    1. B001OKVE03

      Place SST on the brake piston return spring and compress the brake piston return spring with a press.

      SST
      09387-00070

    2. Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.

    3. B001OBGE02
      Text in Illustration
      *1 Brake Piston Return Spring

      Remove the brake piston return spring from the transaxle case sub-assembly.

    4. B001NQ0E02
      Text in Illustration
      *1 No. 3 Brake Piston

      Remove the No. 3 brake piston from the transaxle case sub-assembly.

    5. A01W48L

      Using a screwdriver, remove the 2 O-rings from the No. 3 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

  66. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    Click here

  67. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01W3II

      Remove the bolt, manual detent spring cover and manual detent spring sub-assembly from the transaxle case sub-assembly.

  68. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01W4CX

      Remove the parking lock rod sub-assembly from the manual valve lever shaft sub-assembly.

      Tech Tips

      Align the protrusions with the notches on the manual valve lever shaft sub-assembly to remove the parking lock rod sub-assembly.

  69. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01W5HC

      Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the manual valve lever shaft sub-assembly.

    2. A01W4I6

      Remove the manual valve lever shaft sub-assembly from the transaxle case sub-assembly.

  70. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01VZOF

      Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.