AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B004I5H

      Using a screwdriver with its tip wrapped with protective tape, remove the transmission breather hose sub-assembly from the transaxle case sub-assembly.

    2. B0070QPC01
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-ring

      Using a screwdriver with its tip wrapped with protective tape, remove the No. 1 breather plug from the breather plug hose.

    3. Using a screwdriver with its tip wrapped with protective tape, remove the No. 2 breather plug from the breather plug hose.

    4. Using a screwdriver with its tip wrapped with protective tape, remove the O-ring from the No. 2 breather plug.

  2. REMOVE TRANSMISSION CONTROL SHAFT LEVER


    1. B004J00

      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. B004KV6

      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. B004KQ7

      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. B004MRN

      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. B004NRQ

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

    2. Using a screwdriver with its tip wrapped with protective tape, remove the 3 O-rings from the 3 No. 1 transaxle case plugs.

  7. REMOVE NO. 2 TRANSAXLE CASE PLUG


    1. B004NPP

      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. B006YT1C01
      *a Wooden Block

      Support the automatic transaxle assembly with wooden blocks.

  9. REMOVE OVERFLOW PLUG


    1. B004JRB

      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. B004I5J

      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. B0070YA

      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 from the automatic transaxle oil pan sub-assembly.

  13. REMOVE TRANSMISSION OIL CLEANER MAGNET


    1. B006ZGKC01
      *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. B007024

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

    2. B006Y25

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

  16. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. B006WYQ

      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 TRANSAXLE CASE GASKET


    1. B006XNJ

      Remove the 2 transaxle case gaskets from the transaxle case sub-assembly.

  18. INSPECT INPUT SHAFT END PLAY

    Click here

  19. REMOVE REFILL PLUG


    1. B004LFF

      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. B004JFY

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

    2. Using a screwdriver with its tip wrapped with protective tape, remove the 3 O-rings from the 3 rear transaxle cover plugs.

  21. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B004O0N

      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. B004JHN

      Using a screwdriver with its tip wrapped with protective tape, remove the 3 O-rings from the transaxle case sub-assembly.

    4. B006ZBGC07
      *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. B0070WHC05
      *1 Oil Seal Ring

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 oil seal rings from the rear transaxle cover sub-assembly.

    6. B004L67

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

    7. B0071ILC01
      *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. B006YD5C01
      *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. B006ZDBC01
      *1 O-ring
      *2 Oil Seal Ring

      Using a screwdriver with its tip wrapped with protective tape, remove the O-ring from the rear multiple disc clutch assembly.

    4. Using a screwdriver with its tip wrapped with protective tape, remove the oil seal ring from the rear multiple disc clutch assembly.

  23. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. B00708RC01
      *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. B0071K3C09
      *1 Rear Planetary Sun Gear Assembly

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

    3. B006X9LC01
      *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. B004O3T

      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. B006Y4ON02

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

      SST
      09308-00010

  27. REMOVE FRONT DRIVE SHAFT OIL SEAL RH


    1. B006ZR8N06

      Using SST, remove the front drive shaft oil seal RH from the transaxle housing.

      SST
      09950-60010   ( 09951-00550 )
      09950-70010   ( 09951-07200 )

  28. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)


    1. B006Y29N07

      Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.

      SST
      09308-00010

  29. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B004L43

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

  30. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. B004LKM

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

  31. REMOVE FRONT OIL PUMP ASSEMBLY


    1. B006YGMC01
      *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. B004J8J

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

    4. B006Z77C01
      *1 Thrust Bearing Race

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

    5. B006WYCC01
      *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.

  32. REMOVE NO. 3 BRAKE DISC


    1. B006ZP6C02
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.

    2. B0071POC01
      *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.

  33. INSPECT NO. 3 BRAKE DISC

    Click here

  34. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B004KFX

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

  35. REMOVE NO. 3 BRAKE HUB


    1. B004JAV

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

    2. B00711VC10
      *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.

  36. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B006YECC01
      *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.

  37. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click here

  38. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  39. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. B004LX3

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

    2. B006X64C01
      *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 with its tip wrapped with protective tape, remove the 3 oil seal rings from the input shaft sub-assembly.

  40. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. B0070DTC02
      *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.

  41. REMOVE NO. 1 BRAKE DISC


    1. B0071DIC01
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 snap rings and brake snap ring stopper from the front oil pump assembly.

    2. B006WX5C01
      *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.

  42. INSPECT NO. 1 BRAKE DISC

    Click here

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


    1. B004LI0

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

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

    Click here

  45. REMOVE NO. 1 BRAKE PISTON


    1. B004JE8

      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. B004JJ2

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 O-rings from the No. 1 brake piston.

  46. REMOVE FRONT DIFFERENTIAL CASE


    1. B004L0S

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

  47. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (INNER RACE)


    1. B00715JC02
      *a Turn
      *b Hold

      Using SST, remove the front differential case front tapered roller bearing (inner race) from the front differential case.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00480 )

  48. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (INNER RACE)


    1. B006X9SC02
      *a Turn
      *b Hold

      Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00480 )

  49. REMOVE COUNTER DRIVE GEAR NUT


    1. B00709AN03

      Using SST and a hammer, release the staked part of the front planetary gear assembly.

      SST
      09930-00010
    2. B006XQHN01

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

    3. B007112N03

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

      SST
      09387-00130
    4. B0070UAN01

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

  50. REMOVE COUNTER DRIVEN GEAR


    1. B004LC6

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

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


    1. B0070J1C01
      *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 )

  52. 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.

  53. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)


    1. B006YG0N01

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

      SST
      09308-00010

  54. REMOVE PAWL SHAFT CLAMP


    1. B004ILG

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

  55. REMOVE NO. 1 TRANSMISSION CASE PLATE


    1. B004JKP

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

  56. REMOVE PAWL STOPPER PLATE


    1. B004O10

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

  57. REMOVE PARKING LOCK SLEEVE


    1. B004JGI

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

  58. REMOVE PARKING LOCK PAWL


    1. B006XJ4C08
      *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.

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


    1. B0070BCN02

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

      SST
      09308-00010

  60. REMOVE FRONT DRIVE SHAFT OIL SEAL LH


    1. B006WXUN05

      Using SST, remove the front drive shaft oil seal LH from the transaxle case sub-assembly.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07100 )

  61. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. B0070C3C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

    2. B006ZVOC01
      *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. B006YIQC01
      *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.

  62. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  63. REMOVE PLANETARY RING GEAR FLANGE


    1. B006ZOHC01
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

      Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the planetary ring gear.

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

  64. REMOVE NO. 2 BRAKE DISC


    1. B0070L7C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

    2. B0071QWC01
      *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.

  65. INSPECT NO. 2 BRAKE DISC

    Click here

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


    1. B006XGVC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

    2. B004O07

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

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

    Click here

  68. REMOVE NO. 2 BRAKE PISTON


    1. B004LZ4

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

    2. B004IFB

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 O-rings from the No. 2 brake piston.

  69. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B006XO2N02

      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 )

  70. REMOVE COUNTER DRIVE GEAR


    1. B0071H3N01

      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. Remove the 2 counter drive gear bearings (balls and cage) from the counter drive gear bearing (outer race).

    4. B004IEA

      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).

    5. B006Z8FC01
      *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 )

  71. REMOVE NO. 3 BRAKE PISTON


    1. B00705RN02

      Place SST on the No. 3 brake piston return spring sub-assembly and compress the No. 3 brake piston return spring sub-assembly with a press.

      SST
      09387-00070

    2. Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.

    3. B006ZVUC01
      *1 Brake Piston Return Spring

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

    4. B006YH3C01
      *1 No. 3 Brake Piston

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

    5. B004KX3

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 O-rings from the No. 3 brake piston.

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

    Click here

  73. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B004M1K

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

  74. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B004LFW

      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.

  75. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B004NST

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

    2. B004NN0

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

  76. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B006ZF1C01
      *a Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.