REMOVE BREATHER PLUG HOSE
Using a screwdriver, remove the No. 2 breather plug from the transaxle case sub-assembly.
| *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.
Using a screwdriver, remove the No. 2 breather plug from the breather plug hose.
Using a screwdriver, remove the O-ring from the No. 2 breather plug.
REMOVE TRANSMISSION CONTROL SHAFT LEVER
Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
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.
REMOVE OIL COOLER TUBE UNION (OUTLET)
Remove the oil cooler tube union (outlet) from the transaxle case sub-assembly.
Remove the O-ring from the oil cooler tube union (outlet).
REMOVE OIL COOLER TUBE UNION (INLET)
Remove the oil cooler tube union (inlet) from the transaxle case sub-assembly.
Remove the O-ring from the oil cooler tube union (inlet).
REMOVE NO. 1 TRANSAXLE CASE PLUG
Remove the 3 No. 1 transaxle case plugs from the transaxle case sub-assembly.
Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs.
REMOVE NO. 2 TRANSAXLE CASE PLUG
Using a 6 mm hexagon socket wrench, remove the 3 No. 2 transaxle case plugs from the transaxle housing.
Remove the 3 gaskets from the 3 No. 2 transaxle case plugs.
SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY
| *a | Wooden Block |
Support the automatic transaxle assembly with wooden blocks.
REMOVE OVERFLOW PLUG
Using a 6 mm hexagon socket wrench, remove the overflow plug from the automatic transaxle oil pan sub-assembly.
Remove the gasket from the overflow plug.
REMOVE NO. 1 TRANSMISSION OIL FILLER TUBE
Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle oil pan sub-assembly.
REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
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.
REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
Remove the automatic transaxle oil pan gasket.
REMOVE TRANSMISSION OIL CLEANER MAGNET
| *1 | Transmission Oil Cleaner Magnet |
Remove the 4 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.
INSPECT TRANSMISSION OIL CLEANER MAGNET
Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear has occurred in the automatic transaxle assembly:
| Result |
|---|
| Steel (magnetic) |
| Bearing, gear and plate wear |
| Brass (non-magnetic) |
| Bushing wear |
REMOVE VALVE BODY OIL STRAINER ASSEMBLY
Remove the 2 bolts and valve body oil strainer assembly from the transmission valve body assembly.
| *1 | O-ring |
Remove the O-ring from the valve body oil strainer assembly.
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
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 speed sensor and transaxle case sub-assembly to interfere with each other.
REMOVE NO. 1 GOVERNOR APPLY GASKET
Remove the 2 No. 1 governor apply gaskets from the transaxle case sub-assembly.
INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY
Using a dial indicator, measure the input shaft end play.
| End play |
|---|
| 0.020 to 1.242 mm (0.000787 to 0.0489 in.) |
REMOVE REFILL PLUG
Remove the refill plug from the rear transaxle cover sub-assembly.
Remove the gasket from the refill plug.
REMOVE REAR TRANSAXLE COVER PLUG
Remove the 3 rear transaxle cover plugs from the rear transaxle cover sub-assembly.
Using a screwdriver, remove the 3 O-rings from the 3 rear transaxle cover plugs.
REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY
Remove the 14 bolts from the rear transaxle cover sub-assembly.
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.
Using a screwdriver, remove the 3 O-rings from the transaxle case sub-assembly.
| *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.
| *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.
Using a T30 "TORX" socket wrench, remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly.
| *a | Turn |
| *b | Hold |
Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly.
REMOVE REAR MULTIPLE DISC CLUTCH ASSEMBLY
| *1 | Thrust Needle Roller Bearing |
| *2 | Rear Multiple Disc Clutch Assembly |
Remove the rear multiple disc clutch assembly from the transaxle case sub-assembly.
Remove the thrust needle roller bearing from the transaxle case sub-assembly.
| *1 | O-ring |
| *2 | Oil Seal Ring |
Using a screwdriver, remove the O-ring from the rear multiple disc clutch assembly.
Using a screwdriver, remove the oil seal ring from the rear multiple disc clutch assembly.
REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
| *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.
| *1 | Rear Planetary Sun Gear Assembly |
Remove the rear planetary sun gear assembly from the rear multiple disc clutch assembly.
| *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.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear assembly.
| Standard inside diameter |
|---|
| 25.580 to 25.601 mm (1.00708 to 1.00791 in.) |
| Maximum inside diameter |
|---|
| 25.601 mm (1.0079 in.) |
If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.
REMOVE TRANSAXLE HOUSING
Remove the 20 bolts from the transaxle housing.
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.
REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)
Using SST, remove the differential drive pinion tapered roller bearing RH (outer race) and shim from the transaxle housing.
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING (OUTER RACE)
| *a | Turn |
| *b | Hold |
Using SST, remove the front differential case front tapered roller bearing (inner race) from the front differential case.
Using SST, remove the front differential case front tapered roller bearing (outer race) and shim from the transaxle housing.
REMOVE FRONT TRANSAXLE CASE OIL SEAL
Outside:
Using SST and a hammer, remove the front transaxle case oil seal from the transaxle housing.
Inside:
Using SST, remove the front transaxle case oil seal from the front differential case.
REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
Remove the bolt, clamp and differential gear lube apply tube from the transaxle housing.
REMOVE TRANSAXLE HOUSING OIL SEPARATOR
Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.
REMOVE FRONT OIL PUMP ASSEMBLY
| *1 | Gasket |
Remove the gasket from the front oil pump assembly.
Remove the 7 bolts and front oil pump assembly from the transaxle case sub-assembly.
Remove the O-ring from the front oil pump assembly.
| *1 | Thrust Bearing Race |
Remove the thrust bearing race from the underdrive planetary gear assembly.
| *1 | Thrust Needle Roller Bearing |
| *2 | O-ring |
Remove the thrust needle roller bearing from the counter drive gear nut.
Remove the O-ring from the transaxle case sub-assembly.
REMOVE NO. 3 BRAKE DISC
Using a screwdriver, remove the snap ring from the front oil pump assembly.
| *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.
INSPECT NO. 3 BRAKE DISC
Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are worn or burnt.
Note
If the lining of any No. 3 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 3 brake discs.
Before assembling new No. 3 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY
Remove the underdrive planetary gear assembly from the front oil pump assembly.
REMOVE NO. 3 BRAKE HUB
Remove the No. 3 brake hub from the underdrive planetary gear assembly.
| *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.
REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY
| *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.
Remove the snap ring from the underdrive planetary gear assembly.
INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
Using a feeler gauge, measure the clearance between the underdrive planetary gear assembly and the pinion gear at 4 points.
| Standard clearance |
|---|
| 0.18 to 0.54 mm (0.00709 to 0.0213 in.) |
If the clearance is greater than the standard clearance, replace the underdrive planetary gear assembly.
INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear sub-assembly.
| Standard inside diameter |
|---|
| 25.525 to 25.546 mm (1.00492 to 1.00575 in.) |
| Maximum inside diameter |
|---|
| 25.546 mm (1.00575 in.) |
If the inside diameter is greater than the maximum, replace the planetary sun gear sub-assembly.
REMOVE INPUT SHAFT SUB-ASSEMBLY
Remove the input shaft sub-assembly from the front oil pump assembly.
| *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.
Using a screwdriver, remove the 3 oil seal rings from the input shaft sub-assembly.
REMOVE UNDERDRIVE PLANETARY SUN GEAR
| *1 | Underdrive Planetary Sun Gear |
| *2 | Thrust Needle Roller Bearing |
Remove the underdrive planetary sun gear from the front oil pump assembly.
Remove the thrust needle roller bearing from the front oil pump assembly.
REMOVE NO. 1 BRAKE DISC
| *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.
| *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.
INSPECT NO. 1 BRAKE DISC
Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.
Note
If the lining of any No. 1 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 1 brake discs.
Before assembling new No. 1 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Remove the 3 2nd brake piston return spring sub-assemblies from the front oil pump assembly.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the 3 2nd brake piston return spring sub-assemblies including the spring seats.
| Standard free length |
|---|
| 23.26 mm (0.916 in.) |
If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.
REMOVE NO. 1 BRAKE PISTON
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.
Using a screwdriver, remove the 2 O-rings from the No. 1 brake piston.
REMOVE FRONT DIFFERENTIAL CASE
Remove the front differential case from the transaxle case sub-assembly.
REMOVE COUNTER DRIVE GEAR NUT
Using SST and a hammer, unstake the front planetary gear assembly.
Turn the manual valve lever shaft sub-assembly counterclockwise to set it to the P position as shown in the illustration.
Using SST, remove the counter drive gear nut from the front planetary gear assembly.
Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.
REMOVE COUNTER DRIVEN GEAR
Remove the counter driven gear from the transaxle case sub-assembly.
REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)
| *a | Turn |
| *b | Hold |
Using SST, remove the differential drive pinion tapered roller bearing RH (inner race) from the counter driven gear.
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.
REMOVE PAWL SHAFT CLAMP
Remove the bolt and pawl shaft clamp from the transaxle case sub-assembly.
REMOVE NO. 1 TRANSMISSION CASE PLATE
Remove the bolt and No. 1 transmission case plate from the transaxle case sub-assembly.
REMOVE PAWL STOPPER PLATE
Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.
REMOVE PARKING LOCK SLEEVE
Remove the parking lock sleeve from the transaxle case sub-assembly.
REMOVE PARKING LOCK PAWL
| *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.
REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)
Using SST, remove the differential drive pinion tapered roller bearing LH (outer race) from the transaxle case sub-assembly.
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING (OUTER RACE)
| *a | Turn |
| *b | Hold |
Using SST, remove the front differential case rear tapered roller bearing (inner race) from the front differential case.
Using SST, remove the front differential case rear tapered roller bearing (outer race) from the transaxle case sub-assembly.
REMOVE TRANSAXLE CASE OIL SEAL
Using SST and a hammer, remove the transaxle case oil seal from the transaxle case sub-assembly.
REMOVE ONE-WAY CLUTCH ASSEMBLY
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
| *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.
Remove the thrust needle roller bearing from the front planetary gear assembly.
| *1 | One-way Clutch Assembly |
| *2 | Outer Race Retainer |
| *3 | Planetary Ring Gear |
Remove the one-way clutch assembly from the planetary ring gear.
Remove the outer race retainer from the one-way clutch assembly.
INSPECT ONE-WAY CLUTCH ASSEMBLY
| *1 | Planetary Ring Gear |
| *2 | One-way Clutch Assembly |
| *a | Free |
| *b | Lock |
Temporarily install the one-way clutch assembly to the planetary ring gear.
Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
If the one-way clutch assembly does not operate normally, replace it.
REMOVE PLANETARY RING GEAR FLANGE
| *1 | Snap Ring |
| *2 | Planetary Ring Gear Flange |
| *3 | Planetary Ring Gear |
Using a screwdriver, remove the snap ring from the planetary ring gear.
Remove the planetary ring gear flange from the planetary ring gear.
REMOVE NO. 2 BRAKE DISC
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
| *1 | No. 2 Brake Flange |
| *2 | No. 2 Brake Plate |
| *3 | No. 2 Brake Disc |
Remove the No. 2 brake flange, 5 No. 2 brake discs and 5 No. 2 brake plates from the transaxle case sub-assembly.
INSPECT NO. 2 BRAKE DISC
Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are worn or burnt.
Note
If the lining of any No. 2 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 2 brake discs.
Before assembling new No. 2 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
Remove the 1st and reverse brake return spring sub-assembly from the transaxle case sub-assembly.
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly together with the spring seat.
| Standard free length |
|---|
| 15.79 mm (0.621 in.) |
If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.
REMOVE NO. 2 BRAKE PISTON
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.
Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston.
REMOVE FRONT PLANETARY GEAR ASSEMBLY
Using SST and a press, remove the front planetary gear assembly from the transaxle case sub-assembly.
REMOVE COUNTER DRIVE GEAR
Using SST and a press, remove the counter drive gear with bearing inner race (front side) from the transaxle case sub-assembly.
Remove the bearing inner race (rear side).
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).
| *a | Turn |
| *b | Hold |
Using SST, remove the bearing inner race (front side) from the counter drive gear.
REMOVE NO. 3 BRAKE PISTON
Place SST on the brake piston return spring and compress the brake piston return spring with a press.
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
| *1 | No. 3 Brake Piston Return Spring Sub-assembly |
Remove the No. 3 brake piston return spring sub-assembly from the transaxle case sub-assembly.
| *1 | No. 3 Brake Piston |
Remove the No. 3 brake piston from the transaxle case sub-assembly.
Using a screwdriver, remove the 2 O-rings from the No. 3 brake piston.
INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the No. 3 brake piston return spring sub-assembly together with the spring seat.
| Standard free length |
|---|
| 9.15 mm (0.360 in.) |
If the free length is shorter than the standard free length, replace the No. 3 brake piston return spring sub-assembly.
REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY
Remove the bolt, manual detent spring cover and manual detent spring sub-assembly from the transaxle case sub-assembly.
REMOVE PARKING LOCK ROD SUB-ASSEMBLY
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.
REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY
Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the manual valve lever shaft sub-assembly.
Remove the manual valve lever shaft sub-assembly from the transaxle case sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.