AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B0029GA

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B0029PTC01
      *1 Breather Plug Hose
      *2 Breather Plug
      *3 O-ring

      Remove the breather plug from the breather plug hose.

    3. Remove the O-ring from the breather plug.

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B002ACT

      Remove the nut, washer and control shaft lever from the control shaft.

    2. B002A25

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

      Note

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

  3. REMOVE OIL COOLER TUBE UNION


    1. B002ALS

      Using 19 mm union nut wrench, remove the 2 oil cooler tube unions from the transaxle case.

    2. Remove the 2 O-rings from the 2 oil cooler tube unions.

  4. REMOVE TRANSAXLE CASE PLUG


    1. B002AH9

      Using a 6 mm hexagon socket wrench, remove the 3 transaxle case plugs from the transaxle housing.

    2. Remove the 3 gaskets from the 3 transaxle case plugs.

    3. B002AKP

      Remove the 6 transaxle case plugs from the transaxle case and rear transaxle cover sub-assembly.

    4. Using a screwdriver, remove the 6 O-rings from the 6 transaxle case plugs.

      Note

      Be careful not to damage the transaxle case plugs.

      Tech Tips

      Tape the screwdriver tip before use.

  5. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. B00299H

      Support the automatic transaxle assembly on wooden blocks.

  6. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. 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.

    3. B0029NH

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

    4. B002AF6

      Remove the 18 bolts, automatic transaxle oil pan sub-assembly and automatic transaxle oil pan gasket from the automatic transaxle assembly.

    5. Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.

  7. INSPECT TRANSMISSION OIL CLEANER MAGNET

    Click here

  8. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. B002AAJ

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

    2. B0029SUC02
      *1 O-ring

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

  9. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. B002AG8

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

      Note

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

  10. REMOVE TRANSAXLE CASE GASKET


    1. B002AM6

      Remove the 2 transaxle case gaskets from the transaxle case.

  11. INSPECT INPUT SHAFT SUB-ASSEMBLY

    Click here

  12. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B0029VB

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

    2. Remove the gasket from the refill plug.

    3. B002A5M

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

    4. 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.

    5. B002A6T

      Remove the 3 O-rings from the transaxle case.

    6. B002AB7C09
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

    7. B002AGXC01
      *1 Oil Seal Ring

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

      Note

      Be careful not to damage the rear transaxle cover sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    8. B002AOQ

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

    9. B0029HWC01
      *a Turn
      *b Hold

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

      SST
      09319-60020

  13. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B0029G9C01
      *1 Direct Multiple Disc Clutch Assembly
      *2 Thrust Needle Roller Bearing

      Remove the direct multiple disc clutch assembly from the transaxle case.

    2. Remove the thrust needle roller bearing from the direct multiple disc clutch assembly.

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. B0029HXC01
      *a Protective Tape

      Using a screwdriver, remove the direct multiple disc clutch snap ring from the direct multiple disc clutch assembly.

      Note

      Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B0029D2

      Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly.

    3. B00299FC01
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

      Using a screwdriver, remove the intermediate shaft oil seal from the direct multiple disc clutch assembly.

      Note

      Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

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

      Note

      Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  15. REMOVE NO. 2 CLUTCH DISC


    1. Remove the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates from the direct multiple disc clutch assembly.

  16. INSPECT NO. 2 CLUTCH DISC

    Click here

  17. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. B0029Q0

      Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly.

    2. B002A6X

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

    3. B0029C4C01
      *1 Thrust Needle Roller Bearing
      *2 Thrust Needle Roller Race

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

  18. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  19. REMOVE NO. 1 CLUTCH DISC


    1. B0029H7

      Using 2 screwdrivers, remove the 2 snap rings from the direct multiple disc clutch assembly.

      Note

      Be careful not to damage the direct multiple disc clutch assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates from the direct multiple disc clutch assembly.

  20. INSPECT NO. 1 CLUTCH DISC

    Click here

  21. REMOVE TRANSAXLE HOUSING


    1. B002AFW

      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.

  22. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE


    1. B0029F2N01

      Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing.

      SST
      09308-00010

  23. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE


    1. B00297JN01

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

      SST
      09308-00010

  24. REMOVE TRANSAXLE CASE OIL SEAL RH (OUTER)


    1. B0029CBN03

      Using SST, remove the transaxle case oil seal RH from the transaxle housing.

      SST
      09308-00010

  25. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. B002A40

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

  26. REMOVE OIL PUMP ASSEMBLY


    1. B002A48C01
      *1 Gasket

      Remove the 7 bolts and oil pump assembly from the transaxle case.

    2. Remove the gasket from the oil pump assembly.

    3. B0029KAC05
      *1 Thrust Needle Roller Race

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

    4. B0029M4C04
      *1 Thrust Needle Roller Bearing
      *2 O-ring

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

    5. Remove the O-ring from the transaxle case.

  27. REMOVE FRONT OIL PUMP BODY O-RING


    1. B0029LL

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

  28. REMOVE NO. 3 BRAKE DISC


    1. B002AO0C02
      *1 Snap Ring

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

      Note

      Be careful not to damage the oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

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

  29. INSPECT NO. 3 BRAKE DISC

    Click here

  30. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B002AC3

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

  31. REMOVE NO. 3 BRAKE HUB


    1. B002AK2

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

    2. B0029WRC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing

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

  32. REMOVE UNDERDRIVE PLANETARY RING GEAR


    1. B0029SSC01
      *1 Snap Ring
      *2 Underdrive Planetary Ring Gear

      Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear.

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

  33. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B002AJEC01
      *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.

  34. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click here

  35. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  36. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. B002A71

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

    2. B002A7OC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft

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

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

      Note

      Be careful not to damage the input shaft.

      Tech Tips

      Tape the screwdriver tip before use.

  37. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. B002A7YC01
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

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

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

  38. REMOVE NO. 1 BRAKE DISC


    1. B0029ITC02
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

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

      Note

      Be careful not to damage the oil pump assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates from the oil pump assembly.

  39. INSPECT NO. 1 BRAKE DISC

    Click here

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


    1. B002AGC

      Remove the 3 2nd brake piston return springs from the oil pump assembly.

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

    Click here

  42. REMOVE NO. 1 BRAKE PISTON


    1. B0029HQ

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

    2. B0029ZYC01
      *1 O-ring

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

      Note

      Be careful not to damage the No. 1 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

  43. REMOVE FRONT DIFFERENTIAL CASE


    1. B002AJK

      Remove the front differential case from the transaxle case.

  44. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING INNER RACE


    1. B002A8AC05
      *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
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00480 )

  45. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING INNER RACE


    1. B002A2OC03
      *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 )

  46. REMOVE COUNTER DRIVE GEAR NUT


    1. B0029D3N01

      Using SST and a hammer, unstake the counter drive gear nut.

      SST
      09930-00010
    2. B0029QNN01

      Turn the manual valve lever 2 notches counterclockwise to set it to P as shown in the illustration.

    3. B002A1ON01

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

      SST
      09387-00130

  47. REMOVE COUNTER DRIVEN GEAR


    1. B002AK9N01

      Turn the manual valve lever 2 notches clockwise to set it to N as shown in the illustration.

    2. B0029LW

      Remove the counter driven gear from the transaxle case.

  48. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. B002998C01
      *a Turn
      *b Hold

      Using SST, remove the counter driven gear front tapered roller bearing from the counter driven gear.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00400 )

  49. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. B0029ZFC01
      *a Turn
      *b Hold

      Using SST, remove the counter driven gear rear tapered roller bearing from the counter driven gear.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00320 )

  50. REMOVE PAWL SHAFT CLAMP


    1. B0029OQ

      Remove the bolt and pawl shaft clamp from the transaxle case.

  51. REMOVE PAWL STOPPER PLATE


    1. B0029AW

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

  52. REMOVE PARKING LOCK SLEEVE


    1. B002AL3

      Remove the parking lock sleeve from the transaxle case.

  53. REMOVE PARKING LOCK PAWL


    1. B0029SNC01
      *1 Parking Lock Pawl Shaft
      *2 Parking Lock Pawl
      *3 Spring
      *4 Parking Lock Pawl Pin

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

  54. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE


    1. B002ADHN05

      Using SST, remove the counter driven gear rear tapered roller bearing outer race from the transaxle case.

      SST
      09308-00010

  55. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE


    1. B0029MVN07

      Using SST, remove the front differential case rear tapered roller bearing outer race from the transaxle case.

      SST
      09308-00010

  56. REMOVE TRANSAXLE CASE OIL SEAL LH


    1. B0029QDN07

      Using SST, and a hammer, tap out the transaxle case oil seal LH from the transaxle case.

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

  57. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. B0029NBC01
      *a Protective Tape

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B002A5UC02
      *1 One-way Clutch Assembly
      *2 Thrust Needle Roller Bearing

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

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

  58. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  59. REMOVE PLANETARY RING GEAR


    1. B0029XFC07
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

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

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

  60. REMOVE PLANETARY RING GEAR FLANGE


    1. B002A5SC02
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

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

      Note

      Be careful not to damage the planetary ring gear.

      Tech Tips

      Tape the screwdriver tip before use.

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

  61. REMOVE NO. 2 BRAKE DISC


    1. B002AP8C01
      *a Protective Tape

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the No. 2 brake flange, 5 No. 2 brake discs and 5 No. 2 brake plates from the transaxle case.

  62. INSPECT NO. 2 BRAKE DISC

    Click here

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


    1. B0029ALC01
      *a Protective Tape

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B002A3Q

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

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

    Click here

  65. REMOVE NO. 2 BRAKE PISTON


    1. B0029IL

      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.

    2. B0029VJC01
      *1 O-ring

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

      Note

      Be careful not to damage the No. 2 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

  66. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B0029RPN06

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

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

  67. REMOVE COUNTER DRIVE GEAR

    Note

    Perform this procedure only when the counter drive gear bearing or transaxle case is replaced.


    1. B002A2SN02

      Using SST and a press, remove the counter drive gear and bearing inner race (rear side) from the transaxle case.

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )
    2. B002AIV

      As shown in the illustration, tighten the 3 bolts evenly and leave a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and bearing inner race (front side).

    3. B0029E5C02
      *a Turn
      *b Hold

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

      SST
      09950-00020
      09950-00030
      09950-60020   ( 09951-00710 )

  68. REMOVE NO. 3 BRAKE PISTON


    1. B002AIO

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B0029IVC01
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

      Remove the brake piston return spring from the transaxle case.

    3. Remove the No. 3 brake piston from the transaxle case.

  69. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B002A7W

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

  70. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B0029DXC01
      *1 Parking Lock Rod Sub-assembly
      *2 Manual Valve Lever Sub-assembly

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

      Tech Tips

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

  71. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. B002AA1

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

    2. B0029SX

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

  72. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B00298CC01
      *a Protective Tape

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.