AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A01V7O0

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

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A01V7C5C01
      *1 No. 1 Breather Plug
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug
      *4 O-Ring

      Remove the No. 1 breather plug from the breather plug hose.

    3. Remove the No. 2 breather plug from the breather plug hose.

    4. Remove the O-ring from the No. 2 breather plug.

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01VAHA

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

    2. A01V7Q6

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

      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 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. A01V7OZ

      Using a 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. A01V8M6

      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. A01V9MY

      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. A01V6W8

      Support the automatic transaxle assembly on wooden blocks.

  6. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01VAHV

      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. A01VAVU

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

    4. A01VB17

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

    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. A01VAU4

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

    2. A01VAPUC01
      *1 O-ring

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

  9. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01V95T

      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. A01V7C8

      Remove the 2 transaxle case gaskets from the transaxle case.

  11. INSPECT INPUT SHAFT END PLAY

    Click here

  12. REMOVE REFILL PLUG


    1. A01V6TZ

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

    2. Remove the gasket from the refill plug.

  13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01VAYO

      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.

    3. A01V9A7

      Remove the 3 O-rings from the transaxle case.

    4. A01V9Y5C01
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Needle Roller Bearing Race

      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.

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

    6. A01V8GU

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

    7. A01VASQC01
      *a Turn
      *b Hold

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

      SST
      09319-60020

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01V94MC01
      *1 Thrust Needle Roller Bearing
      *2 Direct Multiple Disc Clutch Assembly

      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.

    3. A01V9XNC01
      *1 O-ring
      *2 Oil Seal Ring

      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.

    4. Using a screwdriver, remove the oil seal 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 REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01V7K1

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

    2. A01V8X9C01
      *1 Rear Planetary Sun Gear Assembly

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

    3. A01V8H7C01
      *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.

  16. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  17. REMOVE TRANSAXLE HOUSING


    1. A01V9FG

      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.

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


    1. A01VA79N01

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

      SST
      09308-00010

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


    1. A01V7SMN06

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

      SST
      09308-00010

  20. REMOVE TRANSAXLE CASE OIL SEAL RH


    1. A01VAI7N05

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

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

  21. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01V7ED

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

  22. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. A01V9U6

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

  23. REMOVE OIL PUMP ASSEMBLY


    1. A01V7HAC01
      *1 O-ring

      Remove the O-ring from the oil pump assembly.

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

    3. A01V7YI

      Remove the O-ring from the oil pump assembly.

    4. A01VB44C01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

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

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

  24. REMOVE NO. 3 BRAKE DISC


    1. A01V6YHC01
      *a Protective Tape

      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.

  25. INSPECT NO. 3 BRAKE DISC

    Click here

  26. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01V6WA

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

  27. REMOVE NO. 3 BRAKE HUB


    1. A01V87J

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

    2. A01V7FYC01
      *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.

  28. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01V8IFC01
      *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.

  29. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click here

  30. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  31. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A01V9O2

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

    2. A01V8CXC01
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

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

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

      Note

      Be careful not to damage the input shaft sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  32. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. A01V7AKC01
      *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.

  33. REMOVE NO. 1 BRAKE DISC


    1. A01VB20C01
      *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, 3 No. 1 brake discs, and 3 No. 1 brake plates from the oil pump assembly.

  34. INSPECT NO. 1 BRAKE DISC

    Click here

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


    1. A01V97F

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

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

    Click here

  37. REMOVE NO. 1 BRAKE PISTON


    1. A01V7VP

      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. A01V9T9

      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.

  38. REMOVE FRONT DIFFERENTIAL CASE


    1. A01V9KZ

      Remove the front differential case from the transaxle case.

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


    1. A01V9F7C04
      *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 )

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


    1. A01V7BSC04
      *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 )

  41. REMOVE COUNTER DRIVE GEAR NUT


    1. A01V764N01

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

      SST
      09930-00010
    2. A01V7VXE01

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

    3. A01V8VQN01

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

      SST
      09387-00130
    4. A01V7F6E01

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

  42. REMOVE COUNTER DRIVEN GEAR


    1. A01V80K

      Remove the counter driven gear from the transaxle case.

  43. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01V84JC01
      *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
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00320 )

  44. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

    Tech Tips

    If removing the counter driven gear rear tapered roller bearing, replace the counter driven gear with a new one.

  45. REMOVE PAWL SHAFT CLAMP


    1. A01V7IF

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

  46. REMOVE NO. 1 TRANSMISSION CASE PLATE


    1. A01V8EL

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

  47. REMOVE PAWL STOPPER PLATE


    1. A01V6XR

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

  48. REMOVE PARKING LOCK SLEEVE


    1. A01V7MD

      Remove the parking lock sleeve from the transaxle case.

  49. REMOVE PARKING LOCK PAWL


    1. A01VAP5C01
      *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.

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


    1. A01V9JHN01

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

      SST
      09308-00010

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


    1. A01V6WCN02

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

      SST
      09308-00010

  52. REMOVE TRANSAXLE CASE OIL SEAL LH


    1. A01V6ZNN04

      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 )

  53. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. A01V8QHC01
      *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. A01V8Y1C01
      *1 One-way Clutch Assembly with Planetary Ring Gear
      *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 front planetary gear assembly.

    4. A01V8QTC01
      *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.

  54. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  55. REMOVE PLANETARY RING GEAR FLANGE


    1. A01VAPCC01
      *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.

  56. REMOVE NO. 2 BRAKE DISC


    1. A01V8RJC01
      *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, 4 No. 2 brake discs, and 4 No. 2 brake plates from the transaxle case.

  57. INSPECT NO. 2 BRAKE DISC

    Click here

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


    1. A01V8H3C01
      *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. A01V925

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

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

    Click here

  60. REMOVE NO. 2 BRAKE PISTON


    1. A01V95P

      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. A01V7RI

      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.

  61. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A01V9MQN01

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

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

  62. REMOVE COUNTER DRIVE GEAR

    Note

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


    1. A01V6V6N01

      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. A01VACX

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

    3. A01V6YPC01
      *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 )

  63. REMOVE NO. 3 BRAKE PISTON


    1. A01VAGQN01

      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.

      Note

      Be careful not to damage the transaxle case.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A01V9ULC01
      *1 Brake Piston Return Spring

      Remove the brake piston return spring from the transaxle case.

    4. A01V9JQC01
      *1 No. 3 Brake Piston

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

    5. A01VAK0

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

      Note

      Be careful not to damage the No. 3 brake piston.

      Tech Tips

      Tape the screwdriver tip before use.

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

    Click here

  65. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01V8X5

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

  66. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01V8DU

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

      Tech Tips

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

  67. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A01VAL7

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

    2. A01V8WS

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

  68. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01VAPIC01
      *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.