AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B003ZO3

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

    2. B003ZS4C01
      *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. B003YZ0

      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. B003Z7L

      Remove the 2 bolts and the 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. B003ZHL

      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. B003ZK7

      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. B003Z9W

      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. B00409U

      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. B00407TC01
      *1 Wooden Block

      Support the automatic transaxle assembly with wooden blocks.

  9. REMOVE OVERFLOW PLUG


    1. B003ZBN

      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. B003ZST

      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. B003ZZV

      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. B003Z3VC03
      *1 Transmission Oil Cleaner Magnet

      Remove the 2 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. B003ZE1

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

    2. B003ZWP

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

  16. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. B00407R

      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 the transaxle case sub-assembly to interfere with each other.

  17. REMOVE NO. 1 GOVERNOR APPLY GASKET


    1. B003ZKL

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

  18. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY

    Click here

  19. REMOVE REFILL PLUG


    1. B003ZPH

      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. B003YWZ

      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. B004030

      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. B003Z8X

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

    4. B003Z1JC01
      *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. B003ZYBC01
      *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. B00400Z

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

    7. B003ZXYC01
      *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. B003ZZ8C01
      *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. B003ZFFC01
      *1 O-ring
      *2 Oil Seal Ring

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

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

  23. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. B004082C01
      *1 Snap Ring

      Using 2 screwdrivers and a hammer, tap out 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. B003ZM3C01
      *1 Rear Planetary Sun Gear Assembly

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

    3. B003ZL9C01
      *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. B003ZAU

      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. B003Z0XE01

      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. B00403Q

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

  28. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. B003ZTA

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

  29. REMOVE FRONT OIL PUMP ASSEMBLY


    1. B003Z4DC01
      *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. B003ZDQ

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

    4. B003ZCAC01
      *1 Thrust Bearing Race

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

    5. B00409PC01
      *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. B004077

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

    2. B003Z7OC01
      *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. B004092

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

  33. REMOVE NO. 3 BRAKE HUB


    1. B003ZOI

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

    2. B003ZKIC01
      *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. B003ZQAC01
      *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. B003ZM4

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

    2. B003ZP2C01
      *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.

  38. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. B003ZKNC01
      *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 BRAKE DISC NO.1


    1. B003ZLKC01
      *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. B003YYIC01
      *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. B003ZFB

      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. B00408S

      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. B003ZX0

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

  44. REMOVE FRONT DIFFERENTIAL CASE


    1. B003ZEK

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

  45. REMOVE COUNTER DRIVE GEAR NUT


    1. B003YYEN01

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

      SST
      09930-00010
    2. B003ZQDN01

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

    3. B003Z3IN01

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

      SST
      09387-00130
    4. B003ZHAN01

      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. B003ZKA

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

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


    1. B003ZCKC01
      *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. B004098

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

  50. REMOVE NO. 1 TRANSMISSION CASE PLATE


    1. B003ZPF

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

  51. REMOVE PAWL STOPPER PLATE


    1. B004058

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

  52. REMOVE PARKING LOCK SLEEVE


    1. B003Z9G

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

  53. REMOVE PARKING LOCK PAWL


    1. B003Z0IC01
      *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. B003ZT1N01

      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. B003Z14

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

    2. B00400LC01
      *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. B003Z4HC01
      *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. B003Z7NC01
      *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. B00407K

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

    2. B003ZICC05
      *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.

  59. INSPECT NO. 2 BRAKE DISC

    Click here

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


    1. B003YZB

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

    2. B00400G

      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. B00405C

      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. B003ZZE

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

  63. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B003ZNON01

      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. B003ZJHN01

      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. B003ZJ9

      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. B003Z87C01
      *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. B003ZVKN01

      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. B00409KC01
      *1 Brake Piston Return Spring

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

    4. B003YXTC01
      *1 No. 3 Brake Piston

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

    5. B003ZPV

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

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

    Click here

  67. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B00402E

      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. B003ZUH

      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. B003Z4G

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

    2. B003YZX

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

  70. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B003Z99

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