AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE BREATHER PLUG HOSE


    1. A002AMW

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

    2. B003ZS4C07
      *1 No. 1 Breather Plug (ATM)
      *2 Breather Plug Hose
      *3 No. 2 Breather Plug (ATM)
      *4 O-ring

      Using a screwdriver, remove the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) from the breather plug hose.

    3. Using a screwdriver, remove the O-ring from the No. 2 breather plug (ATM).

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B003YZ0

      Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.

    2. B003Z7L

      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.

  3. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)


    1. B003ZHL

      Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case sub-assembly.

    2. Remove the O-ring from the oil cooler tube union (outlet oil cooler union).

  4. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION)


    1. B003ZK7

      Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case sub-assembly.

    2. Remove the O-ring from the oil cooler tube union (inlet oil cooler union).

  5. 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.

  6. 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 gasket from each of the 3 No. 2 transaxle case plugs.

  7. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. A0027PN

      Support the automatic transaxle assembly with wooden blocks.

  8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A0028L4

      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. A002BK9

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

    4. A0027R6

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

    5. B003ZLGC07
      *1 Transmission Oil Cleaner Magnet

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

  9. INSPECT TRANSMISSION OIL CLEANER MAGNET

    Click here

  10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A0029T7

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

    2. B003ZLEC05
      *1 O-ring

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

  11. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A002AJX

      Remove the 11 bolts and transmission valve body assembly from 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.

  12. REMOVE TRANSAXLE CASE GASKET


    1. A002AGS

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

  13. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY

    Click here

  14. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. B003ZPH

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

    2. Remove the gasket from the refill plug.

    3. A002B6G

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

    4. Using a screwdriver, remove the 3 O-rings from the 3 No. 1 automatic transaxle case plugs.

    5. A0029PZ

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

    6. 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.

    7. A002ANP

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

      Tech Tips

      Tape the screwdriver tip before use.

    8. B003Z1JC03
      *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.

    9. 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.

    10. A0026VR

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

    11. B003ZXYC07
      *a Turn
      *b Hold

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

      SST
      09319-60020
  15. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B00406KC02
      *1 Direct Multiple Disc Clutch Assembly
      *2 Thrust Needle Roller Bearing

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

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

    3. B003ZIZC01
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

      Using a screwdriver, remove the intermediate shaft oil seal from 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.

      Tech Tips

      Tape the screwdriver tip before use.

  16. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. A01QWJ1

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

    2. A01QVS4

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

  17. REMOVE NO. 2 CLUTCH DISC


    1. B003ZLOC03
      *1 No. 2 Clutch Plate
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Flange

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

  18. INSPECT NO. 2 CLUTCH DISC

    Click here

  19. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01QVS3

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

    2. A01QWDW

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

    3. B003ZD0C03
      *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.

  20. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  21. REMOVE NO. 1 CLUTCH DISC


    1. A01QVWM

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

    2. B003ZB5C03
      *1 No. 1 Clutch Flange
      *2 No. 1 Clutch Plate
      *3 No. 1 Clutch Disc

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

  22. INSPECT NO. 1 CLUTCH DISC

    Click here

  23. REMOVE TRANSAXLE HOUSING


    1. B004061

      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.

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


    1. B003ZBAN02

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

      SST
      09308-00010
  25. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A002B8W

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

  26. REMOVE FRONT OIL PUMP ASSEMBLY


    1. B003ZCNC02
      *1 Gasket

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

    2. Remove the gasket from the front oil pump assembly.

    3. B003ZEXC02
      *1 Thrust Needle Roller Race

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

    4. B003ZE7C01
      *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 sub-assembly.

  27. REMOVE FRONT OIL PUMP BODY O-RING


    1. A002C5Y

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

  28. REMOVE NO. 3 BRAKE DISC


    1. B003ZXSC03
      *1 Snap Ring

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

    2. B003Z2NC08
      *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.

  29. INSPECT NO. 3 BRAKE DISC

    Click here

  30. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A0026WB

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

  31. REMOVE NO. 3 BRAKE HUB


    1. B003ZOI

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

    2. B003ZKIC01
      *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 PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B00408WC01
      *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.

  33. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click here

  34. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  35. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A002CEL

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

    2. B003ZHZC02
      *1 Thrust Needle Roller Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Oil Seal Ring
      *4 Input Shaft Sub-assembly

      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.

      Tech Tips

      Tape the screwdriver tip before use.

  36. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. B003ZR4C02
      *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.

  37. REMOVE NO. 1 BRAKE DISC


    1. B003ZTPC05
      *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. B003ZH3C02
      *1 No. 1 Brake Flange
      *2 No. 1 Brake Plate
      *3 No. 1 Brake Disc

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

  38. INSPECT NO. 1 BRAKE DISC

    Click here

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


    1. A002B30

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

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

    Click here

  41. REMOVE NO. 1 BRAKE PISTON


    1. A0029FW

      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. B004067C03
      *1 O-ring

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

      Tech Tips

      Tape the screwdriver tip before use.

  42. REMOVE FRONT DIFFERENTIAL CASE


    1. A002C9X

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

  43. REMOVE COUNTER DRIVE GEAR NUT


    1. B003ZZBN03

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

      SST
      09930-00010
    2. B003ZD3N01

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

    3. B003ZTWN03

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

      SST
      09387-00130
  44. REMOVE COUNTER DRIVEN GEAR


    1. B003ZFYN01

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

    2. A002CM8

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

  45. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. B003ZOSC02
      *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 )
  46. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. B003ZFWC02
      *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 )
  47. REMOVE PAWL SHAFT CLAMP


    1. A00288J

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

  48. REMOVE PAWL STOPPER PLATE


    1. A0027N6

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

  49. REMOVE PARKING LOCK SLEEVE


    1. A00286K

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

  50. REMOVE PARKING LOCK PAWL


    1. B00400EC04
      *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 sub-assembly.

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


    1. B003ZI3N02

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

      SST
      09308-00010
  52. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. B003Z14

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

    2. B00400LC06
      *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.

  53. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  54. REMOVE PLANETARY RING GEAR


    1. B003Z4HC07
      *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.

  55. REMOVE PLANETARY RING GEAR FLANGE


    1. B003Z7NC08
      *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.

  56. REMOVE NO. 2 BRAKE DISC


    1. B00407K

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

    2. B003ZICC03
      *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.

  57. INSPECT NO. 2 BRAKE DISC

    Click here

  58. 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.

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

    Click here

  60. 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. B00401LC03
      *1 O-ring

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

      Tech Tips

      Tape the screwdriver tip before use.

  61. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B003ZNON08

      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 )
  62. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    Click here

  63. REMOVE COUNTER DRIVE GEAR

    Note

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


    1. B004075N01

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

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )
    2. A0027OU

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

    3. B003ZWKC03
      *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 )
  64. REMOVE NO. 3 BRAKE PISTON


    1. A002CJQ

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

    2. B003ZGYC02
      *1 Brake Piston Return Spring
      *2 No. 3 Brake Piston

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

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

  65. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B00402E

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

  66. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A0027VO

      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.

  67. 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. A002940

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

  68. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A002951

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

      Tech Tips

      Tape the screwdriver tip before use.