AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

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

Using a screwdriver, remove the No. 1 breather plug from the breather plug hose.

Text in Illustration
*1	No. 1 Breather Plug
*2	Breather Plug Hose
*3	No. 2 Breather Plug
*4	O-ring

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
1. Remove the nut, washer, and transmission control shaft lever from the manual valve lever shaft sub-assembly.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. 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 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.
REMOVE OIL COOLER TUBE UNION (OUTLET)
1. 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).
REMOVE OIL COOLER TUBE UNION (INLET)
1. 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).
REMOVE NO. 1 TRANSAXLE CASE PLUG
1. 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.
REMOVE NO. 2 TRANSAXLE CASE PLUG
1. 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.
SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY
1. Support the automatic transaxle assembly on wooden blocks.
  
  Text in Illustration
  
  *1 Wooden Block
REMOVE OVERFLOW PLUG
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.
REMOVE NO. 1 TRANSMISSION OIL FILLER TUBE
1. 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
1. 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
1. Remove the automatic transaxle oil pan gasket.
REMOVE TRANSMISSION OIL CLEANER MAGNET
1. Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.
  
  Text in Illustration
  
  *1 Transmission Oil Cleaner Magnet

Text in Illustration
*1	Wooden Block

Text in Illustration
*1	Transmission Oil Cleaner Magnet

INSPECT TRANSMISSION OIL CLEANER MAGNET

Examine particles in the automatic transaxle oil pan sub-assembly.

Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to see the type of wear which might be found in the automatic transaxle assembly.

Result

Steel (magnetic)	Brass (non-magnetic)
Bearing, gear and plate wear	Bushing wear

REMOVE VALVE BODY OIL STRAINER ASSEMBLY
1. Remove the 2 bolts and valve body oil strainer assembly from the transmission valve body assembly.
2. Remove the O-ring from the valve body oil strainer assembly.
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
1. 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.
REMOVE NO. 1 GOVERNOR APPLY GASKET
1. Remove the 2 No. 1 governor apply gaskets from the transaxle case sub-assembly.
INSPECT INPUT SHAFT END PLAY
1. Using a dial indicator, measure the input shaft end play.
  
  Standard end play
  
  0.020 to 1.242 mm (0.000788 to 0.0488 in.)
REMOVE REFILL PLUG
1. Remove the refill plug from the rear transaxle cover sub-assembly.
2. Remove the gasket from the refill plug.
REMOVE REAR TRANSAXLE COVER PLUG
1. 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.

Standard end play
0.020 to 1.242 mm (0.000788 to 0.0488 in.)

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.

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

Text in Illustration
*1	Oil Seal Ring
*2	Thrust Needle Roller Bearing
*3	No. 4 Thrust Needle Roller Race

Remove the thrust needle roller bearing and No. 4 thrust needle roller race from the rear transaxle cover sub-assembly.
Using a T30 "TORX" socket wrench, remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly.
Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly.

Text in Illustration

*a Turn

*b Hold

SST

09319-60020

Text in Illustration
*a	Turn
*b	Hold

REMOVE REAR MULTIPLE DISC CLUTCH ASSEMBLY

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

Text in Illustration
*1	Thrust Needle Roller Bearing
*2	Rear Multiple Disc Clutch Assembly

Remove the thrust needle roller bearing from the transaxle case sub-assembly.
Using a screwdriver, remove the O-ring from the rear multiple disc clutch assembly.

Text in Illustration

*1 O-ring

*2 Oil Seal Ring
Using a screwdriver, remove the oil seal ring from the rear multiple disc clutch assembly.

Text in Illustration
*1	O-ring
*2	Oil Seal Ring

REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

Using 2 screwdrivers and a hammer, tap out the snap ring from the rear multiple disc clutch assembly.

Text in Illustration

*1 Snap Ring

Tech Tips

Use a piece of cloth to keep the snap ring from flying off.
Remove the rear planetary sun gear assembly from the rear multiple disc clutch assembly.

Text in Illustration

*1 Rear Planetary Sun Gear

Text in Illustration
*1	Rear Planetary Sun Gear

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

Text in Illustration
*1	Thrust Needle Roller Bearing
*2	Thrust Bearing Race

INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.
  
  Standard inside diameter
  
  25.580 to 25.601 mm (1.00708 to 1.00791 in.)
  
  Maximum inside diameter
  
  25.601 mm (1.00791 in.)
  
  If the inside diameter is greater than the maximum, replace the automatic transaxle assembly.
REMOVE TRANSAXLE HOUSING
1. 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.
REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)
1. Using SST, remove the differential drive pinion tapered roller bearing RH (outer race) and shim from the transaxle housing.
  
  SST
  
  09308-00010
REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
1. Remove the bolt, clamp, and differential gear lube apply tube from the transaxle housing.
REMOVE TRANSAXLE HOUSING OIL SEPARATOR
1. Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.

Standard inside diameter
25.580 to 25.601 mm (1.00708 to 1.00791 in.)

Maximum inside diameter
25.601 mm (1.00791 in.)

REMOVE FRONT OIL PUMP ASSEMBLY

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

Text in Illustration

*1 O-ring
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.

Text in Illustration
*1	O-ring

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

Text in Illustration
*1	Thrust Bearing Race
*2	Thrust Needle Roller Bearing
*3	O-ring

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.

Remove the 2 brake flanges, 3 brake discs, and 2 brake plates from the front oil pump assembly.

Text in Illustration
*1	Brake Flange
*2	Brake Plate
*3	Brake Disc

INSPECT NO. 3 BRAKE DISC
1. Check if the contact surfaces of the discs, plates and flanges are worn or burnt.
  Note
  - If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
  If necessary, replace them.
REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY
1. 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.

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

Text in Illustration
*1	Thrust Bearing Race
*2	Thrust Needle Roller Bearing

REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY

While expanding the snap ring with snap ring pliers, remove the planetary sun gear from the underdrive planetary gear assembly.

Text in Illustration
*1	Planetary Sun Gear Sub-assembly
*2	Underdrive Planetary Gear Assembly
*3	Snap Ring

Remove the snap ring from the underdrive planetary gear assembly.

INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the clearance between the underdrive planetary gear 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 automatic transaxle assembly.
INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the bushings of the planetary sun gear.
  
  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.

Standard clearance
0.18 to 0.54 mm (0.00709 to 0.0213 in.)

Standard inside diameter
25.525 to 25.546 mm (1.00492 to 1.00575 in.)

Maximum inside diameter
25.546 mm (1.00575 in.)

REMOVE INPUT SHAFT SUB-ASSEMBLY

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

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

Text in Illustration
*1	Thrust Bearing Race
*2	Thrust Needle Roller Bearing
*3	Input Shaft sub-assembly
*4	Oil Seal Ring

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

REMOVE UNDERDRIVE PLANETARY SUN GEAR

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

Text in Illustration
*1	Underdrive Planetary Sun Gear
*2	Thrust Needle Roller Bearing

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

REMOVE NO. 1 BRAKE DISC

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

Text in Illustration
*1	Snap Ring
*2	Brake Snap Ring Stopper

Remove the No. 1 brake flange, 3 No. 1 brake discs, and 3 No. 1 brake plates from the front oil pump assembly.

Text in Illustration
*1	No. 1 Brake Flange
*2	No. 1 Brake Plate
*3	No. 1 Brake Disc

INSPECT NO. 1 BRAKE DISC
1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.
  Note
  - If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
  If necessary, replace them.
REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Remove the 3 2nd brake piston return springs from the front oil pump assembly.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs 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.
REMOVE NO. 1 BRAKE PISTON
1. 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. Using a screwdriver, remove the 2 O-rings from the No. 1 brake piston.
REMOVE FRONT DIFFERENTIAL CASE
1. Remove the front differential case from the transaxle case sub-assembly.
REMOVE COUNTER DRIVE GEAR NUT
1. Using SST and a hammer, unstake the counter drive gear nut.
  
  SST
  
  09930-00010
2. Turn the manual valve lever shaft counterclockwise to set it to the P position as shown in the illustration.
3. Using SST, remove the counter drive gear nut from the front planetary gear assembly.
  
  SST
  
  09387-00130
4. Turn the manual valve lever shaft 2 notches clockwise to set it to the N position as shown in the illustration.
REMOVE COUNTER DRIVEN GEAR
1. Remove the counter driven gear from the transaxle case sub-assembly.
REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)
1. Using SST, remove the differential drive pinion tapered roller bearing RH (inner race) from the counter driven gear.
  
  Text in Illustration
  
  *a Turn
  
  *b Hold
  
  SST
  
  09950-00020
  
  09950-00030
  
  09950-40011 ( 09957-04010 )
  
  09950-60010 ( 09951-00320 )
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
1. Remove the bolt and pawl shaft clamp from the transaxle case sub-assembly.
REMOVE NO. 1 TRANSMISSION CASE PLATE
1. Remove the bolt and No. 1 transmission case plate from the transaxle case sub-assembly.
REMOVE PAWL STOPPER PLATE
1. Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.
REMOVE PARKING LOCK SLEEVE
1. Remove the parking lock sleeve from the transaxle case sub-assembly.

Standard free length
23.26 mm (0.916 in.)

Text in Illustration
*a	Turn
*b	Hold

REMOVE PARKING LOCK PAWL

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

Text in Illustration
*1	Parking Lock Pawl Pin
*2	Parking Lock Pawl Shaft
*3	Spring
*4	Parking Lock Pawl

REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)
1. Using SST, remove the differential drive pinion tapered roller bearing LH (outer race) from the transaxle case sub-assembly.
  
  SST
  
  09308-00010

REMOVE ONE-WAY CLUTCH ASSEMBLY

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

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

Text in Illustration
*1	One-way Clutch Assembly
*2	Thrust Needle Roller Bearing

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

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

Text in Illustration
*1	One-way Clutch Assembly
*2	Outer Race Retainer
*3	Planetary Ring Gear

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

INSPECT ONE-WAY CLUTCH ASSEMBLY

Temporarily install the one-way clutch assembly to the planetary ring gear.

Text in Illustration
*1	Planetary Ring Gear
*2	One-way Clutch Assembly
*a	Free
*b	Lock

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

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

Text in Illustration
*1	Snap Ring
*2	Planetary Ring Gear Flange
*3	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.

Remove the No. 2 brake flange, 4 No. 2 brake discs, and 4 No. 2 brake plates from the transaxle case sub-assembly.

Text in Illustration
*1	No. 2 Brake Flange
*2	No. 2 Brake Plate
*3	No. 2 Brake Disc

INSPECT NO. 2 BRAKE DISC
1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.
  Note
  - If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
  If necessary, replace them.
REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
2. 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
1. Using a vernier caliper, measure the free length of the 1st and reverse brake return spring together with the spring seat.
  
  Standard free length
  
  15.79 mm (0.622 in.)
  
  If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring.
REMOVE NO. 2 BRAKE PISTON
1. Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the ATF hole to remove the No. 2 brake piston assembly from the transaxle case sub-assembly.
2. Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston.
REMOVE FRONT PLANETARY GEAR ASSEMBLY
1. Using SST and a press, remove the planetary gear assembly from the transaxle case sub-assembly.
  
  SST
  
  09950-60010 ( 09951-00580 )
  
  09950-70010 ( 09951-07100 )
REMOVE COUNTER DRIVE GEAR
1. 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. 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 inner race.
3. Using SST, remove the bearing inner race (front side) from the counter drive gear.
  
  Text in Illustration
  
  *a Turn
  
  *b Hold
  
  SST
  
  09950-00020
  
  09950-00030
  
  09950-40011 ( 09957-04010 )
  
  09950-60020 ( 09951-00710 )
REMOVE NO. 3 BRAKE PISTON
1. 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. Remove the brake piston return spring from the transaxle case sub-assembly.
  
  Text in Illustration
  
  *1 Brake Piston Return Spring
4. Remove the No. 3 brake piston from the transaxle case sub-assembly.
  
  Text in Illustration
  
  *1 No. 3 Brake Piston
5. Using a screwdriver, remove the 2 O-rings from the No. 3 brake piston.
INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the No. 3 brake piston return spring 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.
REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY
1. 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
1. Remove the parking lock rod sub-assembly from the manual valve lever shaft.
  
  Tech Tips
  
  Align the slot with the notches on the manual valve lever shaft to remove the parking lock rod sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY
1. Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the transaxle case sub-assembly.
2. Remove the manual valve lever shaft sub-assembly from the transaxle case sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
1. Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.