AUTOMATIC TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY


    1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle.

    2. Remove the O-ring from the speedometer driven hole cover sub-assembly.

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01CG8C

      Remove the nut, washer and control shaft lever.

    2. A01CEW8

      Using a screwdriver, unstake the lock plate and remove the nut and lock plate.

    3. A01CC78

      Remove the 2 bolts and pull out the park/neutral position switch assembly.

  3. REMOVE BREATHER PLUG SUB-ASSEMBLY


    1. Remove the breather plug sub-assembly from the breather plug hose.

  4. REMOVE BREATHER PLUG HOSE


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

  5. REMOVE NO. 2 BREATHER PLUG


    1. Remove the No. 2 breather plug from the transaxle.

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

  6. REMOVE OIL COOLER OUTLET TUBE UNION

    A01CG7B

    1. Remove the oil cooler outlet tube union.

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

  7. REMOVE OIL COOLER INLET TUBE UNION

    A01CBFE

    1. Remove the oil cooler inlet tube union.

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

  8. REMOVE SPEED SENSOR


    1. A01CB1LE04
      Text in Illustration
      *1 Speed Sensor NT
      *2 Speed Sensor NC

      Remove the speed sensor NT.


      1. Remove the bolt and speed sensor.

      2. Remove the O-ring from the speed sensor.

    2. Remove the speed sensor NC.


      1. Remove the bolt and speed sensor.

      2. Remove the O-ring from the speed sensor.

  9. REMOVE NO. 1 TRANSAXLE CASE PLUG


    1. A01CG9W

      Remove the 4 No. 1 transaxle case plugs from the transaxle.

    2. Remove the 4 O-rings from the 4 No. 1 transaxle case plugs.

    3. A01CD5W

      Remove the 2 No. 1 transaxle case plugs.

    4. Remove the 2 O-rings from the 2 No. 1 transaxle case plugs.

  10. SECURE AUTOMATIC TRANSAXLE ASSEMBLY


    1. A01CC6PE01

      Place the transaxle assembly on wooden blocks.

  11. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01CFNLE01

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

    2. A01CCWIE01
      Text in Illustration
      *1 Magnet

      Remove the automatic transaxle oil pan sub-assembly and 3 magnets.

    3. Remove the gasket from the automatic transaxle oil pan sub-assembly.

  12. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01CGG0E01

      Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnets to anticipate what type of wear has occurred in the transaxle.

      Steel (magnetic): bearing, gear and plate wear

      Brass (non-magnetic): bush wear

  13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A01CEP3E01

      Remove the 3 bolts and valve body oil strainer assembly.

    2. A01CD5XE01

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

  14. REMOVE TRANSMISSION WIRE


    1. A01CFACE06
      Text in Illustration
      *1 Lock Plate

      Disconnect the 5 connectors from the shift solenoid valves.

    2. Remove the bolt, lock plate and ATF temperature sensor.

    3. A01CBTGE08

      Remove the bolt and transmission wire from the transaxle.

    4. A01CFUHE03

      Remove the O-ring from the transmission wire.

  15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01CDO9E05

      Support the transmission valve body assembly and remove the 17 bolts and the transmission valve body assembly.

      Note

      Be careful not to drop the check valve body, spring and accumulator piston.

  16. REMOVE NO. 1 GOVERNOR APPLY GASKET


    1. A01CDPEE01

      Remove the No. 1 governor apply gasket from the transaxle.

  17. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET


    1. A01CDHIE01

      Remove the transaxle case 2nd brake gasket from the transaxle.

  18. REMOVE BRAKE DRUM GASKET


    1. A01CFS1E01

      Remove the brake drum gasket from the transaxle.

  19. REMOVE CHECK BALL BODY


    1. A01CD7HE02

      Remove the check ball body and spring from the transaxle.

  20. REMOVE C-3 ACCUMULATOR PISTON


    1. A01CCJAE01

      Remove the spring from the C-3 accumulator piston.

    2. A01CFWME02

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-3 accumulator piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

    3. A01CG9NE02

      Remove the O-ring from the C-3 accumulator piston.

  21. REMOVE C-1 ACCUMULATOR PISTON


    1. A01CGG9E02

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-1 accumulator piston and spring.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

    2. A01CCEME01

      Remove the 2 O-rings from the C-1 accumulator piston.

  22. REMOVE B-3 ACCUMULATOR PISTON


    1. A01CD2AE02

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

    2. A01CC29E05

      Remove the O-ring from the B-3 accumulator piston.

  23. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01CED6E03

      Remove the 2 bolts, manual detent spring sub-assembly and spring cover.

  24. REMOVE PARKING LOCK PAWL BRACKET


    1. A01CDR2E01

      Remove the 2 bolts and parking lock pawl bracket.

  25. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING


    1. A01CF3AE01

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

  26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A01CCC3E01

      Using a chisel and hammer, unstake and remove the spacer.

    2. A01CFJOE01

      Using a pin punch (3 mm) and hammer, tap out the manual valve lever shaft spring pin.

      Tech Tips

      Slowly drive out the pin so that it will not fall into the transaxle.

    3. A01CDBJE02

      Remove the manual valve lever shaft and manual valve lever sub-assembly.

  27. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01CE5ZE01

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

  28. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01CARAE02

      Using a screwdriver, pry out the oil seal from the transaxle.

  29. INSPECT INPUT SHAFT END PLAY


    1. Secure the transaxle case with the oil pump side facing up.

    2. A01CFZVE01

      Using a dial indicator, measure the input shaft end play.

      Standard end play
      0.26 to 1.25 mm (0.0103 to 0.0492 in.)

      If the end play is not as specified, replace the stator shaft thrust needle roller bearing and the forward clutch hub thrust needle roller bearing.

  30. REMOVE TRANSAXLE HOUSING


    1. A01CB4IE02

      Remove the 18 bolts.

    2. Tap on the circumference of the transaxle housing with a plastic-faced hammer to remove the transaxle housing from the transaxle.

      Note

      The differential may be accidentally removed when the transaxle housing is removed.

  31. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING


    1. A01CDWQE02

      Using SST, remove the underdrive cylindrical roller bearing from the transaxle.

      SST
      09514-35011

  32. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING


    1. A01CD79E07

      Remove the underdrive output shaft oil seal ring from the transaxle housing.

  33. REMOVE OIL PUMP ASSEMBLY


    1. A01CAK2E03

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

  34. REMOVE THRUST NEEDLE ROLLER BEARING


    1. A01CBTQE03

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

  35. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE


    1. A01CFLCE04

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

  36. REMOVE FRONT DIFFERENTIAL ASSEMBLY


    1. A01CCJWE01

      Remove the front differential assembly from the transaxle.

  37. REMOVE OVERDRIVE BRAKE GASKET


    1. A01CAYVE01

      Remove the 2 overdrive brake gaskets from the transaxle.

  38. REMOVE FORWARD CLUTCH ASSEMBLY


    1. A01CE8OE03

      Remove the forward clutch assembly from the transaxle.

    2. A01CCGYE02

      Remove the thrust bearing from the forward clutch.

  39. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


    1. A01CD6CE01

      Install the forward clutch on the oil pump.

      Note

      Be careful not to damage the oil seal ring of the oil pump.

    2. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard piston stroke
      1.74 to 2.08 mm (0.0685 to 0.0819 in.)

      If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.

      If the clearance is not as specified, select another flange.

      Tech Tips

      There are 5 different thicknesses of flanges.

      Standard flange thickness
      No. Thickness No. Thickness
      1 3.00 mm (0.1181 in.) 4 3.45 mm (0.1358 in.)
      2 3.15 mm (0.1240 in.) 5 3.60 mm (0.1417 in.)
      3 3.30 mm (0.1299 in.) - -

  40. REMOVE FORWARD CLUTCH FLANGE HOLE SNAP RING


    1. A01CBXB

      Using a screwdriver, remove the forward clutch flange hole snap ring.

    2. A01CENW

      Remove the flange, 5 discs and 5 plates.

  41. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC


    1. A01CBTJE01

      Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

      If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeling off or discolored, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  42. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01CDQME01

      Place SST on the spring retainer of the forward clutch return spring sub-assembly and compress the return spring with a press.

      SST
      09350-32014   ( 09351-32070 )

    2. Using a snap ring expander, remove the snap ring.

    3. A01CDQD

      Remove the piston return spring.

  43. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01CEJHE01

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      28.23 mm (1.1114 in.)

      If the result is not as specified, replace the spring.

  44. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. Place the forward clutch drum onto the oil pump.

    2. A01CGFA

      Holding the forward clutch piston sub-assembly with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the forward clutch piston sub-assembly.

      Tech Tips

      When the piston is slanted and cannot be removed, remove it by pushing down the protruding side and applying compressed air again, or using need-nose pliers (with its tips wrapped in tape).

  45. REMOVE FORWARD CLUTCH PISTON O-RING


    1. A01CBR1E01

      Remove the 2 O-rings from the forward clutch piston sub-assembly.

  46. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01CDJTE01

      Shake the piston to check that the check ball is not stuck.

    2. A01CCYFE01

      Check that the valve does not leak when applying low compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

  47. REMOVE INPUT SHAFT OIL SEAL RING


    1. A01CD0Y

      Remove the input shaft oil seal ring.

  48. REMOVE MULTIPLE DISC CLUTCH HUB


    1. A01CFYYE01

      Remove the thrust bearing, multiple clutch hub, thrust needle roller bearing and bearing race from the transaxle.

  49. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01CBXKE03

      Remove the bolt and parking lock pawl shaft clamp.

    2. A01CCGDE01

      Remove the parking lock pawl shaft.

    3. A01CBWAE01

      Push the parking lock pawl.

      Tech Tips

      Failure to do so will cause the interference when the underdrive planetary gear is removed.

    4. A01CBLWE04

      Remove the underdrive planetary gear assembly from the transaxle.

      Note

      Be careful so that the underdrive planetary gear assembly will not fall out.

    5. A01CAZYE01

      Remove the tension spring, parking lock pawl pin and parking lock pawl.

  50. REMOVE FRONT PLANETARY GEAR NUT


    1. A01CBUNE03
      Text in Illustration
      *1 Underdrive Planetary Gear

      Using SST, secure the underdrive planetary gear assembly.

      SST
      09387-00050
      09495-65040
    2. A01CAU4E01

      Using SST, loosen the staked part of the front planetary gear nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )
    3. A01CFR4E07
      Text in Illustration
      *1 Underdrive Planetary Gear

      Clamp the underdrive planetary gear in a soft jaw vise.

      Note

      Be careful not to damage the differential drive pinion.

    4. A01CGCOE10
      Text in Illustration
      *1 Underdrive Planetary Gear

      Using a socket wrench, remove the front planetary gear nut.

  51. REMOVE CYLINDRICAL ROLLER BEARING INNER RACE


    1. A01CBHEE09
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the cylindrical roller bearing inner race.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00320 )

  52. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01CF68E01

      Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, underdrive angular ball bearing inner race (front side) and underdrive angular ball bearings.

      SST
      09387-00050
      09495-65040
      09950-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )
    2. A01CAKDE01
      Text in Illustration
      *a Hold
      *b Turn

      Clamp the underdrive planetary gear in soft jaw vise.

    3. Using SST, remove angular ball bearing inner race (rear side) from the underdrive planetary gear.

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00320 )

  53. REMOVE UNDERDRIVE PLANETARY RING GEAR


    1. A01CCJBE04
      Text in Illustration
      *1 Snap Ring

      Using snap ring pliers, remove the underdrive planetary ring hole snap ring.

    2. A01CFMFE04
      Text in Illustration
      *1 Underdrive Planetary Ring Gear
      *2 Counter Driven Gear

      Remove the underdrive planetary ring gear from the counter driven gear.

  54. REMOVE UNDERDRIVE CLUTCH ASSEMBLY


    1. A01CC97E02

      Remove the underdrive clutch assembly, needle roller bearing and No. 3 thrust bearing underdrive race from the transaxle.

  55. INSPECT UNDERDRIVE PACK CLEARANCE


    1. Install the underdrive clutch to the transaxle case.

      Note

      Be careful not to damage the oil seal rings.

    2. A01CECLE01

      Install a dial indicator as shown in the illustration.

    3. A01CCRIE01

      Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard pack clearance
      1.51 to 1.90 mm (0.0594 to 0.0748 in.)

      If the pack clearance is not as specified, inspect the discs, plates and flange.

      If the park clearance is not as specified, select another flange.

      Tech Tips

      There are 3 flanges in different thickness.

      Standard flange thickness
      No. Thickness No. Thickness
      A 3.0 mm (0.118 in.) C 3.4 mm (0.134 in.)
      B 3.2 mm (0.126 in.) - -

  56. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC SNAP RING


    1. A01CBXNE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, pry out the snap ring.

    2. A01CAUC

      Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.

  57. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC


    1. A01CESRE01

      Check to see if the sliding surface of the flange, discs and plates are worn or burnt. If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  58. REMOVE UNDERDRIVE CLUTCH PISTON SET


    1. A01CB0RE02

      Place SST on the clutch balancer and compress the piston return spring with a press.

      SST
      09350-32014   ( 09351-32070 )

    2. Using a snap ring expander, remove the snap ring.

      Note


      • Stop pressing when the spring seat is 1 to 2 mm (0.039 to 0.078 in.) below the snap ring groove to prevent the spring seat from being deformed.

      • Do not expand the snap ring excessively.

    3. A01CB2M

      Remove the clutch balancer and piston return spring from the underdrive clutch drum.

    4. A01CCFP

      Install the underdrive clutch drum to the transaxle case.

      Note

      Be careful not to damage the oil seal rings.

    5. A01CBXY

      Holding the underdrive clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive clutch piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

  59. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01CDRVE01

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      17.14 mm (0.6748 in.)

      If the result is not as specified, replace the spring.

  60. REMOVE UNDERDRIVE CLUTCH DRUM O-RING


    1. A01CFT6

      Remove the underdrive clutch drum O-ring.

  61. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY


    1. A01CD5ME02

      Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bush.

      Standard drum bush
      32.56 to 32.58 mm (1.2818 to 1.2826 in.)
      Maximum drum bush
      32.63 mm (1.2846 in.)

      If the inside diameter is greater than the maximum, replace the underdrive clutch drum sub-assembly.

  62. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY


    1. A01CAP5E02

      Using a screwdriver, pry out the snap ring from the transaxle.

    2. A01CF3OE03

      Remove the one-way clutch from the transaxle.

    3. A01CD48E01

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

  63. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC


    1. A01CAZIE01

      Using a screwdriver, pry out the snap ring from the transaxle.

    2. A01CCYDE01

      Remove the flange, 3 discs and 3 plates from the transaxle.

  64. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC

    A01CDWFE01

    Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

    If necessary, replace them.

    Tech Tips


    • If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

    • Before assembling new discs, soak them in ATF for at least 15 minutes.

  65. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01CCNEE01

      Using SST, a snap ring expander and press, remove the snap ring from the transaxle.

      SST
      09387-00020
    2. A01CBEHE01

      Remove the underdrive brake return spring from the underdrive brake piston.

  66. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01CCN4E01

      Using a vernier caliper, measure the free length of the underdrive brake return spring together with the spring seat.

      Standard free length
      14.04 mm (0.5213 in.)

      If the free length is shorter than the standard free length, replace the under drive brake return spring sub-assembly.

  67. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING


    1. A01CELGE04

      Remove the 2 underdrive clutch drum oil seal rings from the transaxle.

  68. REMOVE UNDERDRIVE BRAKE PISTON


    1. A01CGBXE02

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive brake piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

    2. A01CDUZE02

      Remove the 2 O-rings from the underdrive brake piston.

    3. A01CCAFE02

      Using SST, remove the needle-roller bearing from the transaxle case.

      SST
      09387-00041   ( 09387-01021, 09387-01030, 09387-01041 )

  69. REMOVE NO. 1 TRANSAXLE CASE PLUG


    1. A01CBAA

      Remove the 2 No. 1 transaxle case plugs from the rear transaxle cover sub-assembly.

    2. Remove the 2 O-rings from the 2 No. 1 transaxle case plugs.

  70. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01CE94E08

      Remove the 11 bolts.

    2. Tap the circumference of the rear transaxle cover sub-assembly with a plastic-faced hammer to remove the transaxle rear transaxle cover sub-assembly from the transaxle.

    3. A01CFAHE01

      Remove the 2 outer rear clutch oil seal rings from the rear transaxle cover sub-assembly.

    4. A01CDO8E01

      Using a T30 ''TORX'' socket wrench, remove the 2 screws and rear transaxle cover plate.

    5. A01CFI7E01

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

      SST
      09387-00041   ( 09387-01010, 09387-01030, 09387-01040 )

  71. REMOVE BRAKE APPLY TUBE


    1. A01CE7SE01

      Remove the bolt, No. 1 transaxle apply tube clamp and brake apply tube.

  72. REMOVE FRONT CLUTCH APPLY TUBE


    1. Remove the front clutch apply tube.

  73. REMOVE NO. 1 GOVERNOR APPLY GASKET


    1. A01CDX2E01

      Using a screwdriver, remove the 2 governor apply gaskets.

  74. REMOVE DIRECT CLUTCH ASSEMBLY


    1. A01CC20E01

      Remove the thrust needle roller bearing and direct clutch assembly from the transaxle.

    2. A01CGAAE01

      Remove the bearing race from the direct clutch assembly.

  75. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A01CATVE01

      Install the direct clutch and needle roller bearing on the transaxle rear cover.

    2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Standard pack clearance
      0.605 to 0.825 mm (0.02382 to 0.03248 in.)

      If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

      If the stroke is not as specified, select another flange.

      Tech Tips

      There are 6 flanges in different thickness.

      Standard Flange Thickness
      No. Thickness No. Thickness
      1 3.0 mm (0.118 in.) 4 3.3 mm (0.130 in.)
      2 3.1 mm (0.122 in.) 5 3.4 mm (0.134 in.)
      3 3.2 mm (0.126 in.) 6 3.5 mm (0.138 in.)

  76. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC SNAP RING


    1. A01CENYE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, pry out the direct multiple disc clutch disc snap ring from the direct clutch drum.

    2. Remove the flange, 3 discs and 3 plates from the direct clutch drum.

  77. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC


    1. A01CB3BE01

      Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

      If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  78. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01CF4OE02

      Place SST on the clutch balancer and compress the direct clutch return spring sub-assembly with a press

      SST
      09387-00020

    2. Using a snap ring expander, remove the snap ring from the direct clutch drum.

      Note


      • Stop pressing when the spring seat is 1 to 2 mm (0.039 to 0.078 in.) below the snap ring groove to prevent the spring seat from being deformed.

      • Do not expand the snap ring excessively.

    3. A01CB4K

      Remove the clutch balancer from the direct clutch drum.

    4. A01CG5Z

      Remove the direct clutch return spring sub-assembly from the direct clutch drum.

    5. A01CE0A

      Install the direct clutch drum on the rear transaxle cover sub-assembly.

    6. Holding the direct clutch piston with your hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the rear transaxle cover sub-assembly to remove the direct clutch piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

  79. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01CAUYE03

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      22.58 mm (0.8890 in.)

      If the result is not as specified, replace the spring.

  80. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01CFQGE01

      Remove the rear planetary sun gear from the transaxle.

    2. A01CE0KE01

      Remove the rear planetary sun gear thrust bearing from the rear planetary sun gear assembly.

    3. A01CD97E01

      Remove the No. 1 thrust washer and one-way clutch thrust bearing from the rear planetary sun gear assembly.

  81. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. A01CBPZ

      Remove the No. 2 thrust washer and one-way clutch from the transaxle.

    2. A01CBNIE02

      Remove the one-way clutch inner race from the one-way clutch assembly.

  82. REMOVE OUTER ONE-WAY CLUTCH SLEEVE


    1. A01CF0XE03

      Remove the outer one-way clutch sleeve.

  83. REMOVE 2ND BRAKE CLUTCH DISC


    1. Using a screwdriver, remove the snap ring.

    2. A01CCE5

      Remove the flange, 3 discs and 3 plates from the transaxle.

  84. INSPECT 2ND BRAKE CLUTCH DISC


    1. A01CDWVE01

      Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

      If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  85. REMOVE 2ND BRAKE PISTON ASSEMBLY


    1. A01CCRGE03

      Using a screwdriver, pry out the snap ring.

    2. A01CB4VE01

      Remove the 2nd brake piston assembly from the transaxle.

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


    1. A01CDIZE04

      Place SST on the 2nd brake piston return spring sub-assembly, and compress the 2nd brake piston return spring sub-assembly with a press.

      SST
      09387-00060

    2. Using a screwdriver, pry out the snap ring.

    3. A01CAZZ

      Remove the 2nd brake piston return spring sub-assembly.

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


    1. A01CFIPE02

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      16.61 mm (0.6539 in.)

      If the result is not as specified, replace the spring.

  88. REMOVE 2ND BRAKE PISTON


    1. A01CBE4

      Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

  89. REMOVE 2ND BRAKE PISTON O-RING


    1. A01CE3H

      Remove the 2 O-rings from the 2nd brake piston.

  90. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A01CEHSE01

      Remove the flange, 5 discs and 5 plates from the transaxle.

  91. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A01CCCLE01

      Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

      If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  92. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. A01CDMFE02

      Using a screwdriver, pry out the snap ring from the 2nd brake hub.

    2. A01CBSME01

      Remove the rear planetary gear assembly from the transaxle.

    3. A01CFCAE01

      Remove the thrust washer from the rear planetary gear assembly.

    4. A01CD0DE01

      Remove the No. 3 thrust bearing race from the rear planetary gear assembly.

  93. REMOVE INPUT SUN GEAR


    1. A01CAYFE03

      Remove the 2 thrust bearings, bearing race and input sun gear from the transaxle.

  94. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A01CFPCE02

      Using a chisel and hammer, unstake the lock washer.

      Note

      Push down all claws of the washer. Otherwise SST cannot be fully pressed against the nut and cannot loosen the nut.

    2. A01CF1RE01

      Using SST, remove the lock nut and lock washer.

      SST
      09387-00030
      09387-00080
    3. A01CB08E01

      Using SST and a press, remove the front planetary gear assembly from the counter drive gear.

      SST
      09950-60010   ( 09951-00450 )
    4. A01CEAPE01

      Remove the front planetary gear assembly from the 2nd brake hub.

  95. REMOVE FRONT PLANETARY RING GEAR


    1. A01CGJPE03

      Using a screwdriver, pry out the brake hub snap ring and front planetary ring gear from the 2nd brake hub.

  96. REMOVE 1ST AND REVERSE BRAKE PISTON


    1. A01CF9JE01

      Using SST, a press and ring expander, remove the snap ring.

      SST
      09387-00070

      Note


      • Stop pressing when the spring seat is 1 to 2 mm (0.039 to 0.078 in.) below the snap ring groove to prevent the spring seat from being deformed.

      • Do not expand the snap ring excessively.

    2. A01CAR0E01

      Remove the 1st and reverse brake return spring from the 1st and reverse brake piston.

    3. A01CFVNE01

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle to remove the 1st and reverse brake piston.

      CAUTION:

      Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a piece of cloth.

      Note

      Do not splash ATF when applying compressed air.

    4. A01CDCZE01

      Remove the 2 O-rings from the 1st and reverse brake piston.

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


    1. A01CB58E01

      Using a vernier caliper, measure the free length of the 1st and reverse brake return spring together with the spring seat.

      Standard free length
      15.51 mm (0.6106 in.)

      If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

  98. REMOVE COUNTER DRIVE GEAR


    1. A01CCHDE01

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

      SST
      09950-60010   ( 09951-00590 )
      09950-70010   ( 09951-07100 )
    2. A01CGCAE01

      As shown in the illustration, tighten the 2 bolts evenly and make a clearance of approximately 20.0 mm (0.797 in.) between the counter drive gear and the inner race.

    3. A01CAOIE02

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

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00590 )
    4. A01CBPCE01

      Using a brass bar and a hammer, tap out the 2 counter drive gear bearing outer races from the transaxle case.

  99. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING


    1. A01CCVWE01

      Using a screwdriver, pry out the counter drive gear hole snap ring from the transaxle case.

  100. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01CGFOE01

      Remove the bolt, the No. 2 transaxle apply tube clamp and the differential gear lube apply tube from the transaxle housing.