AUTOMATIC TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE BREATHER PLUG HOSE


    1. A01CG82

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

    2. A01CDGUE02

      Using a screwdriver, remove the 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. A01CBOD

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

    2. A01CDLS

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

      Note

      Before removing the park/neutral position switch assembly, remove any foreign matter 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 (INLET OIL COOLER UNION)


    1. A01CCB7E02

      Loosen the nut while holding the oil cooler tube union (inlet oil cooler union).

    2. Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case.

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

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


    1. A01CBPIE01

      Loosen the nut while holding the oil cooler tube union (outlet oil cooler union).

    2. Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case.

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

  5. REMOVE NO. 1 TRANSAXLE CASE PLUG


    1. A01CAWI

      Remove the 3 No. 1 transaxle case plugs from the transaxle case.

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

    3. A01CCQL

      Using a 6 mm hexagon socket wrench, remove the 3 No. 1 transaxle case plugs from the transaxle housing.

    4. Remove the gasket from each of the 3 No. 1 transaxle case plugs.

  6. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. A01CEBF

      Support the automatic transaxle assembly with wooden blocks.

  7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01CG9X

      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. A01CDX8

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

    4. A01CGCL

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

    5. A01CFCEE04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

  8. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. A01CD8U

      Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle:

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

  9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A01CFOD

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

    2. A01CEF6E02

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

  10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01CD1T

      Remove the 11 bolts and transmission valve body assembly from the transaxle case.

      Note

      When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere with each other.

  11. REMOVE TRANSAXLE CASE GASKET


    1. A01CFOGE01

      Remove the 2 transaxle case gaskets from the transaxle case.

  12. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A01CF81

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

      End play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A01CF5C

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

    2. Remove the gasket from the refill plug.

    3. A01CEKA

      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. A01CF50E02

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

    6. Using a brass bar and hammer, tap on the circumference of the rear transaxle cover sub-assembly to remove the rear transaxle cover sub-assembly from the transaxle case.

    7. A01CFPRE01

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

    8. A01CCM3E01
      Text in Illustration
      *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. A01CFAR

      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. A01CG12E01

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

    11. A01CB1UE05
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09319-60020

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. A01CBDDE01

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

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

    3. A01CDIYE01
      Text in Illustration
      *1 Intermediate Shaft Oil Seal
      *2 O-ring

      Using a screwdriver, remove the intermediate shaft oil seal from the direct multiple disc clutch assembly.

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

  15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING


    1. A01CCC8

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

    2. A01CBTK

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

  16. REMOVE NO. 2 CLUTCH DISC


    1. A01CAQ5E03
      Text in Illustration
      *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.

  17. INSPECT NO. 2 CLUTCH DISC


    1. A01CDIO

      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.

  18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01CEVV

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

    2. A01CFNW

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

    3. A01CG9OE02
      Text in Illustration
      *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.

  19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01CBEG

      Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.

      Standard inside diameter
      25.580 to 25.601 mm (1.0071 to 1.0079 in.)
      Maximum inside diameter
      25.601 mm (1.0079 in.)

      If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.

  20. REMOVE NO. 1 CLUTCH DISC


    1. A01CEA6

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

    2. A01CBUDE03
      Text in Illustration
      *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.

  21. INSPECT NO. 1 CLUTCH DISC


    1. A01CDA4

      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.

  22. REMOVE TRANSAXLE HOUSING


    1. A01CBCUE04

      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.

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


    1. A01CCRAE01

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

      SST
      09308-00010

  24. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A01CDITE01

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

  25. REMOVE FRONT OIL PUMP ASSEMBLY


    1. A01CEKXE02
      Text in Illustration
      *1 Gasket

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

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

    3. A01CC53E01
      Text in Illustration
      *1 Thrust Needle Roller Race

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

    4. A01CD2JE05
      Text in Illustration
      *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.

  26. REMOVE FRONT OIL PUMP BODY O-RING


    1. A01CDV0

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

  27. REMOVE NO. 3 BRAKE DISC


    1. A01CFIHE03
      Text in Illustration
      *1 Snap Ring

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

    2. A01CDUUE02
      Text in Illustration
      *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.

  28. INSPECT NO. 3 BRAKE DISC


    1. A01CCA2

      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.

  29. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01CG3H

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

  30. REMOVE NO. 3 BRAKE HUB


    1. A01CESZ

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

    2. A01CDFLE04

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

  31. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01CGEWE03

      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.

  32. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01CBWT

      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 underdrive planetary gear.

  33. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01CFTN

      Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear.

      Standard inside diameter
      25.525 to 25.546 mm (1.0049 to 1.0057 in.)
      Maximum inside diameter
      25.546 mm (1.0057 in.)

      If the inside diameter is greater than the maximum, replace the planetary sun gear.

  34. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A01CER0

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

    2. A01CC5VE08

      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.

  35. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. A01CE7HE01

      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.

  36. REMOVE NO. 1 BRAKE DISC


    1. A01CD8BE01

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

    2. A01CCP3E04
      Text in Illustration
      *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.

  37. INSPECT NO. 1 BRAKE DISC


    1. A01CCA2

      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.

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


    1. A01CFGP

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

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


    1. A01CEPU

      Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs including the spring seats.

      Standard free length
      23.85 mm (0.939 in.)

      If the free length is shorter than the standard free length, replace the 2nd brake piston return spring.

  40. REMOVE NO. 1 BRAKE PISTON


    1. A01CDTH

      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. A01CFFSE02

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

  41. REMOVE FRONT DIFFERENTIAL CASE


    1. A01CGEG

      Remove the front differential case from the transaxle case.

  42. REMOVE COUNTER DRIVE GEAR NUT


    1. A01CFGSE01

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

      SST
      09930-00010
    2. A01CE5DE01

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

    3. A01CAOFE01

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

      SST
      09387-00130

  43. REMOVE COUNTER DRIVEN GEAR


    1. A01CCJIE01

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

    2. A01CF2S

      Remove the counter driven gear from the transaxle case.

  44. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING


    1. A01CF8RE03
      Text in Illustration
      *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 )

  45. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING


    1. A01CBYWE03
      Text in Illustration
      *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 )

  46. REMOVE PAWL SHAFT CLAMP


    1. A01CCGP

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

  47. REMOVE PAWL STOPPER PLATE


    1. A01CGCM

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

  48. REMOVE PARKING LOCK SLEEVE


    1. A01CGJ3

      Remove the parking lock sleeve from the transaxle case.

  49. REMOVE PARKING LOCK PAWL


    1. A01CF7GE01

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

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


    1. A01CC5RE01

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

      SST
      09308-00010

  51. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. A01CGA7

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

    2. A01CBKAE01

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

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

  52. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. A01CDUTE01

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

    2. 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.

  53. REMOVE PLANETARY RING GEAR


    1. A01CCP1E02
      Text in Illustration
      *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.

  54. REMOVE PLANETARY RING GEAR FLANGE


    1. A01CDRIE01

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

    2. Remove the planetary ring gear flange from the planetary ring gear.

  55. REMOVE NO. 2 BRAKE DISC


    1. A01CBLI

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

    2. A01CAM7E02
      Text in Illustration
      *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.

  56. INSPECT NO. 2 BRAKE DISC


    1. A01CDYQ

      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.

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


    1. A01CDIA

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

    2. A01CCCN

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

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

    A01CFP3

    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 (0.621 in.)

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

  59. REMOVE NO. 2 BRAKE PISTON


    1. A01CC9U

      Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the ATF hole to remove the No. 2 brake piston from the transaxle case.

    2. A01CFUUE02

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

  60. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A01CESME01

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

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

  61. REMOVE COUNTER DRIVE GEAR

    Note

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


    1. A01CBRSE01

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

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )
    2. A01CDRY

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

    3. A01CGEPE03
      Text in Illustration
      *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 )

  62. REMOVE NO. 3 BRAKE PISTON


    1. A01CDE2

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

    2. A01CDO7E01

      Remove the brake piston return spring from the transaxle case.

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

  63. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01CCA4

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

  64. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01CFSA

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

      Tech Tips

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

  65. REMOVE MANUAL VALVE LEVER SHAFT


    1. A01CCUS

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

    2. A01CERJ

      Using a screwdriver, slide the spacer of the manual valve lever sub-assembly.

    3. A01CBAJ

      Using a 3 mm pin punch and hammer, drive out the slotted spring pin from the manual valve lever sub-assembly.

      Tech Tips

      To prevent the slotted spring pin from falling into the transaxle case, drive the slotted spring pin until it has cleared the manual valve lever shaft.

    4. A01CF84

      Using a screwdriver, slide the spacer of the parking lock lever sub-assembly.

    5. A01CBYH

      Using a 3 mm pin punch and hammer, drive out the slotted spring pin from the parking lock lever sub-assembly.

      Tech Tips

      To prevent the slotted spring pin from falling into the transaxle case, drive the slotted spring pin until it has cleared the manual valve lever shaft.

    6. A01CB24

      Remove the manual valve lever shaft, manual valve lever sub-assembly, parking lock lever sub-assembly and 2 spacers from the transaxle case.

  66. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01CBUP

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