AUTOMATIC TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE BREATHER PLUG HOSE

    A00E7HM

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

    2. A00E7B6

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

    3. Remove the O-ring from the breather plug.

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A00E9JM

    1. Remove the nut, washer, and control shaft lever from the control shaft.

    2. A00E9AD

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

      Note


      • Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft.

      • 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 cannot be reinstalled correctly.

  3. REMOVE OIL COOLER TUBE UNION (OUTLET)

    A00E74O

    1. Loosen the nut while holding the oil cooler tube union.

    2. Remove the oil cooler tube union from the transaxle case.

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

  4. REMOVE OIL COOLER TUBE UNION (INLET)

    A00EAA3

    1. Loosen the nut while holding the oil cooler tube union.

    2. Remove the oil cooler tube union from the transaxle case.

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

  5. REMOVE NO. 1 TRANSAXLE CASE PLUG

    A00EB9E

    1. 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. A00E9UA

      Using a 6 mm hexagon wrench, remove the 3 transaxle case plugs from the transaxle housing.

    4. Remove the gasket from each of the 3 transaxle case plugs.

  6. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY

    A00E8LL

    1. Support the transaxle assembly on wooden blocks.

  7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. Using a 6 mm hexagon wrench, remove the overflow plug from the automatic transaxle oil pan.

    2. Remove the gasket from the overflow plug.

    3. A00E8JJ

      Using a 6 mm hexagon wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle.

    4. A00E9J3

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

    5. A00E713E05
      Text in Illustration
      *1 Magnet

      Remove the 2 magnets from the automatic transaxle oil pan.

  8. INSPECT TRANSMISSION OIL CLEANER MAGNET

    A00E891

    1. Examine the particles in the oil pan.


      1. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle.

        Steel (magnetic): bearing, gear and plate wear

        Brass (non-magnetic): bush wear

  9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A00E80G

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

    2. A00E8TD

      Remove the O-ring from the oil strainer.

  10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A00E7MJ

    1. Remove the 11 bolts and valve body from the transaxle case.

      Note

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

  11. REMOVE TRANSAXLE CASE GASKET


    1. A00E8CTE01

      Remove the 2 gaskets from the transaxle case.

  12. INSPECT INPUT SHAFT SUB-ASSEMBLY

    A00E8J4

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

      Standard end play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A00E921

      Remove the refill plug from the rear transaxle cover.

    2. Remove the gasket from the refill plug.

    3. A00E7GY

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

    4. Remove the 3 O-rings from the 3 No. 1 automatic transaxle case plugs.

    5. A00E90V

      Remove the 14 bolts from the rear transaxle cover.

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

    7. A00E6OOE01

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

    8. A00EBES

      Remove the 2 oil seal rings from the rear transaxle cover.

    9. Remove the thrust needle roller bearing race and thrust needle roller bearing from the rear transaxle cover.

    10. A00E7NDE01

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

    11. A00EB9HE03
      Text in Illustration
      *1 Turn
      *2 Hold

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

      SST
      09319-60020

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    A00E9OV

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

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

  15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING

    A00EA4E

    1. Using a screwdriver, pry out the snap ring from the direct multiple disc clutch.

    2. A00E8TK

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

    3. A00EBAQ

      Remove the intermediate shaft oil seal from the direct multiple disc clutch.

    4. Remove the O-ring from the direct multiple disc clutch.

  16. REMOVE NO. 2 CLUTCH DISC

    A00EB8L

    1. Remove the 3 clutch plates, 3 clutch discs and flange from the direct multiple disc clutch.

  17. INSPECT NO. 2 CLUTCH DISC

    A00E7C6

    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 the discs.

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

      If necessary, replace the discs, plates and flange.

  18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

    A00E8I3

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

    2. A00E9M6

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

    3. A00E6VK

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

  19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    A00EA1Q

    1. 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 (1.007 to 1.008 in.)
      Maximum inside diameter
      25.601 mm (1.008 in.)

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

  20. REMOVE NO. 1 CLUTCH DISC

    A00E755

    1. Using screwdriver, pry out the 2 snap rings from the direct multiple disc clutch.

    2. A00EAUS

      Remove the flange, 4 clutch discs, and 4 clutch plates from the direct multiple disc clutch.

  21. INSPECT NO. 1 CLUTCH DISC

    A00E7WK

    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 the discs.

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

      If necessary, replace the discs, plates and flange.

  22. REMOVE TRANSAXLE HOUSING

    A00E9N7

    1. Remove the 20 bolts from the transaxle housing.

    2. Using a brass bar and hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case.

  23. REMOVE COUNTER DRIVEN GEAR BEARING OUTER RACE (FRONT)

    A00E9Q8E01

    1. Using SST, tap out the counter driven gear bearing outer race and shim from the transaxle housing.

      SST
      09308-00010

  24. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE

    A00E8Y8E01

    1. Using SST, tap out the front differential case bearing outer race and shim from the transaxle housing.

      SST
      09308-00010

  25. REMOVE TRANSAXLE CASE OIL SEAL RH

    A00E8WOE03

    1. Using SST and a hammer, tap out the transaxle case oil seal from the transaxle housing.

      SST
      09950-60010   ( 09951-00540 )
      09950-70010   ( 09951-07200 )

  26. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

    A00E87SE01

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

  27. REMOVE FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

    A00E80O

    1. Remove the 7 bolts and oil pump from the transaxle case.

    2. Remove the O-ring from the oil pump.

    3. A00E9JF

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

    4. Remove the O-ring from the transaxle case.

  28. REMOVE NO. 3 BRAKE DISC

    A00E7URE04

    1. Using a screwdriver, pry out the snap ring from the oil pump.

    2. A00E6K3

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

  29. INSPECT NO. 3 BRAKE DISC

    A00EB4E

    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 the discs.

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

      If necessary, replace the discs, plates and flange.

  30. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A00E9Q0

    1. Remove the underdrive planetary gear from the oil pump.

  31. REMOVE NO. 3 BRAKE HUB

    A00E9TA

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

    2. A00E7CY

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

  32. REMOVE UNDERDRIVE PLANETARY RING GEAR

    A00EAVB

    1. Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear.

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

  33. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY

    A00E7W2

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

    2. Remove the snap ring from the underdrive planetary gear.

  34. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A00EA6S

    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 more than the standard, replace the underdrive planetary gear assembly.

  35. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    A00E8VJ

    1. 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 (1.00 to 1.01 in.)
      Maximum inside diameter
      25.546 mm (1.01 in.)

      If the inside diameter is more than the maximum, replace the planetary sun gear sub-assembly.

  36. REMOVE INPUT SHAFT SUB-ASSEMBLY

    A00E98C

    1. Remove the input shaft from the oil pump.

    2. A00E86C

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

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

  37. REMOVE UNDERDRIVE PLANETARY SUN GEAR

    A00EBDD

    1. Remove the underdrive planetary sun gear from the oil pump.

    2. Remove the thrust needle roller bearing from the oil pump.

  38. REMOVE NO. 1 BRAKE DISC

    A00EADG

    1. Using a screwdriver, pry out the 2 snap rings and brake snap ring stopper from the oil pump.

    2. A00EAFV

      Remove the flange, 4 brake discs, and 4 brake plates from the oil pump.

  39. INSPECT NO. 1 BRAKE DISC

    A00EB4E

    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 the discs.

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

      If necessary, replace the discs, plates and flange.

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

    A00E8Y7

    1. Remove the 3 2nd brake piston return springs from the oil pump.

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

    A00EA53

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

      Standard free length
      23.85 mm (0.939 in.)

      If the free length is less than the standard, replace the 2nd brake piston return spring sub-assembly.

  42. REMOVE NO. 1 BRAKE PISTON

    A00E6WH

    1. Holding the oil pump by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil pump to remove the No. 1 brake piston.

    2. A00E87DE06
      Text in Illustration
      *1 O-ring

      Remove the 2 O-rings from the No. 1 brake piston.

  43. REMOVE FRONT DIFFERENTIAL CASE

    A00E8H1

    1. Remove the differential case from the transaxle case.

  44. REMOVE COUNTER DRIVE GEAR NUT

    A00E7MBE02

    1. Using SST and a hammer, unstake the counter drive gear nut.

      SST
      09930-00010
    2. A00EAEEE01

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

    3. A00EAFIE02

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

      SST
      09387-00130

  45. REMOVE COUNTER DRIVEN GEAR

    A00EAUCE01

    1. Turn the manual valve lever 2 notches clockwise to set it to the N position as shown in the illustration.

    2. A00E7M8

      Remove the counter driven gear from the transaxle case.

  46. REMOVE COUNTER DRIVEN GEAR BEARING (FRONT)

    A00E8MDE07
    Text in Illustration
    *1 Turn
    *2 Hold

    1. Using SST, remove the counter driven gear bearing from the counter driven gear.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00400 )

  47. REMOVE COUNTER DRIVEN GEAR BEARING (REAR)

    A00EAVGE04
    Text in Illustration
    *1 Turn
    *2 Hold

    1. Using SST, remove the counter driven gear bearing and differential drive pinion 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 )

  48. REMOVE PAWL SHAFT CLAMP

    A00E7AH

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

  49. REMOVE PAWL STOPPER PLATE

    A00E79N

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

  50. REMOVE PARKING LOCK SLEEVE

    A00E750

    1. Remove the parking lock sleeve from the transaxle case.

  51. REMOVE PARKING LOCK PAWL

    A00E7YJE04

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

  52. REMOVE COUNTER DRIVEN GEAR BEARING OUTER RACE (REAR)

    A00E7AOE01

    1. Using SST, tap out the counter driven gear bearing outer race from the transaxle case.

      SST
      09308-00010

  53. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE

    A00E7HZE01

    1. Using SST, tap out the front differential case rear tapered roller bearing outer race from the transaxle case.

      SST
      09308-00010

  54. REMOVE TRANSAXLE CASE OIL SEAL LH

    A00E8E9E02

    1. Using SST and a hammer, tap out the transaxle case oil seal from the transaxle case.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07100 )

  55. REMOVE ONE-WAY CLUTCH ASSEMBLY

    A00E7V8

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

    2. A00EA1W

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

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

  56. INSPECT ONE-WAY CLUTCH ASSEMBLY

    A00E6O3E02

    1. 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 as specified, replace it.

  57. REMOVE PLANETARY RING GEAR

    A00E8HW

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

  58. REMOVE PLANETARY RING GEAR FLANGE

    A00E6LI

    1. Using a screwdriver, pry out the snap ring from the planetary ring gear.

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

  59. REMOVE NO. 2 BRAKE DISC

    A00E7JL

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

    2. A00E925

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

  60. INSPECT NO. 2 BRAKE DISC

    A00E8EA

    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 the discs.

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

      If necessary, replace the discs, plates and flange.

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

    A00E6V5

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

    2. A00E99Z

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

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

    A00EA2N

    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 less than the standard, replace the 1st and reverse brake return spring.

  63. REMOVE NO. 2 BRAKE PISTON

    A00E82J

    1. 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. A00EB95E04
      Text in Illustration
      *1 O-Ring

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

  64. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A00E9FGE02

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

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

  65. REMOVE COUNTER DRIVE GEAR

    A00E6TAE02

    1. 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. A00E930

      As shown in the illustration, install 3 service bolts and tighten them evenly so that there is a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and inner race. Then remove the bolts.

    3. A00E7SFE04
      Text in Illustration
      *1 Turn
      *2 Hold

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

      SST
      09950-00020
      09950-00030
      09950-60020   ( 09951-00710 )

  66. REMOVE NO. 3 BRAKE PISTON

    A00E8BE

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

    2. A00E85R

      Remove the brake piston return spring from the transaxle case.

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

  67. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY

    A00E9RYE02

    1. Remove the bolt, cover, and manual detent spring from the transaxle case.

  68. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A00EASP

    1. Remove the parking lock rod from the parking lock lever.

      Tech Tips

      Align the protrusions on the parking lock rod with the notches in the parking lock lever to remove the parking lock rod.

  69. REMOVE MANUAL VALVE LEVER SHAFT

    A00EB1DE02

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

    2. A00E6PB

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

    3. A00E8ND

      Using a 3 mm pin punch and hammer, tap out the slotted spring pin from the manual valve lever.

      Tech Tips

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

    4. A00EA33

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

    5. A00EACV

      Using a 3 mm pin punch and hammer, tap out the slotted spring pin from the parking lock lever.

      Tech Tips

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

    6. A00E6OI

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

  70. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A00EB2M

    1. Using a screwdriver, pry out the manual valve lever shaft oil seal from the transaxle case.