AUTOMATIC TRANSAXLE UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A019M72

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

    2. A019OY7E04
      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. 1 breather plug from the breather plug hose.

    3. Using a screwdriver, remove the No. 2 breather plug from the breather plug hose.

    4. Using a screwdriver, remove the O-ring from the No. 2 breather plug.

  2. REMOVE TRANSMISSION CONTROL SHAFT LEVER


    1. A019MIW

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

  3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A019ONI

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

  4. REMOVE OIL COOLER TUBE UNION (OUTLET)


    1. A019N4L

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

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

  5. REMOVE OIL COOLER TUBE UNION (INLET)


    1. for Straight Type:


      1. A019KWJ

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

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

    2. for Elbow Type:


      1. A019L5N

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

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

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

  6. REMOVE NO. 1 TRANSAXLE CASE PLUG


    1. A019MZQ

      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.

  7. REMOVE NO. 2 TRANSAXLE CASE PLUG


    1. A019LWO

      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.

  8. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY


    1. A019MIDE01
      Text in Illustration
      *1 Wooden Block

      Support the transaxle assembly on wooden blocks.

  9. REMOVE OVERFLOW PLUG


    1. A019PEJ

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

    2. Remove the gasket from the overflow plug.

  10. REMOVE NO. 1 TRANSMISSION OIL FILLER TUBE


    1. A019OHD

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

  11. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A019KKJ

      Remove the 19 bolts and automatic transaxle oil pan from the transaxle case.

      Note

      Some fluid will remain in the automatic transaxle oil pan. Remove all the bolts, and carefully remove the automatic transaxle oil pan.

  12. REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET


    1. Remove the automatic transaxle oil pan gasket.

  13. REMOVE TRANSMISSION OIL CLEANER MAGNET


    1. A019P1ME04
      Text in Illustration
      *1 Transmission Oil Cleaner Magnet

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

  14. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. Examine particles in the automatic transaxle oil pan.


      1. A019KK7

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

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

  15. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A019JMP

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

    2. A019O29

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

  16. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A019NT7

      Remove the 11 bolts and transmission valve body 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.

  17. REMOVE TRANSAXLE CASE GASKET


    1. A019MEJ

      Remove the 2 transaxle case gaskets from the transaxle case.

  18. INSPECT INPUT SHAFT END PLAY


    1. A019NIY

      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.)

  19. REMOVE REFILL PLUG


    1. A019PKP

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

    2. Remove the gasket from the refill plug.

  20. REMOVE REAR TRANSAXLE COVER PLUG


    1. A019N19

      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.

  21. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A019KLPE02

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

    2. 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.

    3. A019NJBE01

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

    4. A019L5QE02
      Text in Illustration
      *1 Oil Seal Ring
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race

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

    5. Remove the thrust needle roller bearing and thrust bearing race from the rear transaxle cover sub-assembly.

    6. A019KOF

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

    7. A019M1TE03
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09319-60020

  22. REMOVE REAR MULTIPLE DISC CLUTCH ASSEMBLY


    1. A019OKAE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Rear Multiple Disc Clutch Assembly

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

    2. Remove the thrust needle roller bearing from the transaxle case.

    3. A019JSVE01
      Text in Illustration
      *1 O-ring
      *2 Oil Seal Ring

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

    4. Using a screwdriver, remove the oil seal ring from the rear multiple disc clutch assembly.

  23. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. A019KJKE02
      Text in Illustration
      *1 Snap Ring

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

      Tech Tips

      Use a piece of cloth to keep the snap ring from flying off.

    2. A019OPXE02
      Text in Illustration
      *1 Rear Planetary Sun Gear

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

    3. A019K2HE02
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

  24. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. A019OEI

      Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear assembly.

      Standard inside diameter
      25.580 to 25.601 mm (1.00708 to 1.00791 in.)
      Maximum inside diameter
      25.601 mm (1.0079 in.)

      If the inside diameter is greater than the maximum, replace the automatic transaxle assembly.

  25. REMOVE TRANSAXLE HOUSING


    1. A019MYJ

      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.

  26. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (OUTER RACE)


    1. A019K7IE01

      Using SST, remove the differential drive pinion tapered roller bearing RH (outer race) and shim from the transaxle housing.

      SST
      09308-00010

  27. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE


    1. A019LBF

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

  28. REMOVE TRANSAXLE HOUSING OIL SEPARATOR


    1. A019NQ8

      Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.

  29. REMOVE FRONT OIL PUMP ASSEMBLY


    1. A019PDRE02
      Text in Illustration
      *1 O-ring

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

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

    3. A019JYJ

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

    4. A019L85E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 O-ring

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

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

  30. REMOVE NO. 3 BRAKE DISC


    1. A019KQ8

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

    2. A019KH6E02
      Text in Illustration
      *1 Brake Flange
      *2 Brake Plate
      *3 Brake Disc

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

  31. INSPECT NO. 3 BRAKE DISC


    1. A019NIE

      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.

  32. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A019NDH

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

  33. REMOVE NO. 3 BRAKE HUB


    1. A019PMB

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

    2. A019LD7E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing

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

  34. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A019PFME02
      Text in Illustration
      *1 Planetary Sun Gear Sub-assembly
      *2 Underdrive Planetary Gear Assembly
      *3 Snap Ring

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

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

  35. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A019OO2

      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 assembly.

  36. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A019P6Y

      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 (1.0057 in.)

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

  37. REMOVE INPUT SHAFT SUB-ASSEMBLY


    1. A019NKU

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

    2. A019OJ7E02
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 Input Shaft Sub-assembly
      *4 Oil Seal Ring

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

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

  38. REMOVE UNDERDRIVE PLANETARY SUN GEAR


    1. A019NWPE02
      Text in Illustration
      *1 Underdrive Planetary Sun Gear
      *2 Thrust Needle Roller Bearing

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

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

  39. REMOVE NO. 1 BRAKE DISC


    1. A019OZOE02
      Text in Illustration
      *1 Snap Ring
      *2 Brake Snap Ring Stopper

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

    2. A019LEZE03
      Text in Illustration
      *1 Flange
      *2 Brake Plate
      *3 Brake Disc

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

  40. INSPECT NO. 1 BRAKE DISC


    1. A019PMA

      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.

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


    1. A019MQR

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

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


    1. A019N35

      Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs together with 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.

  43. REMOVE NO. 1 BRAKE PISTON


    1. A019PAG

      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. A019NB1E04

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

  44. REMOVE FRONT DIFFERENTIAL CASE


    1. A019OJS

      Remove the front differential case from the transaxle case.

  45. REMOVE COUNTER DRIVE GEAR NUT


    1. A019JM8E01

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

      SST
      09930-00010
    2. A019LO2E01

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

    3. A019KYTE01

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

      SST
      09387-00130
    4. A019MRXE01

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

  46. REMOVE COUNTER DRIVEN GEAR


    1. A019LKP

      Remove the counter driven gear from the transaxle case.

  47. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING RH (INNER RACE)


    1. A019MFFE09
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the differential drive pinion tapered roller bearing RH (inner race) from the counter driven gear.

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

  48. 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.

  49. REMOVE PAWL SHAFT CLAMP


    1. A019K81

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

  50. REMOVE NO. 1 TRANSMISSION CASE PLATE


    1. A019M0X

      Remove the bolt and No. 1 transmission case plate from the transaxle case.

  51. REMOVE PAWL STOPPER PLATE


    1. A019NPU

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

  52. REMOVE PARKING LOCK SLEEVE


    1. A019LTR

      Remove the parking lock sleeve from the transaxle case.

  53. REMOVE PARKING LOCK PAWL


    1. A019OPNE02
      Text in Illustration
      *1 Parking Lock Pawl Pin
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 Parking Lock Pawl

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

  54. REMOVE DIFFERENTIAL DRIVE PINION TAPERED ROLLER BEARING LH (OUTER RACE)


    1. A019LOUE01

      Using SST, remove the differential drive pinion tapered roller bearing LH (outer race) from the transaxle case.

      SST
      09308-00010

  55. REMOVE ONE-WAY CLUTCH ASSEMBLY


    1. A019JZF

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

    2. A019OD2E02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Thrust Needle Roller Bearing

      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.

    4. A019K08E02
      Text in Illustration
      *1 One-way Clutch Assembly
      *2 Outer Race Retainer
      *3 Planetary Ring Gear

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

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

  56. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. A019LSFE04
      Text in Illustration
      *1 Planetary Ring Gear
      *2 One-way Clutch Assembly
      *a Free
      *b Lock

      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.

  57. REMOVE PLANETARY RING GEAR FLANGE


    1. A019MTUE02
      Text in Illustration
      *1 Snap Ring
      *2 Planetary Ring Gear Flange
      *3 Planetary Ring Gear

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

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

  58. REMOVE NO. 2 BRAKE DISC


    1. A019OGR

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

    2. A019MZRE02
      Text in Illustration
      *1 Brake Flange
      *2 Brake Plate
      *3 Brake Disc

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

  59. INSPECT NO. 2 BRAKE DISC


    1. A019PFZ

      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.

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


    1. A019O05

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

    2. A019KZI

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

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


    1. A019PDE

      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.

  62. REMOVE NO. 2 BRAKE PISTON


    1. A019N2M

      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.

    2. A019KAZ

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

  63. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A019M3FE01

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

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

  64. REMOVE COUNTER DRIVE GEAR


    1. A019MB0E01

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

      SST
      09950-60020   ( 09951-00710 )
      09950-70010   ( 09951-07100 )

    2. Remove the bearing inner race (rear side).

    3. A019K3F

      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.

    4. A019ONWE03
      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
      09950-40011   ( 09957-04010 )
      09950-60020   ( 09951-00710 )

  65. REMOVE NO. 3 BRAKE PISTON


    1. A019KVWE01

      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.

    3. A019KT4E02
      Text in Illustration
      *1 Brake Piston Return Spring

      Remove the brake piston return spring from the transaxle case.

    4. A019LABE02
      Text in Illustration
      *1 No. 3 Brake Piston

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

    5. A019OD5

      Using a screwdriver, remove the 2 O-rings from the No. 3 brake piston.

  66. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A019M8S

      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.

  67. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A019MMQ

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

  68. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A019K9J

      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.

  69. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY


    1. A019JYX

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

    2. A019OXW

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

  70. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A019P4G

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