AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE

  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    1. C206503

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

    2. C190664C01

      *1

      Breather Plug Hose

      *2

      Breather Plug

      *3

      O-ring

      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

    1. C136685

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

    2. C136686

      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 assembly cannot be reinstalled correctly.

  3. REMOVE OIL COOLER TUBE UNION

    1. C278537

      Using 19 mm union nut wrench, remove the 2 oil cooler tube unions from the transaxle case.

    2. Remove the 2 O-rings from the 2 oil cooler tube unions.

  4. REMOVE TRANSAXLE CASE PLUG

    1. C134959

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

    2. Remove the 3 gaskets from the 3 transaxle case plugs.

    3. C278538

      Remove the 6 transaxle case plugs from the transaxle case and rear transaxle cover sub-assembly.

    4. Using a screwdriver, remove the 6 O-rings from the 6 transaxle case plugs.

      Note:

      Be careful not to damage the transaxle case plugs.

      Tip:

      Tape the screwdriver tip before use.

  5. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY

    1. C206507

      Support the automatic transaxle assembly on wooden blocks.

  6. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

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

    2. Remove the gasket from the overflow plug.

    3. C206508

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

    4. C206509

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

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

  7. INSPECT TRANSMISSION OIL CLEANER MAGNET

    Click hereClick hereClick here

  8. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    1. C136687

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

    2. C136688C02

      *1

      O-ring

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

  9. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    1. C136689

      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.

  10. REMOVE TRANSAXLE CASE GASKET

    1. C274805

      Remove the 2 transaxle case gaskets from the transaxle case.

  11. INSPECT INPUT SHAFT SUB-ASSEMBLY

    Click hereClick hereClick here

  12. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY

    1. C206510

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

    2. Remove the gasket from the refill plug.

    3. C274806

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

    4. 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.

    5. C274807

      Remove the 3 O-rings from the transaxle case.

    6. C297890C09

      *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.

    7. C299131C01

      *1

      Oil Seal Ring

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

      Note:

      Be careful not to damage the rear transaxle cover sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

    8. C274808

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

    9. C274809C01

      *a

      Turn

      *b

      Hold

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

      09319-60020

  13. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    1. C136442C01

      *1

      Direct Multiple Disc Clutch Assembly

      *2

      Thrust Needle Roller Bearing

      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.

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING

    1. C281630C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the direct multiple disc clutch assembly.

      Tip:

      Tape the screwdriver tip before use.

    2. C136434

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

    3. C136428C01

      *1

      Intermediate Shaft Oil Seal

      *2

      O-ring

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

      Note:

      Be careful not to damage the direct multiple disc clutch assembly.

      Tip:

      Tape the screwdriver tip before use.

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

      Note:

      Be careful not to damage the direct multiple disc clutch assembly.

      Tip:

      Tape the screwdriver tip before use.

  15. REMOVE NO. 2 CLUTCH DISC

    1. Remove the No. 2 clutch flange, 3 No. 2 clutch discs and 3 No. 2 clutch plates from the direct multiple disc clutch assembly.

  16. INSPECT NO. 2 CLUTCH DISC

    Click hereClick hereClick here

  17. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

    1. C136436

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

    2. C136437

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

    3. C136438C01

      *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.

  18. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click hereClick hereClick here

  19. REMOVE NO. 1 CLUTCH DISC

    1. C136445

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

      Note:

      Be careful not to damage the direct multiple disc clutch assembly.

      Tip:

      Tape the screwdriver tip before use.

    2. Remove the No. 1 clutch flange, 4 No. 1 clutch discs and 4 No. 1 clutch plates from the direct multiple disc clutch assembly.

  20. INSPECT NO. 1 CLUTCH DISC

    Click hereClick hereClick here

  21. REMOVE TRANSAXLE HOUSING

    1. C209723

      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.

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

    1. C194889N01

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

      09308-00010

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

    1. C196810N01

      Using SST, remove the front differential case front tapered roller bearing outer race and shim from the transaxle housing.

      09308-00010

  24. REMOVE TRANSAXLE CASE OIL SEAL RH (OUTER)

    1. C196824N03

      Using SST, remove the transaxle case oil seal RH from the transaxle housing.

      09308-00010

  25. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

    1. C274811

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

  26. REMOVE OIL PUMP ASSEMBLY

    1. C296578C01

      *1

      Gasket

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

    2. Remove the gasket from the oil pump assembly.

    3. C293908C05

      *1

      Thrust Needle Roller Race

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

    4. C293909C04

      *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.

  27. REMOVE FRONT OIL PUMP BODY O-RING

    1. C293910

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

  28. REMOVE NO. 3 BRAKE DISC

    1. C136451C02

      *1

      Snap Ring

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

      Note:

      Be careful not to damage the oil pump assembly.

      Tip:

      Tape the screwdriver tip before use.

    2. Remove the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates from the oil pump assembly.

  29. INSPECT NO. 3 BRAKE DISC

    Click hereClick hereClick here

  30. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

    1. C136458

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

  31. REMOVE NO. 3 BRAKE HUB

    1. C136454

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

    2. C136455C01

      *1

      Thrust Needle Roller Race

      *2

      Thrust Needle Roller Bearing

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

  32. REMOVE UNDERDRIVE PLANETARY RING GEAR

    1. C136456C01

      *1

      Snap Ring

      *2

      Underdrive Planetary Ring Gear

      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 assembly.

  33. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY

    1. C136457C01

      *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 sub-assembly from the underdrive planetary gear assembly.

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

  34. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    Click hereClick hereClick here

  35. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click hereClick hereClick here

  36. REMOVE INPUT SHAFT SUB-ASSEMBLY

    1. C136459

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

    2. C136460C01

      *1

      Thrust Needle Roller Race

      *2

      Thrust Needle Roller Bearing

      *3

      Input Shaft Oil Seal Ring

      *4

      Input Shaft

      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.

      Note:

      Be careful not to damage the input shaft.

      Tip:

      Tape the screwdriver tip before use.

  37. REMOVE UNDERDRIVE PLANETARY SUN GEAR

    1. C136461C01

      *1

      Underdrive Planetary Sun Gear

      *2

      Thrust Needle Roller Bearing

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

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

  38. REMOVE NO. 1 BRAKE DISC

    1. C153477C02

      *1

      Snap Ring

      *2

      Brake Snap Ring Stopper

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

      Note:

      Be careful not to damage the oil pump assembly.

      Tip:

      Tape the screwdriver tip before use.

    2. Remove the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates from the oil pump assembly.

  39. INSPECT NO. 1 BRAKE DISC

    Click hereClick hereClick here

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

    1. C136464

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

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

    Click hereClick hereClick here

  42. REMOVE NO. 1 BRAKE PISTON

    1. C136465

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

    2. C136466C01

      *1

      O-ring

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

      Note:

      Be careful not to damage the No. 1 brake piston.

      Tip:

      Tape the screwdriver tip before use.

  43. REMOVE FRONT DIFFERENTIAL CASE

    1. C196803

      Remove the front differential case from the transaxle case.

  44. REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING INNER RACE

    1. C205371C05

      *a

      Turn

      *b

      Hold

      Using SST, remove the front differential case front tapered roller bearing inner race from the front differential case.

      09950-00020

      09950-00030

      09950-40011

      09957-04010

      09950-60010

      09951-00480

  45. REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING INNER RACE

    1. C317736C03

      *a

      Turn

      *b

      Hold

      Using SST, remove the front differential case rear tapered roller bearing inner race from the front differential case.

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00480

  46. REMOVE COUNTER DRIVE GEAR NUT

    1. C136698N01

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

      09930-00010

    2. C136700N01

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

    3. C136468N01

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

      09387-00130

  47. REMOVE COUNTER DRIVEN GEAR

    1. C136699N01

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

    2. C136469

      Remove the counter driven gear from the transaxle case.

  48. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING

    1. C194890C01

      *a

      Turn

      *b

      Hold

      Using SST, remove the counter driven gear front tapered roller bearing from the counter driven gear.

      09950-00020

      09950-00030

      09950-60010

      09951-00400

  49. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING

    1. C194891C01

      *a

      Turn

      *b

      Hold

      Using SST, remove the counter driven gear rear tapered roller bearing from the counter driven gear.

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04071

      09957-04010

      09958-04011

      09950-60010

      09951-00320

  50. REMOVE PAWL SHAFT CLAMP

    1. C136472

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

  51. REMOVE PAWL STOPPER PLATE

    1. C136473

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

  52. REMOVE PARKING LOCK SLEEVE

    1. C136474

      Remove the parking lock sleeve from the transaxle case.

  53. REMOVE PARKING LOCK PAWL

    1. C136475C01

      *1

      Parking Lock Pawl Shaft

      *2

      Parking Lock Pawl

      *3

      Spring

      *4

      Parking Lock Pawl Pin

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

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

    1. C194892N05

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

      09308-00010

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

    1. C196814N07

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

      09308-00010

  56. REMOVE TRANSAXLE CASE OIL SEAL LH

    1. C138709N07

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

      09950-60010

      09951-00650

      09950-70010

      09951-07100

  57. REMOVE ONE-WAY CLUTCH ASSEMBLY

    1. C281634C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

    2. C141526C02

      *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 planetary gear assembly.

  58. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click hereClick hereClick here

  59. REMOVE PLANETARY RING GEAR

    1. C201345C07

      *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.

  60. REMOVE PLANETARY RING GEAR FLANGE

    1. C136480C02

      *1

      Snap Ring

      *2

      Planetary Ring Gear Flange

      *3

      Planetary Ring Gear

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

      Note:

      Be careful not to damage the planetary ring gear.

      Tip:

      Tape the screwdriver tip before use.

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

  61. REMOVE NO. 2 BRAKE DISC

    1. C281633C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

    2. Remove the No. 2 brake flange, 5 No. 2 brake discs and 5 No. 2 brake plates from the transaxle case.

  62. INSPECT NO. 2 BRAKE DISC

    Click hereClick hereClick here

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

    1. C281631C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

    2. C136484

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

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

    Click hereClick hereClick here

  65. REMOVE NO. 2 BRAKE PISTON

    1. C136485

      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. C136673C01

      *1

      O-ring

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

      Note:

      Be careful not to damage the No. 2 brake piston.

      Tip:

      Tape the screwdriver tip before use.

  66. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    1. C136674N06

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

      09950-60010

      09951-00580

      09950-70010

      09951-07100

  67. REMOVE COUNTER DRIVE GEAR

    Note:

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

    1. C274813N02

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

      09950-60020

      09951-00710

      09950-70010

      09951-07100

    2. C136676

      As shown in the illustration, tighten the 3 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. C194894C02

      *a

      Turn

      *b

      Hold

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

      09950-00020

      09950-00030

      09950-60020

      09951-00710

  68. REMOVE NO. 3 BRAKE PISTON

    1. C136678

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.

    2. C136679C01

      *1

      Brake Piston Return Spring

      *2

      No. 3 Brake Piston

      Remove the brake piston return spring from the transaxle case.

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

  69. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY

    1. C201354

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

  70. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    1. C201355C01

      *1

      Parking Lock Rod Sub-assembly

      *2

      Manual Valve Lever Sub-assembly

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

      Tip:

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

  71. REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY

    1. C201356

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

    2. C201357

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

  72. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    1. C281632C01

      *a

      Protective Tape

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

      Note:

      Be careful not to damage the transaxle case.

      Tip:

      Tape the screwdriver tip before use.