PROCEDURE
REMOVE BREATHER PLUG HOSE
Using a screwdriver, remove the breather plug hose from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case.
Tech Tips
Tape the screwdriver tip before use.
| *1 | No. 1 Breather Plug (ATM) |
| *2 | Breather Plug Hose |
| *3 | No. 2 Breather Plug (ATM) |
| *4 | O-ring |
Using a screwdriver, remove the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) from the breather plug hose.
Using a screwdriver, remove the O-ring from the No. 2 breather plug (ATM).
Note
Be careful not to damage the No. 2 breather plug (ATM).
Tech Tips
Tape the screwdriver tip before use.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.
Remove the 2 bolts and park/neutral position switch assembly from the transaxle case sub-assembly.
Note
Before removing the park/neutral position switch assembly, remove any dirt 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.
REMOVE OIL COOLER UNION SUB-ASSEMBLY
Remove the union bolt and 2 gasket from the transaxle case sub-assembly.
Remove the bolt and oil cooler union sub-assembly from the transaxle case sub-assembly.
REMOVE OIL COOLER TUBE ELBOW
Remove the oil cooler tube elbow from the transaxle case sub-assembly.
Remove the O-ring from the oil cooler tube elbow.
REMOVE NO. 1 TRANSAXLE CASE PLUG
Remove the 6 No. 1 transaxle case plugs from the transaxle case sub-assembly and rear transaxle cover sub-assembly.
Using a screwdriver, remove the 6 O-rings from the 6 No. 1 transaxle case plugs.
REMOVE NO. 2 TRANSAXLE CASE PLUG
Using a 6 mm hexagon socket wrench, remove the 3 No. 2 transaxle case plugs from the transaxle case sub-assembly and transaxle housing.
Remove the gasket from each of the 3 No. 2 transaxle case plugs.
SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY
Support the automatic transaxle assembly with wooden blocks.
REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle oil pan sub-assembly.
Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle oil pan sub-assembly.
Remove the 18 bolts, automatic transaxle oil pan sub-assembly and automatic transaxle oil pan gasket from the automatic transaxle assembly.
Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.
INSPECT TRANSMISSION OIL CLEANER MAGNET
REMOVE VALVE BODY OIL STRAINER ASSEMBLY
Remove the 2 bolts and valve body oil strainer assembly from the transmission valve body assembly.
| *1 | O-ring |
Remove the O-ring from the valve body oil strainer assembly.
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
Remove the 11 bolts and transmission valve body assembly from transaxle case sub-assembly.
Note
When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and transaxle case sub-assembly to interfere with each other.
Make sure the manual valve does not fall when removing the transmission valve body assembly, as the manual valve is not fixed to the transmission valve body assembly.
REMOVE TRANSAXLE CASE GASKET
Remove the 2 transaxle case gaskets from the transaxle case sub-assembly.
REMOVE NO. 1 CHECK VALVE SUB-ASSEMBLY (w/ Stop And Start System)
Remove the No. 1 check valve sub-assembly from the transaxle case sub-assembly.
INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY
REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY
Remove the refill plug from the rear transaxle cover sub-assembly.
Remove the gasket from the refill plug.
Remove the 14 bolts from the rear transaxle cover sub-assembly.
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 sub-assembly.
Using a screwdriver, remove the 3 O-rings from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
| *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.
| *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.
Tech Tips
Tape the screwdriver tip before use.
Using a T30 "TORX" socket wrench, remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly.
| *1 | Needle Roller Bearing |
| *a | Turn |
| *b | Hold |
Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly.
REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY
| *1 | Direct Multiple Disc Clutch Assembly |
| *2 | Thrust Needle Roller Bearing |
Remove the direct multiple disc clutch assembly from the transaxle case sub-assembly.
Remove the thrust needle roller bearing from the direct multiple disc clutch assembly.
| *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.
Tech Tips
Tape the screwdriver tip before use.
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.
Tech Tips
Tape the screwdriver tip before use.
REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING
| *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.
Tech Tips
Tape the screwdriver tip before use.
Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly.
REMOVE NO. 2 CLUTCH DISC
| *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.
INSPECT NO. 2 CLUTCH DISC
REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly.
Note
Do not expand the snap ring excessively.
Remove the rear planetary sun gear assembly from the direct multiple disc clutch assembly.
| *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.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
REMOVE NO. 1 CLUTCH DISC
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.
Tech Tips
Tape the screwdriver tip before use.
| *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.
INSPECT NO. 1 CLUTCH DISC
REMOVE TRANSAXLE HOUSING
Remove the 20 bolts from the transaxle housing.
Using a brass bar and a hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case sub-assembly.
REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE
Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing.
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING OUTER RACE
Using SST, remove the front differential case front tapered roller bearing outer race and shim from the transaxle housing.
REMOVE FRONT DRIVE SHAFT OIL SEAL RH (OUTER)
Using SST, remove the front drive shaft oil seal RH (outer) from the transaxle housing.
REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
Remove the bolt, clamp and differential gear lube apply tube from the transaxle housing.
REMOVE FRONT OIL PUMP ASSEMBLY
| *1 | Gasket |
Remove the 7 bolts and front oil pump assembly from the transaxle case sub-assembly.
Remove the gasket from the front oil pump assembly.
| *1 | Thrust Needle Roller Race |
Remove the thrust needle roller race from the front oil pump assembly.
| *1 | Thrust Needle Roller Bearing |
| *2 | O-ring |
Remove the thrust needle roller bearing from the counter drive gear nut.
Remove the O-ring from the transaxle case sub-assembly.
REMOVE FRONT OIL PUMP BODY O-RING
Remove the front oil pump body O-ring from the front oil pump body assembly.
REMOVE NO. 3 BRAKE DISC
| *1 | Snap Ring |
Using a screwdriver, remove the snap ring from the front oil pump assembly.
Note
Be careful not to damage the front oil pump assembly.
Tech Tips
Tape the screwdriver tip before use.
| *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.
INSPECT NO. 3 BRAKE DISC
REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY
Remove the underdrive planetary gear assembly from the front oil pump assembly.
REMOVE NO. 3 BRAKE HUB
Remove the No. 3 brake hub from the underdrive planetary gear assembly.
| *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.
REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY
| *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.
Remove the snap ring from the underdrive planetary gear assembly.
INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
REMOVE INPUT SHAFT SUB-ASSEMBLY
Remove the input shaft sub-assembly from the front oil pump assembly.
| *1 | Thrust Needle Roller Race |
| *2 | Thrust Needle Roller Bearing |
| *3 | Input Shaft Sub-assembly |
| *4 | Input Shaft Oil Seal Ring |
Remove the thrust needle roller bearing and thrust needle roller race from the input shaft sub-assembly.
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 sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
REMOVE UNDERDRIVE PLANETARY SUN GEAR
| *1 | Underdrive Planetary Sun Gear |
| *2 | Thrust Needle Roller Bearing |
Remove the underdrive planetary sun gear from the front oil pump assembly.
Remove the thrust needle roller bearing from the front oil pump assembly.
REMOVE NO. 1 BRAKE DISC
| *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.
Note
Be careful not to damage the front oil pump assembly.
Tech Tips
Tape the screwdriver tip before use.
| *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.
INSPECT NO. 1 BRAKE DISC
REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Remove the 3 2nd brake piston return spring sub-assemblies from the front oil pump assembly.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
REMOVE NO. 1 BRAKE PISTON
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.
| *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.
Tech Tips
Tape the screwdriver tip before use.
REMOVE FRONT DIFFERENTIAL CASE
Remove the front differential case from the transaxle case sub-assembly.
REMOVE FRONT DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING INNER RACE
| *a | Turn |
| *b | Hold |
Using SST, remove the front differential case front tapered roller bearing inner race from the front differential case.
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING INNER RACE
| *a | Turn |
| *b | Hold |
Using SST, remove the front differential case rear tapered roller bearing inner race from the front differential case.
REMOVE COUNTER DRIVE GEAR NUT
Using SST and a hammer, release the staked part of the front planetary gear assembly.
Note
Do not grind the tip of SST with a grinder or other device.
Completely loosen the staked part of the counter drive gear nut when removing it.
Do not damage the threads of the front planetary gear assembly.
Turn the manual valve lever shaft sub-assembly 2 notches counterclockwise to set it to the P position as shown in the illustration.
Using SST, remove the counter drive gear nut from the front planetary gear assembly.
REMOVE COUNTER DRIVEN GEAR
Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.
Remove the counter driven gear from the transaxle case sub-assembly.
REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING
| *a | Turn |
| *b | Hold |
Using SST, remove the counter driven gear front tapered roller bearing from the counter driven gear.
REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING
| *a | Turn |
| *b | Hold |
Using SST, remove the counter driven gear rear tapered roller bearing from the counter driven gear.
REMOVE PAWL SHAFT CLAMP
Remove the bolt and pawl shaft clamp from the transaxle case sub-assembly.
REMOVE PAWL STOPPER PLATE
Remove the 2 bolts and pawl stopper plate from the transaxle case sub-assembly.
REMOVE PARKING LOCK SLEEVE
Remove the parking lock sleeve from the transaxle case sub-assembly.
REMOVE PARKING LOCK PAWL
| *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 sub-assembly.
REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE
Using SST, remove the counter driven gear rear tapered roller bearing outer race from the transaxle case sub-assembly.
REMOVE FRONT DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING OUTER RACE
Using SST, remove the front differential case rear tapered roller bearing outer race from the transaxle case.
REMOVE FRONT DRIVE SHAFT OIL SEAL LH
Using SST, remove the front drive shaft oil seal LH from the transaxle case sub-assembly.
REMOVE ONE-WAY CLUTCH ASSEMBLY
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
| *1 | One-way Clutch Assembly with Planetary Ring Gear |
| *2 | Thrust Needle Roller Bearing |
Remove the one-way clutch assembly with planetary ring gear from the transaxle case sub-assembly.
Remove the thrust needle roller bearing from the front planetary gear assembly.
INSPECT ONE-WAY CLUTCH ASSEMBLY
REMOVE PLANETARY RING GEAR
| *1 | One-way Clutch Assembly |
| *2 | Outer Race Retainer |
| *3 | Planetary Ring Gear |
Remove the planetary ring gear from the one-way clutch assembly.
Remove the outer race retainer from the one-way clutch assembly.
REMOVE PLANETARY RING GEAR FLANGE
| *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 and planetary ring gear flange.
Tech Tips
Tape the screwdriver tip before use.
Remove the planetary ring gear flange from the planetary ring gear.
REMOVE NO. 2 BRAKE DISC
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
| *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 sub-assembly.
INSPECT NO. 2 BRAKE DISC
REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the 1st and reverse brake return spring sub-assembly from the transaxle case sub-assembly.
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
REMOVE NO. 2 BRAKE PISTON
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 sub-assembly.
| *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.
Tech Tips
Tape the screwdriver tip before use.
REMOVE FRONT PLANETARY GEAR ASSEMBLY
Using SST and a press, remove the front planetary gear assembly from the transaxle case sub-assembly.
INSPECT FRONT PLANETARY GEAR ASSEMBLY
REMOVE COUNTER DRIVE GEAR
Note
Perform this procedure only when the counter drive gear bearing or transaxle case sub-assembly is replaced.
Using SST and a press, remove the counter drive gear and bearing inner race (rear side) from the transaxle case sub-assembly.
As shown in the illustration, tighten 3 service bolts evenly to make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and bearing inner race (front side).
| *a | Turn |
| *b | Hold |
Using SST, remove the bearing inner race (front side) from the counter drive gear.
REMOVE NO. 3 BRAKE PISTON
Using a screwdriver, remove the snap ring from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
| *1 | Brake Piston Return Spring |
| *2 | No. 3 Brake Piston |
Remove the brake piston return spring from the transaxle case sub-assembly.
Remove the No. 3 brake piston from the transaxle case sub-assembly.
REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY
Remove the bolt, cover and manual detent spring sub-assembly from the transaxle case sub-assembly.
REMOVE PARKING LOCK ROD SUB-ASSEMBLY
Remove the parking lock rod sub-assembly from the manual valve lever shaft sub-assembly.
Tech Tips
Align the protrusions with the notches on the manual valve lever shaft sub-assembly to remove the parking lock rod sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT SUB-ASSEMBLY
Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the manual valve lever shaft sub-assembly.
Remove the manual valve lever shaft sub-assembly from the transaxle case sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
| *a | Protective Tape |
Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.
Note
Be careful not to damage the transaxle case transaxle case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.