AUTOMATIC TRANSAXLE UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE BREATHER PLUG HOSE

    A004OA2

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

    2. A004SFA

      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

    A004RG4

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

    2. A004MNW

      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)

    A004OUS

    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)

    A004NIX

    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

    A004U3K

    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. A004RGQ

      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

    A004RHP

    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. A004OPK

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

    4. A004RBO

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

    5. A004NGPE05
      Text in Illustration
      *1 Magnet

      Remove the 2 magnets from the automatic transaxle oil pan.

  8. INSPECT TRANSMISSION OIL CLEANER MAGNET

    Click here

  9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A004RL7

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

    2. A004MV3

      Remove the O-ring from the oil strainer.

  10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A004O2G

    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. A004S45

      Remove the 2 gaskets from the transaxle case.

  12. INSPECT INPUT SHAFT SUB-ASSEMBLY

    Click here

  13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY


    1. A004SGC

      Remove the refill plug from the rear transaxle cover.

    2. Remove the gasket from the refill plug.

    3. A004SCK

      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. A004OAV

      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. A004TGM

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

    8. A004NW5

      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. A004OPL

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

    11. A004MPLE01
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09319-60020

  14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

    A004R7W

    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

    A004N66

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

    2. A004U4N

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

    3. A004S1W

      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

    A004QHG

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

  17. INSPECT NO. 2 CLUTCH DISC

    Click here

  18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

    A004OH1

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

    2. A004OQ7

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

    3. A004RTY

      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

    Click here

  20. REMOVE NO. 1 CLUTCH DISC

    A004Q7C

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

    2. A004QPP

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

  21. INSPECT NO. 1 CLUTCH DISC

    Click here

  22. REMOVE TRANSAXLE HOUSING

    A004OC1

    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)

    A004RRQE01

    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

    A004SLNE01

    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

    A004N1KE03

    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

    A004OS7

    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

    A004QRP

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

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

    3. A004Q6M

      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

    A004PS9E01

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

    2. A004RWB

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

  29. INSPECT NO. 3 BRAKE DISC

    Click here

  30. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A004OM3

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

  31. REMOVE NO. 3 BRAKE HUB

    A004TY3

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

    2. A004PQP

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

  32. REMOVE UNDERDRIVE PLANETARY RING GEAR

    A004R8Y

    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

    A004RG5

    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

    Click here

  35. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  36. REMOVE INPUT SHAFT SUB-ASSEMBLY

    A004PZF

    1. Remove the input shaft from the oil pump.

    2. A004PGW

      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

    A004P15

    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

    A004MYL

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

    2. A004T1U

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

  39. INSPECT NO. 1 BRAKE DISC

    Click here

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

    A004NVS

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

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

    Click here

  42. REMOVE NO. 1 BRAKE PISTON

    A004S3Z

    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. A004P1JE06
      Text in Illustration
      *1 O-ring

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

  43. REMOVE FRONT DIFFERENTIAL CASE

    A004OYR

    1. Remove the differential case from the transaxle case.

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


    1. A004T1HE06
      Text in Illustration
      *a Turn
      *a Hold

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

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00480 )

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


    1. A004SH1E01
      Text in Illustration
      *a Turn
      *a Hold

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

      SST
      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

    A004QQEE02

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

      SST
      09930-00010
    2. A004S5IE01

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

    3. A004PFHE02

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

      SST
      09387-00130

  47. REMOVE COUNTER DRIVEN GEAR

    A004MZKE01

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

    2. A004OC2

      Remove the counter driven gear from the transaxle case.

  48. REMOVE COUNTER DRIVEN GEAR BEARING (FRONT)

    A004T5FE01
    Text in Illustration
    *a Turn
    *b Hold

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

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

  49. REMOVE COUNTER DRIVEN GEAR BEARING (REAR)

    A004MLUE01
    Text in Illustration
    *a Turn
    *b 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 )

  50. REMOVE PAWL SHAFT CLAMP

    A004T15

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

  51. REMOVE PAWL STOPPER PLATE

    A004OMS

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

  52. REMOVE PARKING LOCK SLEEVE

    A004MUJ

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

  53. REMOVE PARKING LOCK PAWL

    A004TV6

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

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

    A004R1IE01

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

      SST
      09308-00010

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

    A004O2NE06

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

      SST
      09308-00010

  56. REMOVE TRANSAXLE CASE OIL SEAL LH

    A004O7SE08

    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 )

  57. REMOVE ONE-WAY CLUTCH ASSEMBLY

    A004T2Q

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

    2. A004QRU

      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.

  58. INSPECT ONE-WAY CLUTCH ASSEMBLY

    Click here

  59. REMOVE PLANETARY RING GEAR

    A004RO5

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

  60. REMOVE PLANETARY RING GEAR FLANGE

    A004P1Q

    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.

  61. REMOVE NO. 2 BRAKE DISC

    A004OT8

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

    2. A004R84

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

  62. INSPECT NO. 2 BRAKE DISC

    Click here

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

    A004P77

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

    2. A004PYO

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

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

    Click here

  65. REMOVE NO. 2 BRAKE PISTON

    A004Q2B

    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. A004QKAE09
      Text in Illustration
      *1 O-ring

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

  66. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A004TPKE02

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

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

  67. REMOVE COUNTER DRIVE GEAR

    A004N37E01

    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. A004P43

      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. A004U2AE01
      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 )

  68. REMOVE NO. 3 BRAKE PISTON

    A004RTB

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

    2. A004OC7

      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

    A004TAO

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

  70. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A004SHI

    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.

  71. REMOVE MANUAL VALVE LEVER SHAFT

    A004QX5E01

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

    2. A004QX3

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

    3. A004QIB

      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. A004SMV

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

    5. A004QSV

      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. A004TLL

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

  72. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A004RYD

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