PROCEDURE
REMOVE BREATHER PLUG HOSE
Using a screwdriver with its tip wrapped with protective tape, remove the transmission breather hose sub-assembly from the transaxle case sub-assembly.
| *1 | No. 1 Breather Plug |
| *2 | Breather Plug Hose |
| *3 | No. 2 Breather Plug |
| *4 | O-ring |
Using a screwdriver with its tip wrapped with protective tape, remove the No. 1 breather plug from the breather plug hose.
Using a screwdriver with its tip wrapped with protective tape, remove the No. 2 breather plug from the breather plug hose.
Using a screwdriver with its tip wrapped with protective tape, remove the O-ring from the No. 2 breather plug.
REMOVE TRANSMISSION CONTROL SHAFT LEVER
Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.
REMOVE PARK/NEUTRAL POSITION SWITCH 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
| *1 | Union Bolt |
| *a | Bolt |
Remove the union bolt and 2 gaskets 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 3 No. 1 transaxle case plugs from the transaxle case sub-assembly.
Using a screwdriver with its tip wrapped with protective tape, remove the 3 O-rings from the 3 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 housing.
Remove the 3 gaskets from the 3 No. 2 transaxle case plugs.
SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY
| *a | Wooden Block |
Support the automatic transaxle assembly with wooden blocks.
REMOVE OVERFLOW PLUG
Using a 6 mm hexagon socket wrench, remove the overflow plug from the automatic transaxle oil pan sub-assembly.
Remove the gasket from the overflow plug.
REMOVE NO. 1 TRANSMISSION OIL FILLER TUBE
Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transaxle oil pan sub-assembly.
REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
REMOVE AUTOMATIC TRANSAXLE OIL PAN GASKET
REMOVE TRANSMISSION OIL CLEANER MAGNET
INSPECT TRANSMISSION OIL CLEANER MAGNET
REMOVE VALVE BODY OIL STRAINER ASSEMBLY
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
REMOVE NO. 1 CHECK VALVE SUB-ASSEMBLY
REMOVE TRANSAXLE CASE GASKET
INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY
REMOVE REFILL PLUG
Remove the refill plug from the rear transaxle cover sub-assembly.
Remove the gasket from the refill plug.
REMOVE REAR TRANSAXLE COVER PLUG
Remove the 3 rear transaxle cover plugs from the rear transaxle cover sub-assembly.
Using a screwdriver with its tip wrapped with protective tape, remove the 3 O-rings from the 3 rear transaxle cover plugs.
REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY
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 with its tip wrapped with protective tape, remove the 3 O-rings from the transaxle case sub-assembly.
| *1 | Thrust Needle Roller Bearing |
| *2 | Thrust Bearing Race |
Remove the thrust needle roller bearing and thrust bearing race from the rear transaxle cover sub-assembly.
| *1 | Oil Seal Ring |
Using a screwdriver with its tip wrapped with protective tape, remove the 2 oil seal rings from the rear transaxle cover sub-assembly.
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 transaxle case sub-assembly.
| *1 | Intermediate Shaft Oil Seal |
| *2 | O-ring |
Using a screwdriver with its tip wrapped with protective tape, remove the O-ring from the direct multiple disc clutch assembly.
Using a screwdriver with its tip wrapped with protective tape, remove the intermediate shaft oil seal from the direct multiple disc clutch assembly.
REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING
| *a | Protective Tape |
Using a screwdriver with its tip wrapped with protective tape, remove the direct multiple disc clutch snap ring from the direct multiple disc clutch assembly.
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
| *1 | Snap Ring |
| *a | Protective Tape |
Using 2 screwdrivers with their tips wrapped with protective tape and a hammer, remove the snap ring from the direct multiple disc clutch assembly.
Tech Tips
Use a piece of cloth to keep the snap ring from flying off.
| *1 | Rear Planetary Sun Gear Assembly |
Remove the rear planetary sun gear assembly from the direct multiple disc clutch assembly.
| *1 | Thrust Needle Roller Bearing |
| *2 | Thrust Bearing Race |
Remove the thrust needle roller bearing and thrust bearing race from the direct multiple disc clutch assembly.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
REMOVE NO. 1 CLUTCH DISC
Using a screwdriver with its tip wrapped with protective tape, remove the 2 snap rings from the direct multiple disc clutch assembly.
Note
Be careful not to damage the direct multiple disc clutch assembly.
| *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
Using SST, remove the front drive shaft oil seal RH 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 gasket from the front oil pump assembly.
Remove the 7 bolts and front oil pump assembly from the transaxle case sub-assembly.
Remove the front oil pump body O-ring from the front oil pump assembly.
| *1 | Thrust Bearing Race |
Remove the thrust bearing race from the underdrive planetary gear 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 NO. 3 BRAKE DISC
| *a | Protective Tape |
Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.
| *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 Bearing Race |
| *2 | Thrust Needle Roller Bearing |
Remove the thrust needle roller bearing and thrust bearing 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 a snap ring expander, 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 Bearing 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 bearing race from the input shaft sub-assembly.
Using a screwdriver with its tip wrapped with protective tape, remove the 3 input shaft oil seal rings from the input shaft sub-assembly.
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 with its tip wrapped with protective tape, remove the 2 snap rings and brake snap ring stopper from the front oil pump assembly.
| *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 from the front oil pump assembly.
| *1 | O-ring |
Using a screwdriver with its tip wrapped with protective tape, remove the 2 O-rings from the No. 1 brake piston.
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.
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.
Turn the manual valve lever shaft sub-assembly 2 notches clockwise to set it to the N position as shown in the illustration.
REMOVE COUNTER DRIVEN GEAR
Remove the counter driven gear from the transaxle case sub-assembly.
REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING (INNER RACE)
| *a | Turn |
| *b | Hold |
Using SST, remove the counter driven gear front tapered roller bearing (inner race) from the counter driven gear.
REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING (INNER RACE)
| *a | Turn |
| *b | Hold |
Using SST, remove the counter driven gear rear tapered roller bearing (inner race) from the counter driven gear.
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 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 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 sub-assembly.
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 with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.
| *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.
| *1 | One-way Clutch Assembly |
| *2 | Outer Race Retainer |
| *3 | Planetary Ring Gear |
Remove the one-way clutch assembly from the planetary ring gear.
Remove the outer race retainer from the one-way clutch assembly.
INSPECT ONE-WAY CLUTCH ASSEMBLY
REMOVE PLANETARY RING GEAR FLANGE
| *1 | Snap Ring |
| *2 | Planetary Ring Gear Flange |
| *3 | Planetary Ring Gear |
Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the planetary ring gear.
Remove the planetary ring gear flange from the planetary ring gear.
REMOVE NO. 2 BRAKE DISC
| *a | Protective Tape |
Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.
| *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 with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.
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 oil hole to remove the No. 2 brake piston from the transaxle case sub-assembly.
| *1 | O-ring |
Using a screwdriver with its tip wrapped with protective tape, remove the 2 O-rings from the No. 2 brake piston.
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 with counter drive gear bearing (bearing inner race (front side)) from the transaxle case sub-assembly.
Remove the counter drive gear bearing (bearing inner race (rear side)) from the transaxle case sub-assembly.
Remove the 2 counter drive gear bearings (balls and cage) from the counter drive gear bearing (outer race).
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 counter drive gear bearing (bearing inner race (front side)).
| *a | Turn |
| *b | Hold |
Using SST, remove the counter drive gear bearing (bearing inner race (front side)) from the counter drive gear.
REMOVE NO. 3 BRAKE PISTON
Place SST on the brake piston return spring and compress the brake piston return spring with a press.
| *a | Protective Tape |
Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the transaxle case sub-assembly.
| *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, manual detent spring 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 with its tip wrapped with protective tape, remove the manual valve lever shaft oil seal from the transaxle case sub-assembly.