Automatic Transaxle Unit Disassembly

Remove the nut, washer and control shaft lever.

Using a screwdriver, pry off the lock plate.

Remove the nut and lock plate.

Remove the 2 bolts and pull out the switch.

Remove the breather plug hose from the transaxle case.

Remove the elbow.

Remove the O-ring from the elbow.

Remove the elbow.

Remove the O-ring from the elbow.

Remove the 2 bolts and the 2 speed sensors from the transaxle.

Remove the 4 No. 1 transaxle case plugs from the transaxle case.

Remove the 4 O-rings from the 4 No. 1 transaxle case plugs.

Remove the bolt and speedometer driven hole cover sub-assembly.

Remove the O-ring from the speedometer driven hole cover sub-assembly.

Secure the transaxle.

Remove the 18 bolts, oil pan and gasket.

Remove the 2 magnets from the oil pan.

Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle.

Result:

Steel (magnetic):

Bearing, gear and plate wear

Brass (non-magnetic):

Bushing wear

Remove the 3 bolts and oil strainer.

Remove the O-ring from the oil strainer.

Remove the 7 connectors from the shift solenoid valves.

Remove the bolt, lock plate and temperature sensor.

Remove the bolt and transmission wire from the transaxle case.

Support the valve body and remove the 17 bolts and valve body assembly.

Remove the No. 1 governor apply gasket from the transaxle case.

Remove the transaxle case 2nd brake gasket from the transaxle case.

Remove the brake drum gasket from the transaxle case.

Remove the check ball body and spring from the transaxle case.

Remove the spring from the C-3 accumulator piston.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole and remove the C-3 accumulator piston.

NOTICE:

1. Applying compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.
   
2. Take care not to splash ATF when applying compressed air.
   

Remove the O-ring from the C-3 accumulator piston.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole and remove the reverse clutch accumulator piston and spring.

NOTICE:

1. Applying compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.
   
2. Take care not to splash ATF when applying compressed air.
   

Remove the 2 O-rings from the reverse clutch accumulator piston.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.

NOTICE:

1. Applying compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.
   
2. Take care not to splash ATF when applying compressed air.
   

Remove the O-ring from the B-3 accumulator piston.

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

Remove the 2 bolts, manual detent spring sub-assembly and cover.

Remove the 2 bolts and parking lock pawl bracket.

Using a chisel and hammer, cut off and remove the spacer.

Using a pin punch (φ3.5 mm) and hammer, drive out the pin.

HINT:

Slowly drive out the pin so that it does not fall into the transaxle case.

Remove the manual valve lever shaft and manual valve lever.

Remove the parking lock rod from the manual valve lever.

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

NOTICE:

Do not apply excessive force when removing the manual valve lever shaft oil seal.

Secure the transaxle case in place with the oil pump side facing up.

Using a dial indicator, measure the input shaft end play.

Standard end play:

0.262 to 1.244 mm (0.01 to 0.049 in.)

Remove the 16 bolts.

Tap on the circumference of the transaxle housing with a plastic-faced hammer to remove the transaxle housing from the transaxle case.

NOTICE:

The differential may be accidentally removed while removing the transaxle housing.

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

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

Remove the thrust bearing underdrive race from the underdrive planetary gear assembly.

Remove the differential gear assembly from the transaxle case.

Remove the 2 overdrive brake gaskets from the transaxle case.

Remove the forward clutch assembly from the transaxle case.

Remove the thrust needle roller bearing from the forward clutch.

Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and No. 1 thrust bearing race from the transaxle case.

Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.

Standard inside diameter:

23.03 to 23.05 mm (0.9067 to 0.9075 in.)

Maximum inside diameter:

23.09 mm (0.9091 in.)

NOTICE:

1. Check the contact surface of the bushing in the direct clutch shaft. If any scratches or discoloration is found, replace the direct clutch assembly with a new one.
   

Remove the bolt and pawl shaft clamp.

Remove the parking lock pawl shaft.

Push the parking lock pawl.

HINT:

Failure to do so will cause interference when the underdrive planetary gear is removed.

Remove the underdrive planetary gear from the transaxle case.

NOTICE:

Make sure that the underdrive planetary gear assembly will not fall off.

Remove the spring, pawl pin and parking lock pawl.

Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle case.

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

NOTICE:

Do not apply excessive force when removing the snap ring.

Remove the underdrive one-way clutch from the transaxle case.

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

Using a screwdriver, remove the snap ring.

NOTICE:

Do not apply excessive force when removing the snap ring.

Remove the flange, 4 discs and 4 plates from the transaxle case.

Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of a disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
   
2. Before installing new discs, immerse them in ATF for at least 15 minutes.
   

Remove the 11 bolts.

Tap on the circumference of the rear cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.

Remove the 4 No. 1 transaxle case plugs from the rear transaxle cover.

Remove the 4 O-rings from the 4 No. 1 transaxle case plugs.

Remove the 3 rear clutch oil seal rings from the transaxle rear cover.

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

SST

09387-00041(09387-01021,09387-01030,09387-01040)

Using a screwdriver, remove the 3 No. 1 governor apply gaskets.

Remove the bolt, clamp and brake apply tube.

Remove the clutch apply tube.

Remove the brake apply tube from the clamp.

NOTICE:

Do not bend the tubes.

Remove the thrust bearing and the direct clutch assembly from the transaxle case.

Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub from the planetary gear.

Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.

Standard inside diameter:

23.025 to 23.046 mm (0.9065 to 0.9073 in.)

Maximum inside diameter:

23.09 mm (0.9091 in.)

NOTICE:

1. Check the contact surface of the bushing in the direct clutch shaft. If any scratches or discoloration is found, replace the direct clutch assembly with a new one.
   

Remove the rear planetary sun gear assembly from the transaxle case.

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

Remove the No. 2 planetary carrier thrust washer from the rear planetary sun gear assembly.

Remove the one-way clutch assembly and thrust needle roller bearing from the transaxle case.

Remove the one-way clutch inner race from the one-way clutch assembly.

Remove the one-way clutch sleeve outer from the transaxle case.

Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly.

Using a screwdriver, remove the snap ring.

Remove the flange, 4 discs and 4 plates from the transaxle case.

Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of a disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
   
2. Before installing new discs, immerse them in ATF for at least 15 minutes.
   

Using a screwdriver, remove the snap ring.

Remove the 2nd brake piston assembly from the transaxle case.

Using a screwdriver, remove the snap ring.

Remove the rear planetary gear assembly from the transaxle case.

Remove the 2 thrust needle roller bearings, No. 2 thrust bearing race and the input sun gear from the transaxle case.

Remove the flange, 6 discs and 6 plates from the transaxle case.

Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of a disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
   
2. Before installing new discs, immerse them in ATF for at least 15 minutes.
   

Using a chisel and hammer, release the lock washer.

NOTICE:

Push down all the claws of the washer. Otherwise SST cannot be fully pressed against the nut, and cannot loosen the nut.

Using SST, remove the nut.

SST

09387-00030
09387-00080

Using SST and a press, remove the front planetary gear assembly from the counter drive gear.

SST

09950-60010(09951-00450)
09950-70010(09951-07100)

Remove the front planetary gear assembly from the brake hub.

Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.

Place SST on the return spring, and compress the return spring with a press.

NOTICE:

Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.

SST

09387-00070

Using a snap ring expander, remove the snap ring.

NOTICE:

Do not expand the snap ring excessively.

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

17.61 mm (0.6933 in.)

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle case to remove the 1st and reverse brake piston.

NOTICE:

1. Applying compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.
   
2. Take care not to splash ATF when applying compressed air.
   

Remove the 2 O-rings from the 1st and reverse brake piston.

Using SST and a press, remove the counter drive gear from the transaxle case.

SST

09950-60010(09951-00590)
09950-70010(09951-07100)

As shown in the illustration, tighten the 2 bolts evenly and make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and the inner race.

Using SST, remove the tapered roller bearing.

SST

09950-60010(09951-00590)
09950-00020
09950-00030
09950-40011(09957-04010)

Using a snap ring expander, remove the snap ring.

Using SST and a press, remove the bearing outer race.

SST

09950-60020(09951-00910)

Place SST on the return spring, and compress the return spring with a press.

NOTICE:

Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove to prevent the spring seat from being deformed.

SST

09387-00020

Using a snap ring expander, remove the snap ring.

NOTICE:

Do not expand the snap ring excessively.

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

13.24 mm (0.5213 in.)

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle case to remove the underdrive brake piston.

Remove the 2 O-rings from the underdrive brake piston.

Using SST, remove the needle roller bearing from the transaxle case.

SST

09387-00041(09387-01010,09387-01030,09387-01040)

Remove the 2 underdrive clutch drum oil seal rings from the transaxle case.

Remove the 2 No. 1 transaxle case plugs.

Remove the 2 O-rings from the 2 No. 1 transaxle case plugs.

Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.

SST

09514-35011

Remove the oil seal ring from the transaxle housing.

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

NOTICE:

Do not bend the tubes.