Automatic Transaxle Unit Disassembly

Remove the nut, washer and control shaft lever.

Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper.

Remove the 2 bolts and pull out the park/neutral position switch.

Remove the No. 2 breather plug from the transaxle case.

Remove the hose and O-ring from the No. 2 breather plug.

Remove the elbow.

Remove the O-ring from the elbow.

Remove the union.

Remove the O-ring from the union.

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

Remove the 2 O-rings from the 2 speed sensors.

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

Remove the O-ring from each No. 1 transaxle case plug.

Secure the transaxle assembly onto wooden blocks.

Remove the drain plug and drain plug gasket from the oil pan.

Remove the 18 bolts, oil pan and gasket.

Remove the 2 transmission oil cleaner 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

Disconnect the 7 connectors from the shift solenoid valves.

Remove the bolt, lock plate, and ATF temperature sensor.

Remove the bolt and transmission wire from the transaxle case.

Remove the 3 bolts and oil strainer.

Remove the O-ring from the oil strainer.

Support the valve body assembly 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.

Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.

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 accumulator piston and spring.

NOTICE:

1. Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a 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 by hand using a 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 and manual detent spring sub-assembly.

Remove the 2 bolts and parking lock pawl bracket.

Using a screwdriver, slide the spacer.

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

HINT:

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

Remove the manual valve lever shaft, manual valve lever and spacer.

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

HINT:

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

Using a screwdriver, remove the oil seal from the transaxle case.

Secure the transaxle case with the oil pump facing up.

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

End play:

0.262 to 1.249 mm (0.0103 to 0.0492 in.)

Remove the 18 bolts.

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

NOTICE:

The differential may be accidentally removed when the transaxle housing is removed.

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 No. 2 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.

Install the forward clutch on the oil pump.

NOTICE:

Be careful not to damage the oil seal ring of the oil pump.

Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Pack clearance:

1.00 to 1.25 mm (0.0394 to 0.0492 in.)

HINT:

1. As the opening is large, cover it with a piece of cloth or shop rag to prevent the compressed air from being released.
   
2. There are 7 different thicknesses of flanges available.
   

Flange Thickness:

No.	Thickness (mm (in.))	No.	Thickness (mm (in.))
0	2.85 (0.1122)	4	3.45 (0.1358)
1	3.00 (0.1181)	5	3.60 (0.1417)
2	3.15 (0.1240)	6	3.75 (0.1476)
3	3.30 (0.1299)	-	-

Using a screwdriver, remove the snap ring.

Remove the flange, 5 discs and 5 plates from the input shaft assembly.

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

SST

09387-00020

Using a snap ring expander, remove the snap ring.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the clutch balancer from the input shaft.

Remove the forward clutch return spring from the input shaft.

Place the forward clutch drum onto the oil pump.

Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil pump to remove the forward clutch piston.

HINT:

If the piston is slanted and cannot be removed, either blow air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped.

Remove the input shaft oil seal ring from the input shaft.

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 dial indicator, measure the inside diameter of the multiple disc 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:

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

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

Remove the parking lock pawl shaft from the transaxle case.

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 assembly from the transaxle case.

NOTICE:

Do not drop the underdrive planetary gear assembly.

Using SST and a hammer, loosen the staked part of the gear nut.

SST

09930-00010(09931-00010,09931-00020)
09387-00050
09495-65040

Clamp the underdrive planetary gear in a soft jaw vise.

NOTICE:

Be careful not to damage the differential drive pinion.

Using a socket wrench, remove the gear nut.

Using SST, remove the cylindrical roller bearing race inner.

SST

09950-00020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00320)

Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.

SST

09387-00050
09495-65040
09950-60010(09951-00320)
09950-70010(09951-07100)

Clamp the underdrive planetary gear in a soft jaw vise.

Using SST, remove the rear angular ball bearing from the underdrive planetary gear.

SST

09950-00020
09950-00030
09950-40011(09957-04010)
09950-60010(09951-00320)

Using snap ring pliers, remove the snap ring.

Remove the underdrive planetary ring gear from the counter driven gear.

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 No. 2 underdrive clutch flange hole snap ring.

Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum.

Place SST on the clutch balancer and compress the spring with a press.

SST

09350-32014(09351-32070)

Using a snap ring expander, remove the snap ring.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the clutch balancer from the underdrive clutch drum.

Remove the return spring from the underdrive clutch drum.

Remove the underdrive clutch from the transaxle case.

NOTICE:

Be careful not to damage the oil seal ring.

Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle case to remove the underdrive clutch piston.

Using a screwdriver, remove the O-ring from the underdrive clutch drum.

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

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.

Remove the flange, 3 discs and 3 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 linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak 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 transaxle rear cover from the transaxle case.

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

Remove the O-ring from each No. 1 transaxle case plug.

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

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

SST

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

Using a screwdriver, remove the 3 apply gaskets.

Remove the bolt, clamp and brake apply tube.

Remove the clutch apply tube.

Remove the brake apply tube from the clamp.

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

Install the intermediate shaft and needle roller bearing on the transaxle rear cover.

NOTICE:

Be careful not to damage the oil seal ring outers.

Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Pack clearance:

1.05 to 1.47 mm (0.04134 to 0.05787 in.)

Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Pack clearance:

0.61 to 0.83 mm (0.02402 to 0.03268 in.)

Using a screwdriver, remove the snap ring from the intermediate shaft.

Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.

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

NOTICE:

1. If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

Using a screwdriver, remove the snap ring from the intermediate shaft.

Remove the flange, 3 discs and 3 plates from the intermediate shaft.

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

NOTICE:

1. If the linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

Place SST on the clutch balancer and compress the spring with a press.

SST

09387-00020

Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the clutch balancer from the overdrive direct clutch drum.

Remove the overdrive clutch return spring from the overdrive direct clutch drum.

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

Standard free length:

25.91 mm (1.0201 in.)

Install the intermediate shaft on the transaxle rear cover.

Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle rear cover to remove the direct clutch piston.

Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle rear cover to remove the direct clutch drum.

Using a screwdriver, remove the O-ring from the direct clutch drum.

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

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 the 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 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, 3 discs and 3 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 linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak 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.

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

SST

09387-00060

Using a screwdriver, remove the snap ring.

Remove the 2nd brake piston return spring sub-assembly.

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

Standard free length:

16.61 mm (0.6539 in.)

Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.

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

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 races, No. 3 thrust bearing race, and input sun gear from the transaxle case.

Remove the flange, 5 discs and 5 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 linings of a disc is peeled off or discolored, or even if a part of the groove is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

Using a chisel and hammer, unstake the lock washer.

NOTICE:

Push down all claws of the washer. If the claws are not pushed down, SST cannot be fully pressed against the nut, and the nut cannot be loosened.

Using SST, remove the nut and washer.

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.

SST

09387-00070

Using a snap ring expander, remove the snap ring.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the return spring.

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

Standard free length:

17.63 mm (0.6941 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 by hand using a 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)

Tighten the 2 bolts evenly and make a clearance of approximately. 20.0 mm (0.797 in.) between the counter drive gear and the inner race.

Using SST, remove the tapered roller bearing inner race.

SST

09950-00020
09950-00030
09950-60010(09951-00590)

Remove the bearing inner race (rear side) and angular ball (rear side).

Using SST, remove the bearing outer race (rear side) from the transaxle case.

SST

09308-00010

Remove the angular ball (front side).

Using SST and a press, remove the bearing outer race (front side) from the transaxle case.

SST

09950-60020(09951-00810)
09950-70010(09951-07200)

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

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

SST

09387-00020

Using a snap ring expander, remove the snap ring.

NOTICE:

1. Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
   
2. Do not expand the snap ring excessively.
   

Remove the return spring.

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 oil seal rings from the transaxle case.

Remove the 2 No. 1 transaxle case plugs.

Remove the O-ring from each No. 1 transaxle case plug.

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

SST

09820-00031
09950-40011(09952-04010,09954-04010,09955-04061,09957-04010)
09950-50013(09951-05010,09953-05020)

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.