Automatic Transaxle Unit Disassembly

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

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

Remove the nut and washer and remove the control shaft lever.

Using a screwdriver, pry out the lock plate and remove the manual valve shaft nut.

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

Remove the bolt and speed sensor from the transaxle case.

Remove the 2 oil cooler tube unions from the transaxle case.

Remove the O-ring from oil cooler tube union.

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

Remove the No. 1 transaxle case plug from the transaxle case.

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

Remove the breather plug hose from the breather plug.

Remove the breather plug from the transaxle case.

Secure the transaxle onto wooden blocks.

Remove the 19 bolts and remove the oil pan and oil pan gasket.

Remove the 2 oil cleaner magnets from the oil pan.

Examine the particles in the oil pan.

1. Collect any steel chips with the removed magnets.
   Carefully look at the foreign matter and particles in the oil pan and on the magnets to predict the type of wear which might be found in the transaxle.
   Steel (magnetic): bearing, gear and clutch plate wear
   Brass (non-magnetic): bearing wear
   

Remove the 3 bolts and remove the oil strainer assembly.

Remove the oil strainer gasket from the oil strainer assembly.

Disconnect the 5 solenoid connectors.

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

Remove the 2 bolts and remove the detent spring cover and detent spring.

Remove the 13 bolts and the valve body assembly from the transaxle case.

Remove the bolt and the transmission wire from the transaxle case.

Remove the O-ring from the transmission wire.

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

Remove the transaxle case 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.

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

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Remove the 2 O-rings from the B-2 accumulator piston.

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

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Remove the 2 O-rings 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-2 accumulator piston and the spring.

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Remove the 2 O-rings from the C-2 accumulator piston.

Remove the 14 bolts.

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

NOTICE:

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

Measure the end play in the axial direction.

End play:

0.38 to 1.29 mm (0.0149 to 0.0507 in.)

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

Remove the differential gear assembly from the transaxle case.

Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.

Remove the input shaft assembly from the transaxle case.

Remove the stator shaft thrust needle roller bearing from the input shaft.

Using a screwdriver, remove the snap ring.

Remove the flange, 4 discs and 4 plates from the input shaft.

Using SST on the clutch balancer, compress the return spring with a press.

SST

09320-89010

NOTICE:

Do not compress the return spring excessively.

Using a snap ring expander, remove the snap ring.

Remove the clutch balancer and piston return spring.

Place the input shaft 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 cannot be removed because it is tilted, either apply compressed air again while keeping the piston level or remove the piston using needle-nose pliers with their tips wrapped in protective tape.

Using a screwdriver, remove the clutch piston O-ring from the forward clutch piston.

Using a screwdriver, remove the input shaft oil seal ring from the input shaft.

Remove the forward clutch hub thrust needle roller bearing from the forward clutch hub.

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

End play:

0.21 to 0.96 mm (0.00826 to 0.0377 in.)

Remove the forward clutch hub from the transaxle case.

Remove the 11 bolts.

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

Remove the 4 rear transaxle cover plugs from the rear transaxle cover.

Using a screwdriver, remove the O-ring from each rear transaxle cover plug.

Using SST, a press and a screwdriver, remove the snap ring.

SST

09387-00070

NOTICE:

Stop the press when the overdrive brake piston is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove to prevent the overdrive brake piston from being deformed.

Remove the overdrive brake return spring from the rear transaxle cover.

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

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Using a screwdriver, remove the 2 O-rings from the 2nd coast and overdrive brake piston.

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

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

SST

09387-00041(09387-01021)

Remove the 4 transaxle case gaskets.

Using a magnetic pick-up tool, remove the rear clutch drum thrust needle roller bearing.

Remove the intermediate shaft assembly from the transaxle case.

Using a screwdriver, remove the snap ring.

Remove the flange, 3 discs and 3 plates.

Using a screwdriver, remove the snap ring.

Remove the direct clutch flange, 3 discs and 3 rear clutch flanges.

Using SST and a press.

SST

09387-00020

Using snap ring pliers, remove the snap ring.

Remove the direct clutch return spring sub-assembly from the intermediate shaft.

Install the intermediate shaft onto the rear transaxle cover.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole shown in the illustration and remove the direct clutch piston from the intermediate shaft.

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Install the intermediate shaft onto the rear transaxle cover.

Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the oil hole shown in the illustration and remove the direct clutch drum from the intermediate shaft.

NOTICE:

1. Blowing air may cause the drum to jump out. When removing the drum, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

Using a screwdriver, remove the 2 piston O-rings from the direct clutch piston.

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

Remove the flange, 2 discs and 2 No. 2 flanges from the transaxle.

Using a magnetic pick-up tool, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the No. 3 thrust bearing race from the direct clutch hub.

Remove the direct clutch hub from the transaxle case.

Using a magnetic pick-up tool, remove the rear No. 2 planetary sun gear thrust needle roller bearing from the rear planetary sun gear assembly.

Remove the rear planetary sun gear from the transaxle case.

Remove the rear planetary sun gear thrust needle roller bearing and No. 1 planetary carrier thrust washer from the one-way clutch assembly.

Hold the rear planetary sun gear and turn the one-way clutch.

Make sure that the one-way clutch turns freely counterclockwise and locks when turned clockwise.

Remove the one-way clutch assembly and No. 2 planetary carrier thrust washer from the rear planetary sun gear.

Using a screwdriver, remove the 2 snap rings.

Remove the 2 flanges, 4 discs and 3 flanges from the transaxle.

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

Turn the rear planetary gear assembly.

Make sure that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.

Using a screwdriver, remove the snap ring.

Remove the rear planetary gear assembly from the transaxle case.

Remove the thrust needle roller bearing and 2 bearing races from the rear planetary gear assembly.

Separate the 2nd brake assembly, No. 2 one-way clutch and the rear planetary gear.

Remove the retainer from the No. 2 one-way clutch.

Using SST and a press, remove the snap ring from the 2nd brake piston.

SST

09387-00060

Remove the 2nd brake return spring from the 2nd brake cylinder.

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

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.

Using a screwdriver, remove the 2 O-rings from the 2nd brake cylinder.

Remove the front planetary sun gear and thrust needle roller bearing from the transaxle case.

Using a screwdriver, remove the snap ring.

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

Secure the counter driven gear with the parking lock pawl.

Using SST and a hammer, release the lock nut washer.

SST

09930-00010

Using SST, remove the nut and lock nut washer.

SST

09387-00121

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

SST

09950-60010(09951-00400,09951-00320,09952-06010)
09950-70010(09951-07100)

Install the 2 bolts to the counter drive gear.

Bolt (M6):

Length = 40 to 80 mm (1.57 to 3.15 in.)

Pitch = 1.0 mm (0.0394 in.)

Rotate the 2 bolts and remove the counter drive gear and front planetary sun gear.

Remove the 2 radial ball bearings from the counter drive gear and front planetary sun gear.

Using SST, a press and a screwdriver, remove the snap ring.

SST

09387-00070

Remove the 1st and reverse brake return spring sub-assembly.

Apply compressed air (392 kPa, 4.0 kgf/cm², 57 psi) to the transaxle case to remove the No. 2 1st and reverse brake piston.

NOTICE:

1. Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   
2. Do not splash ATF with compressed air.
   

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

Remove the 3 bolts, cam guide and bracket from the transaxle case.

Remove the manual valve lever shaft retainer spring from the manual valve lever shaft.

Using a screwdriver, release and remove the spacer.

Using a pin punch and hammer, drive out the manual valve lever shaft spring pin.

Remove the manual valve lever shaft and manual valve lever.

Remove the parking lock rod from the manual valve lever.

Remove the manual valve lever shaft from the transaxle case.

Using a screwdriver, remove the parking lock pawl shaft from the transaxle case.

Remove the parking lock pawl torsion spring and parking lock pawl from the transaxle case.

Remove the counter driven gear, drive pinion and drive pinion thrust bearing LH from the transaxle case.

Using a brass bar and a hammer, remove the differential drive pinion plug.

Using SST and a press, remove the differential drive pinion from the counter driven gear.

SST

09950-60010(09951-00350)
09950-70010(09951-07150)

Remove the bolt and the bearing lock plate.

Remove the differential gear lube apply tube from the transaxle housing.

Using SST, remove the front drive pinion front tapered roller bearing from the transaxle housing.

SST

09308-10010

Using SST, remove the front drive pinion rear tapered roller bearing from the transaxle case.

SST

09612-65014(09612-01040)

Remove the No. 1 transaxle case plate from the transaxle case.

Remove the counter drive gear bearing inner race LH and angular ball from the transaxle case.

Using SST, remove the counter drive gear bearing outer race LH from the transaxle case.

SST

09308-00010

Remove the counter drive gear bearing RH from the transaxle case.

Using SST, remove the counter drive gear bearing outer race RH from the transaxle case.

SST

09308-00010

Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.

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

Using SST and a hammer, remove the No. 2 transaxle case oil seal from the transaxle case.

SST

09950-60010(09951-00550)
09950-70010(09951-07100)

Using SST and a hammer, remove the No. 1 transaxle case oil seal from the transaxle housing.

SST

09950-60010(09951-00530)
09950-70010(09951-07100)