Part 1

DISASSEMBLY





1. REMOVE TRANSAXLE REVOLUTION SENSOR AND BREATHER PLUG
a. Remove the bolt and transaxle revolution sensor.
b. Remove the O-ring from the transaxle revolution sensor.
c. Remove the clip and breather hose.
d. Remove the breather plug and O-ring.





2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Remove the nut, washer and control lever.
b. Using a screwdriver, unstake the lock nut.
c. Remove the 2 bolts and nut, and pull out the park/neutral position switch.





3. REMOVE ELBOW AND UNION
a. Remove the elbow and union.
b. remove the 2 O-rings from the elbow and union.
4. REMOVE SCREW PLUG





a. Remove the 4 screw plugs from the transaxle housing and transaxle case.
b. Remove the 4 O-rings from the 4 screw plugs.





c. Remove the screw plug and O-ring.





5. PLACE TRANSAXLE ON WOODEN BLOCKS





6. REMOVE OIL PAN AND GASKET
a. Remove the drain plug and gasket from the oil pan.
b. Remove the 19 bolts, oil pan and gasket.





7. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips.
Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the trans axle.
Steel (magnetic) ... bearing, gear and plate wear
Brass (non-magnetic) ... bushing wear
8. REMOVE OIL STRAINER





a. Remove the 3 bolts and oil strainer.





b. Remove the O-ring from the oil strainer.
9. REMOVE VALVE BODY ASSEMBLY





a. Remove the bolt, lock plate and ATF temperature sensor.
b. Remove the O-ring from the ATF temperature sensor.
c. Disconnect the 5 solenoid connectors.





d. Remove the 2 bolts, detent spring cover and detent spring.
e. Support the valve body assembly and remove the 13 bolts and valve body assembly.
10. REMOVE TRANSAXLE WIRE





a. Remove the bolt.
b. Remove the transaxle wire from the transaxle case.





c. Remove the O-ring from the transaxle wire.





11. REMOVE 2 APPLY GASKETS





12. REMOVE BRAKE DRUM GASKET





13. REMOVE CHECK VALVE
a. Remove the check valve and spring.
14. REMOVE ACCUMULATOR PISTON AND SPRING





a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C2 accumulator piston and spring.
b. Remove the spring.

NOTICE:
- Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth.
- Take care not to splash ATF when air-blowing.





c. Remove the 2 O-rings from the C2 accumulator piston.





d. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C3 accumulator piston and spring.
e. Remove the spring.

NOTICE:
- Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth.
- Take care not to splash ATF when air-blowing.





f. Remove the 2 O-rings from the C3 accumulator piston.





g. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the 132 accumulator piston and spring.
h. Remove the spring.

NOTICE:
- Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth.
- Take care not to splash ATF when air-blowing.





i. Remove the 2 O-rings from the B2 accumulator piston.





15. REMOVE TRANSAXLE HOUSING
a. Remove the 14 bolts.
b. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.

NOTICE: Differential gear assembly may be accidentally removed when the transaxle housing is removed.





16. REMOVE OIL PUMP
Remove the 7 bolts and oil pump.





17. REMOVE DIFFERENTIAL GEAR ASSEMBLY





18. REMOVE 2 APPLY GASKETS
19. REMOVE FORWARD MULTIPLE DISC CLUTCH ASSEMBLY





a. Remove the forward multiple disc clutch assembly from the transaxle case.





b. Remove the thrust needle roller bearing from the forward multiple disc clutch assembly.





20. REMOVE FORWARD CLUTCH HUB
Remove the forward clutch hub and thrust needle roller bearing from the transaxle case.
21. REMOVE COUNTER DRIVE GEAR





a. Fix the counter driven gear with the parking lock pawl.





b. Using a screwdriver and hammer, unstake the lock washer.





c. Using SST, remove the nut.
SST 09387-00030,09387-00080





d. Install the 2 bolts to the counter drive gear.
Bolt (M6):
L = 40 - 80 mm
Pitch = 1.0 mm
e. Rotate 2 bolts in order and remove the counter drive gear and front planetary sun gear.
f. Remove 2 radial ball bearings from the counter drive gear and front planetary sun gear.
22. REMOVE MANUAL VALVE LEVER SHAFT





a. Remove the 3 bolts, cam guide and bracket.





b. Remove the retainer spring.





c. Using a chisel and hammer, unstake and remove the spacer.





d. Using a pin punch and hammer, drive out the pin.
e. Remove the manual valve lever shaft and manual valve lever.





f. Using a screwdriver, remove the oil seal.