Part 1 of 2
DISASSEMBLY1. REMOVE NEUTRAL START SWITCH
a. Remove the nut, washer and control shaft lever.
b. Using a screwdriver, unstake the lock washer.
c. Remove the nut.
d. Remove the 2 bolts, and pull out the neutral start switch.
2. REMOVE UNION AND ELBOW
a. Remove the union and elbow.
b. Remove the 2 O-rings from the union and elbow.
3. REMOVE TRANSAXLE CASE PLUG NO. 1
a. Remove the transaxle case plug No. 1 from the transaxle case.
b. Remove the O-ring from the transaxle case plug No. 1.
4. REMOVE SPEED SENSOR
a. Remove the 2 bolts and 2 speed sensors from the transaxle.
b. Remove the 2 O-rings from the sensors.
5. REMOVE SOLENOID WIRE RETAINING BOLT
NOTICE: Remove the bolt only and do not remove the solenoid wire.
6. PLACE TRANSAXLE ON WOODEN BLOCKS
NOTICE: Be careful not to damage the oil seal.
7. REMOVE OIL PAN AND GASKET
a. Remove the 18 bolts.
b. Remove the oil pan and gasket.
8. EXAMINE PARTICLES IN 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:
Steel (magnetic) bearing, gear and plate wear
Brass (non-magnetic) bushing wear
9. REMOVE TRANSAXLE SOLENOID WIRE
a. Remove the 5 connectors from the shift solenoid valves.
b. Remove the bolt, lock plate and ATF temperature sensor.
c. Remove the transaxle solenoid wire from the transaxle case.
d. Remove the O-ring from the transaxle solenoid wire.
10. REMOVE OIL STRAINER
a. Remove the 3 bolts and oil strainer.
b. Remove the O-ring from the oil strainer.
11. REMOVE VALVE BODY ASSEMBLY Support the valve body assembly and remove the bolts and the valve body assembly.
12. REMOVE 3 APPLY GASKETS
13. REMOVE CHECK VALVE
Remove the check valve and spring.
14. REMOVE ACCUMULATOR SPRING AND PISTON
a. Remove the spring from the C3 accumulator piston.
b. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) into the oil hole and remove the C3 accumulator piston.
NOTICE:
^ Blowing off the air may cause the piston's jumping out. When removing the piston, hold it by hand with a waste cloth.
^ Take care not to splash ATF when air-blowing.
c. Remove the O-ring from the piston.
d. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) into the oil hole and remove the C1 accumulator piston and spring.
NOTICE:
^ Blowing off the air may cause the piston's jumping out. When removing the piston, hold it by hand with a waste cloth.
^ Take care not to splash ATF when air-blowing.
e. Remove the 2 O-rings from the piston.
f. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) into the oil hole and remove the 133 accumulator piston and 2 springs.
NOTICE:
^ Blowing off the air may cause the piston's jumping out. When removing the piston, hold it by hand with a waste cloth.
^ Take care not to splash ATF when air-blowing.
g. Remove the O-ring from the piston.
15. REMOVE MANUAL VALVE LEVER SHAFT
a. Using needle-nose pliers, remove the retainer spring.
b. Remove the 2 bolts and manual detent spring and cover.
c. Remove the 2 bolts and parking lock pawl bracket.
d. Using a chisel and a hammer, expand the spacer and move it to the place where the pin can be seen by turning the spacer.
e. Using a pin punch and a hammer, drive out the pin.
HINT: Slowly drive out the pin so that it will not fall into the transaxle case.
f. Remove the manual valve lever shaft and manual valve lever.
g. Remove the parking lock rod from the manual valve lever shaft.
h. Using a screwdriver, remove the oil seal from the transaxle case.
NOTICE: Take care not to damage the press-fit surface of the oil seal of the transaxle case.
16. PLACE TRANSAXLE CASE
Fix the transaxle case with the oil pump side facing up.
17. INSPECT INPUT SHAFT END PLAY
Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.01031 - 0.0491 inch)
18. REMOVE TRANSAXLE HOUSING
a. Remove the 16 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 may be accidentally removed when the transaxle housing is removed.
19. REMOVE OIL PUMP
a. Remove the 7 bolts and oil pump.
b. Remove the O-ring from the oil pump.
20. REMOVE THRUST BEARING AND THRUST BEARING RACE NO. 2
21. REMOVE DIFFERENTIAL ASSEMBLY
22. REMOVE 2 APPLY GASKETS
23. REMOVE FORWARD CLUTCH
a. Remove the forward clutch from the transaxle case.
b. Remove the thrust bearing from the forward clutch.
c. Remove the multiple clutch hub, 2 thrust bearings and bearing race from the transaxle case.
24. REMOVE U/D PLANETARY GEAR ASSEMBLY
a. Remove the bolt and pawl shaft clamp.
b. Remove the parking lock pawl shaft.
c. Push the parking lock pawl.
HINT: When the U/D planetary gear is removed, interference will be caused. And so push the parking lock pawl aside temporarily.
d. Remove the U/D planetary gear assembly from the transaxle case.
NOTICE: Care should be taken not to drop the U/D planetary gear assembly.
e. Remove the spring, pawl pin and parking lock pawl.