Part 2

AUTOMATIC TRANSAXLE UNIT

DISASSEMBLY (Continued)





47. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle roller bearing from the transaxle rear cover.
SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)





48. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Using a screwdriver, remove the 3 apply gaskets.





49. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.





50. REMOVE DIRECT CLUTCH ASSEMBLY
(a) Remove the thrust bearing and the direct clutch assembly from the transaxle case.

51. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
52. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH





53. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the intermediate shaft.





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

54. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC





55. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the intermediate shaft.
(b) Remove the flange, 3 discs and 3 plates from the intermediate shaft.

56. INSPECT OVERDRIVE DIRECT CLUTCH DISC





57. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY
(a) Place SST on the clutch balancer and compress the spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring from the direct clutch drum.

NOTICE:
^ Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 inch) from the snap ring groove. This prevents the spring seat from being deformed.
^ Do not expand the snap ring excessively.





(c) Remove the clutch balancer from the overdrive direct clutch drum.





(d) Remove the overdrive clutch return spring from the overdrive direct clutch drum.

58. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUBASSEMBLY





59. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install the intermediate shaft on the transaxle rear cover.
(b) 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.





60. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY
(a) 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.





61. REMOVE OVERDRIVE DIRECT CLUTCH O-RING
(a) Using a screwdriver, remove the O-ring from the direct clutch drum.





62. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUBASSEMBLY
(a) Remove the thrust bearing race, thrust bearing, and overdrive direct clutch hub from the planetary gear assembly.





63. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Remove the rear planetary sun gear assembly from the transaxle case.





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





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





64. REMOVE ONE-WAY CLUTCH ASSEMBLY
(a) Remove the one-way clutch assembly and the thrust needle roller bearing from the transaxle case.





(b) Remove the one-way clutch inner race from the one-way clutch assembly.





65. REMOVE ONE-WAY CLUTCH SLEEVE
(a) Remove the one-way clutch sleeve from the transaxle case.





66. REMOVE NO. 1 PLANETARY CARRIER THRUST WASHER
(a) Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly.





67. REMOVE 2ND BRAKE DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 3 discs and 3 plates from the transaxle case.

68. INSPECT 2ND BRAKE DISC





69. REMOVE SECOND BRAKE PISTON ASSEMBLY
(a) Using a screwdriver, remove the snap ring.





(b) Remove the second brake piston assembly from the transaxle case.





70. REMOVE 2ND BRAKE PISTON RETURN SPRING SUBASSEMBLY
(a) Place SST on the return spring and compress it with a press.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.





(c) Remove the 2nd brake piston return spring subassembly.

71. INSPECT 2ND BRAKE PISTON RETURN SPRING SUBASSEMBLY





72. REMOVE 2ND BRAKE PISTON
(a) 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.





73. REMOVE 2ND BRAKE PISTON O-RING
(a) Remove the 2 O-rings from the 2nd brake piston.





74. REMOVE REAR PLANETARY GEAR ASSEMBLY
(a) Using a screwdriver, remove the snap ring.





(b) Remove the rear planetary gear assembly from the transaxle case.





75. REMOVE INPUT SUN GEAR
(a) 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.





76. REMOVE 1ST AND REVERSE BRAKE DISC
(a) Remove the flange, 5 discs and 5 plates from the transaxle case.

77. INSPECT 1ST AND REVERSE BRAKE DISC





78. REMOVE FRONT PLANETARY GEAR ASSEMBLY
(a) Using a chisel and hammer, unstake the lock washer.

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





(b) Using SST, remove the nut and washer.
SST 09387-00030, 09387-00080





(c) 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)





(d) Remove the front planetary gear assembly from the brake hub.





79. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.





80. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUBASSEMBLY
(a) Place SST on the return spring, and compress the return spring with a press.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.

NOTICE:
^ Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 inch) from the snap ring groove to prevent the spring seat from being deformed.
^ Do not expand the snap ring excessively.

(c) Remove the return spring.

81. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUBASSEMBLY





82. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the 1st and reverse brake piston.

NOTICE:
^ Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth.
^ Take care not to splash ATF when applying the air.





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





83. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)





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





(c) Using SST, remove the tapered roller bearing inner race.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00590)





84. REMOVE COUNTER DRIVE ANGULAR BALL BEARING
(a) Remove the bearing inner race (rear side) and angular ball (rear side).





(b) Using SST, remove the bearing outer race (rear side) from the transaxle case.
SST 09308-00010





(c) Remove the angular ball (front side).





(d) 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)





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





85. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUBASSEMBLY
(a) Place SST on the return spring, and compress the return spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.

NOTICE:
^ Stop the press when the spring seat is lowered to the place 1 to 2 mm (0.039 to 0.078 inch) from the snap ring groove to prevent the spring seat from being deformed.
^ Do not expand the snap ring excessively.

(c) Remove the return spring.

86. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUBASSEMBLY





87. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the underdrive brake piston.





(b) Remove the 2 O-rings from the underdrive brake piston.





88. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle roller bearing from the transaxle case.
SST 09387-00041 (09387-01010, 09387-01030, 09387-01040)





89. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 oil seal rings from the transaxle case.





90. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 No. 1 transaxle case plugs.
(b) Remove the 2 O-rings from the 2 No. 1 transaxle case plugs.





91. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) 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)





92. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
(a) Remove the oil seal ring from the transaxle housing.





93. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.