Part 1

AUTOMATIC TRANSAXLE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

DISASSEMBLY
1. REMOVE BREATHER PLUG HOSE
2. REMOVE BREATHER PLUG NO.1 (ATM)
(a) Remove the breather plug No. 1 and O-ring from the transaxle case.

3. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the transaxle case No. 1 plug and O-ring from the transaxle case.





4. REMOVE TRANSMISSION CONTROL SHAFT LEVER
(a) Remove the nut, washer and transmission control shaft lever.

5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
(a) Pry off the lock washer and remove the nut.
(b) Remove the 2 bolts and pull out the park / neutral position switch assembly.





6. REMOVE OIL COOLER TUBE UNION
(a) Remove the 2 oil cooler tube unions.
(b) Remove the 2 O-rings from the 2 oil cooler tube unions.





7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
(a) Remove the 18 bolts.
(b) Remove the automatic transaxle oil pan sub-assembly by lifting the transaxle case.

NOTICE: Do not turn the transaxle over as it will contaminate the valve body with the foreign materials from the bottom of the pan.

(c) Remove the automatic transaxle oil pan gasket.
(d) Place the transaxle on wooden blocks to prevent damage to the pipes.

8. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
9. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Place automatic transaxle assembly on wooden blocks.





10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
(a) Remove the 3 bolts and valve body oil strainer assembly and oil strainer gasket.





11. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY
(a) Remove the bolt, manual detent spring sub-assembly and manual detent spring cover.





12. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
(a) Disconnect the solenoid connectors.





(b) Remove the 17 bolts.





(c) Disconnect the manual valve connecting rod from the manual valve lever sub-assembly, then remove the transmission valve body assembly.





13. REMOVE TRANSMISSION WIRE
(a) Remove the bolt.





(b) Remove the transmission wire from the transaxle case.
(c) Remove the O-ring from the transmission wire.





14. REMOVE CHECK BALL BODY
(a) Remove the check ball body and compression spring from the transaxle case.





15. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No. 1 from the transaxle case.





16. REMOVE BRAKE DRUM GASKET
(a) Using needle-nose pliers, pull out the brake drum gasket from the transaxle case.





17. REMOVE B-2 ACCUMULATOR PISTON
(a) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the B-2 accumulator piston into a rag and remove the compression spring.
(b) Remove the 2 O-rings from the B-2 accumulator piston.





18. REMOVE C-2 ACCUMULATOR PISTON
(a) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the C-2 accumulator piston into a rag and remove the compression spring.
(b) Remove the 2 O-rings from the C-2 accumulator piston.





19. REMOVE C-1 ACCUMULATOR PISTON
(a) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the C-1 accumulator piston into a rag and remove the compression spring.
(b) Remove the 2 O-rings from the C-1 accumulator piston.





20. REMOVE C-3 ACCUMULATOR PISTON
(a) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the C-3 accumulator piston into a rag and remove the 2 compression springs.
(b) Remove the 2 O-rings from the C-3 accumulator piston.





21. REMOVE MANUAL VALVE LEVER SHAFT
(a) Using a screwdriver and hammer, unstake the spacer and remove it.





(b) Using a pin punch and hammer, drive out the slotted spring pin.

HINT: Drive out the spring pin slowly so that it will not fall into the transaxle case.





(c) Remove the retainer spring.
(d) Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.





(e) Slide out the manual valve lever shaft and remove the manual valve lever sub-assembly and washer plate.





(f) Using a screwdriver, remove the manual valve lever shaft oil seal.





22. REMOVE TRANSAXLE HOUSING
(a) Remove the 17 bolts and transaxle housing.





23. REMOVE FRONT DIFFERENTIAL ASSEMBLY
(a) Remove the front differential assembly from the transaxle case.

24. REMOVE TRANSMISSION CASE PLATE NO.1
(a) Remove the bolt and transmission case plate No. 1 from the transaxle case.





25. REMOVE GOVERNOR APPLY GASKET NO.2
(a) Remove the governor apply gasket No. 2 from the transaxle case.





26. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 6 bolts and holding the oil pump assembly from the transaxle case.





(b) Pill out the oil pump assembly from the transaxle case.





(c) Using a screwdriver, remove the O-ring from the oil pump assembly.





27. REMOVE TRANSAXLE APPLY TUBE CLAMP NO.3
(a) Remove the bolt and transaxle apply tube clamp No. 3 from the transaxle case.





28. REMOVE GOVERNOR PRESSURE TUBE
(a) Using a screwdriver, remove the governor pressure tube from the transaxle case.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to bend or damage the tube.

29. INSPECT PISTON STROKE OF 2ND COAST BRAKE





30. REMOVE 2ND COAST BRAKE PISTON
(a) Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)





(b) Using low-pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi), pop out the cover into a rag.





(c) Remove the 2nd coast brake cover, 2nd coast brake piston and compression spring.
(d) Remove the 2 O-rings from the 2nd coast brake cover.





31. REMOVE INPUT SHAFT ASSEMBLY
(a) Remove the direct clutch with the forward clutch from the case.





(b) Remove the direct clutch from the forward clutch.





(c) Remove the clutch drum thrust washer and 2 thrust needle roller bearing from the forward clutch.





32. REMOVE 2ND COAST BRAKE BAND ASSEMBLY
(a) Pull out the pin.
(b) Remove the 2nd coast brake band assembly from the transaxle case.

33. INSPECT 2ND COAST BRAKE BAND ASSEMBLY





34. REMOVE FRONT PLANETARY RING GEAR
(a) Remove the front planetary ring gear from the transaxle case.





(b) Remove the thrust needle roller bearing and thrust bearing race from the front planetary ring gear.





35. REMOVE FRONT PLANETARY GEAR ASSEMBLY
(a) Remove the front planetary gear assembly with the thrust needle roller bearing and thrust bearing race from the transaxle case.





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

36. INSPECT FRONT PLANETARY GEAR ASSEMBLY





37. REMOVE SUN GEAR INPUT DRUM ASSEMBLY
(a) Remove the planetary sun gear sub-assembly with the sun gear input drum and planetary thrust washer No. 3 from the transaxle case.





38. REMOVE 1 WAY CLUTCH ASSEMBLY
(a) Remove the 1 way clutch assembly from the transaxle case.

39. INSPECT 1 WAY CLUTCH ASSEMBLY
40. INSPECT 2ND BRAKE PISTON





41. REMOVE 2ND COAST BRAKE BAND GUIDE PLATE
(a) Remove the bolt and brake band guide plate retainer and 2nd coast brake band guide plate from the transaxle case.





42. REMOVE SECOND BRAKE PISTON ASSEMBLY
(a) Using a screwdriver, remove the snap ring from the transaxle case.

HINT: Tape the screwdriver tip before use.





(b) Remove the 2nd brake piston assembly from the transaxle case.

HINT: If the brake drum is difficult to remove, lightly tap it with a wooden block.





43. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
(a) Remove the 2nd brake piston return spring sub-assembly from the transaxle case.





44. REMOVE 2ND BRAKE CLUTCH DISC
(a) Remove the 3 plates, 3 2nd brake clutch discs and flange from the transaxle case.

45. INSPECT 2ND BRAKE CLUTCH DISC





46. REMOVE REAR PLANETARY GEAR ASSEMBLY
(a) Using 2 screwdrivers, remove the snap ring from the transaxle case.

HINT: Tape the screwdriver tip before use.





(b) Remove the 1 way clutch No. 2 assembly and rear planetary gear assembly with the 2 planetary carrier thrust washer No. 2s from the transaxle case.





(c) Remove the 2 planetary carrier thrust washer No. 2s from the rear planetary gear assembly.
(d) Remove the 1 way clutch No. 2 assembly from the rear planetary gear assembly.





(e) Remove the thrust needle roller bearing and thrust bearing race from the transaxle case.

47. INSPECT REAR PLANETARY GEAR ASSEMBLY
48. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE





49. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the transaxle case.

HINT: Tape the screwdriver tip before use.





(b) Remove the flange, 6 plates and 6 1st & reverse brake clutch discs from the transaxle case.

50. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC





51. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
(a) Using SST and a press, in the return spring until the snap ring is free from the return spring.
SST 09350-32014 (09351-32040)





(b) Using snap ring pliers, remove the snap ring.
(c) Remove the 1st & reverse brake return spring sub-assembly from the transaxle case.