Disassembly

TRANSAXLE DISASSEMBLY

CAUTION:
Because the automatic transaxle is composed of component parts of an especially high degree of precision, these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them. A rubber mat should be placed on the workbench, and it should always be kept clean. During disassembly, cloth gloves or rags should not be used. If such items must be used, use articles made of nylon, or use paper towels. All disassembled parts must be thoroughly cleaned. Metal parts may be cleaned with ordinary detergents, but must be thoroughly air dried. Clean the clutch disc, resin thrust plate and rubber parts by using ATF (automatic transaxle fluid), being very careful that dust, dirt, etc. do not adhere. If the transaxle main unit is damaged, also disassemble and clean the cooler system.

1. Clean away any sand, mud, etc. adhered around the transaxle.
2. Place the transaxle assembly on the workbench with the oil pan down.
3. Remove the torque converter.





4. Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required (except when major parts are replaced). Thrust washers are located between reaction shaft support and rear clutch retainer, and between reaction shaft support and rear clutch retainer. Mount a dial indicator to converter housing with the Dial indicator Support. Make sure that the indicator plunger is seated against end of input shaft. When checking end play, pull out or push in the input shaft with pliers. Record indicator reading for reference when reassembling the transaxle.





5. Remove the pulse generators "A" and "B".





6. Remove manual control lever, then remove transaxle range switch.





7. Remove the snap ring and kickdown servo switch.





8. Remove the oil pan and gasket.





9. Remove the oil filter from the valve body.





10. Remove the oil-temperature sensor installation bolt; then, after removal from the bracket, pull out from the connector side.





11. Press the tab of the solenoid valve harness grommet, and then push into the case.





12. Remove the bolts, and then remove the valve body.





13. Remove the end clutch cover mounting bolt, the cover holder, and the end clutch over.





14. Remove the end clutch assembly.





15. Remove the thrust plate.





16. Remove the end clutch hub and thrust bearing.





17. Pull out the end clutch shaft.





18. Remove the 14 bolts and remove converter housing.





19. Remove 6 oil pump mounting bolts. Screw special tool (09452-33100) into two oil pump removing holes in oil pump housing. Turn both removers simultaneously and uniformly to remove oil pump assembly. Oil pump may sometimes tilt to A side, because straight line connecting oil pump removing holes does not pass center of pump. If this is the case, tap oil pump lightly on B side or tilt removers to B side as pump is removed.

20. Remove the oil pump gasket and adapter.





21. Remove the spacer and the differential assembly.





22. Remove the fiber thrust washer.





23. Pull up the input shaft, and then remove the front clutch assembly and the rear clutch assembly together.





24. Remove the thrust bearing.





25. Remove the clutch hub.





26. Remove the thrust race and bearing.





27. Remove the kickdown drum.





28. Remove the kickdown band.





29. Using special tools (09222-28000, 09222-28100, 09456-21100), push in the kickdown servo and remove the snap ring.





30. Remove the kickdown servo piston and spring.





31. Remove the anchor rod.





32. Remove the snap ring.





33. Attach special tool (09453-21310) on center support. Holding handle of tool, pull center support straight upward.





34. Remove reverse sun gear and forward sun gear together.





35. Remover planet carrier assembly and thrust bearing.





36. Remove the wave spring, return spring, pressure plate, brake disc, brake plate, and brake reaction plate.





37. Since screw lock paste is coated on the bolt threads, tap the bolt head for easier removal.





38. Using an impact driver, loosen the bolt.





39. If an impact driver is not available, use a punch or something similar.





40. Remove the idler shaft lock plate.





41. Loosen transfer idler shaft with special tool. (09454-21100)





42. Pull out transfer idler shaft. Remove transfer idle gear bearing inner races (2 pieces) from inside of case.





43. Remove the spacer.





44. Remove snap ring from bearing.





45. Remove internal gear, output flange, transfer drive gear and bearing as an assembly from case.





46. Remove the transfer shaft cover.





47. Remove the transfer shaft cover.





48. Fix the transfer shaft converter housing side.





49. Remove the locking nut.

NOTE: The lock nut is left-hand threaded.





50. Knock off the transfer shaft to the converter housing side.





51. Using the special tool (09432-33200), pull the bearing from the transfer shaft.





52. Using the special tools (09432-33800, 09433-21000), pull the bearing from the transfer driven gear.





53. Using the special tool (09517-21400), remove the transfer shaft bearing outer race.





54. Remove two bolts of the sprag rod support and the bolt of the detent spring assembly.





55. Remove the set screw and the manual control shaft assembly. Remove the sprag rod and the detent spring assembly.