Disassembly

DISASSEMBLY

CAUTION:
Because the automatic transaxle is composed of precision parts, it should be handled very carefully during disassembly and assembly so as not to break 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 solvents, but must be thoroughly air dried. Clean the clutch disc, resin thrust plate and rubber parts by using ATE (automatic transaxle fluid), being careful that dust, dirt, etc. does not adhere. If the transaxle unit is damaged, also clean and flush the transaxle oil cooler.

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





4. Measuring the 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 the reaction shaft support and rear clutch retainer, and between reaction shaft support and front clutch retainer.
Mount a dial indicator to the converter housing with the Dial Indicator Support. Make sure that the indicator plunger is seated against the end of the input shaft.
When checking end play, pull or push on the input shaft with pliers. Be careful not to scratch the input shaft. Record the reading for reference when reassembling the transaxle.





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





6. Remove the manual control lever, then remove the inhibitor switch.





7. Remove the snap ring, then remove the kickdown servo switch.





8. Remove the oil pan and gasket.





9. Remove the oil filter from the valve body.





10. Remove valve body and oil temperature sensor.





11. Press the tabs of the solenoid valve harness grommet, and then push it into the case and remove.





12. Remove the parking sprag rod support.





13. Remove the set screw and the manual control shaft assembly.

Tightening torque:
Detent spring assembly mounting bolt 10 - 12 Nm (100 - 120 kgf.cm, 7.4 - 8.9 ft. lbs.)





14. Remove the detent spring assembly.





15. Remove the differential cover with O-ring





16. Remove the differential bearing cap.





17. Remove the differential bearing retainer, spacer, and outer race.





18. Remove the differential assembly.





19. Remove the end clutch cover mounting bolt, the cover holder and the end clutch cover.





20. Remove the end clutch assembly.





21. Remove the thrust plate.





22. Remove the end clutch hub.
23. Remove the thrust bearing.

NOTE: The thrust bearing may be stuck to the end clutch hub.





24. Pull out the end clutch shaft.





25. Remove the 6 idler gear cover bolts and remove the idler gear cover with gasket.





26. Replace the idler shaft rocker plate, then remove the idler shaft bolt.





27. Remove the idler shaft.
28. Remove the idler gear and the bearing inner race.





29. Remove the spacer.





30. Remove the 6 oil pump assembly bolts and remove the assembly with special tool (09452-21100). Screw special tool 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.





31. Remove the fiber thrust washer and thrust race.





32. Pull the input shaft, and then remove the front and rear clutch together.





33. Remove the thrust bearing.





34. Remove the clutch hub.





35. Remove the thrust race and bearing.





36. Remove the kickdown drum.





37. Remove the kickdown band.





38. Using the special tools (09222-28000, 09222-28100, 09456-1100), push in the kickdown servo and remove the snap ring.





39. Remove the kickdown servo piston and spring.





40. Remove the anchor rod.





41. Remove the air exhaust plug.





42. Remove the snap ring.





43. Attach special tool (09453-21310) to the center support. Holding the handle of the tool, pull the center support straight upward.





44. Remove the reverse sun gear and forward sun gear together.





45. Remove the planetary carrier assembly with thrust bearing.





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





47. Since thread locking component is applied to the bolt threads, tap the bolt head for easier removal.





48. Using an impact driver, loosen the bolt.





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





49. Remove the snap ring from the bearing.





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





51. Remove the transfer shaft cover.





52. Remove the transfer shaft.





53. Remove the bearing outer race.