Part 1

U660E AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE NO. 2 BREATHER PLUG

(a) Using a screwdriver, remove the breather plug hose from the transaxle case.

(b) Using a screwdriver, remove the breather plug from the breather plug hose.
(c) Using a screwdriver, remove the O-ring from the breather plug.
(d) Using a screwdriver, remove the breather plug cap from the breather breather plug hose.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Remove the nut, washer, and control shaft lever from the control shaft.

(b) Remove the 2 bolts and the park/neutral position switch assembly from the transaxle case.
NOTE:
Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly.

3. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION)

(a) Loosen the nut while holding the oil cooler tube union (inlet oil cooler union).
(b) Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case.
(c) Remove the O-ring from the oil cooler tube union (inlet oil cooler union).
4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Loosen the nut while holding the oil cooler tube union (outlet oil cooler union).
(b) Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case.
(c) Remove the O-ring from the oil cooler tube union (outlet oil cooler union).
5. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 3 No. 1 transaxle case plugs from the transaxle case.
(b) Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs.

(c) Using a hexagon wrench (6 mm), remove the 3 hexagon bolts from the transaxle housing.
(d) Remove the 3 gaskets from the 3 hexagon bolts.
6. FIX AUTOMATIC TRANSAXLE ASSEMBLY

(a) Secure the transaxle assembly on wooden blocks.
7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Using a hexagon wrench (6 mm), remove the overflow plug from the automatic transaxle oil pan sub-assembly.
(b) Remove the gasket from the overflow plug.

(d) Remove the 18 bolts, automatic transaxle oil pan sub-assembly, and gasket from the automatic transaxle assembly.

(e) Remove the 2 magnets from the automatic transaxle oil pan sub-assembly.
8. INSPECT TRANSMISSION OIL CLEANER MAGNET Transaxle Unit
9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Remove the 2 bolts and oil strainer assembly from the valve body assembly.

(b) Remove the O-ring from the oil strainer assembly.
10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Remove the 11 bolts and valve body assembly from the transaxle case.
NOTE:
When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere each other.

11. REMOVE TRANSAXLE CASE GASKET

(a) Remove the 2 gaskets from the transaxle case.
12. INSPECT INPUT SHAFT SUB-ASSEMBLY Transaxle Unit
13. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY

(a) Remove the refill plug from the transaxle rear cover.
(b) Remove the gasket from the refill plug.

(c) Remove the 2 No. 1 automatic transaxle case plugs from the transaxle rear cover.
(d) Using a screwdriver, remove the 2 O-rings from the 2 No. 1 automatic transaxle case plugs.

(e) Remove the 14 bolts from the transaxle rear cover.
(f) Using a brass bar and hammer, tap on the circumference of the rear transaxle cover, to remove the transaxle rear cover from the transaxle case.

(g) Using a screwdriver, remove the 3 O-rings from the transaxle case.

(h) Using a screwdriver, remove the 2 oil seal rings from the transaxle rear cover.
(i) Remove the thrust needle roller bearing and thrust needle roller race from the transaxle rear cover.

(j) Using a "TORX" wrench (T30), remove the 2 "TORX" screws and transaxle rear cover plate from the transaxle rear cover.

(k) Using SST, remove the needle roller bearing from the transaxle rear cover.
SST: 09319-60020
14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

(a) Remove the direct multiple disc clutch assembly from the transaxle case.
(b) Remove the thrust needle roller bearing from the direct multiple disc clutch assembly.
15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING

(a) Using 2 screwdrivers, remove the snap ring from the direct multiple disc clutch assembly.

(b) Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly.

(c) Using a screwdriver, remove the intermediate shaft oil seal ring from the direct No. 2 direct clutch piston.
(d) Using a screwdriver, remove the O-ring from the direct multiple disc clutch assembly.
16. REMOVE NO. 2 DIRECT MULTIPLE DISC CLUTCH FLANGE

(a) Remove the flange, 3 clutch discs and 3 clutch plates from the direct multiple disc clutch assembly.
17. INSPECT NO. 2 CLUTCH DISC Transaxle Unit
18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

(a) Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly.

(b) Remove the rear planetary sun gear from the direct multiple disc clutch assembly.

(c) Remove the thrust needle roller bearing and thrust needle roller race from the direct multiple disc clutch assembly.
19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY Transaxle Unit
20. REMOVE NO. 1 DIRECT MULTIPLE DISC CLUTCH FLANGE

(a) Using 2 screwdrivers, remove the 2 snap rings from the direct multiple disc clutch assembly.

(b) Remove the flange, 4 clutch discs, and 4 clutch plates from the direct multiple disc clutch assembly.
21. INSPECT NO. 1 CLUTCH DISC Transaxle Unit
22. REMOVE TRANSAXLE HOUSING

(a) Remove the 20 bolts from the transaxle housing.
(b) Using a brass bar and hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case.
23. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing.
SST: 09308-00010
24. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Remove the bolt, clamp, and differential gear lube apply tube from the transaxle housing.
25. REMOVE FRONT OIL PUMP AND GEAR BODY SUB-ASSEMBLY

(a) Remove the 7 bolts and oil pump from the transaxle case.
(b) Remove the O-ring from the oil pump assembly.

(c) Remove the thrust needle roller bearing and thrust needle roller race from the carrier lock nut.
(d) Remove the O-ring from the transaxle case.
26. REMOVE NO. 3 BRAKE DISC

(a) Using a screwdriver, remove the snap ring from the oil pump assembly.

(b) Remove the 2 brake flanges, 3 brake discs, and 2 brake plates from the oil pump assembly.
27. INSPECT NO. 3 BRAKE DISC Transaxle Unit
28. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Remove the underdrive planetary gear assembly from the oil pump assembly.
29. REMOVE NO. 3 BRAKE HUB

(a) Remove the No. 3 brake hub from the underdrive planetary gear assembly.

(b) Remove the thrust needle roller bearing and thrust needle roller race from the underdrive planetary gear assembly.
30. REMOVE UNDERDRIVE PLANETARY RING GEAR

(a) Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear.
(b) Remove the underdrive planetary ring gear from the underdrive planetary gear assembly.
31. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY

(a) While expanding the snap ring with snap ring pliers, remove the front planetary sun gear from the underdrive planetary gear assembly.
(b) Remove the snap ring from the underdrive planetary gear assembly.
32. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY Transaxle Unit
33. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY Transaxle Unit