Disassembly
GENERAL NOTES1. The oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the transaxle and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transaxle is never tipped completely over while the oil pan is still installed.
2. Disassemble the transaxle in a clean, dust-proof area to prevent entry of dust into the mechanisms.
3. Use only plastic hammers when applying force to separate the light alloy case joints.
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
5. Several parts look alike; organize them so they do not get mixed up.
6. Disassemble the control valve assembly and thoroughly clean it when a clutch or brake band is burnt or when the ATF has degenerated.
CLEANING NOTES
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air.
Torque Converter, Accumulators And Control Valve Body:
Clutches, Oil Pump, Planetary Carrier:
Parking Mechanism, Output Gear, Reduction Gear And Idler Gear:
Differential:
PROCEDURE
1. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any remaining fluid from spilling.
2. Remove the bracket together with the manual rod.
3. Install the Special Service Tool (SST).
WARNING: Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.
4. Lift the transaxle and mount it on the SST.
5. Remove the Transmission range sensor
a. Disconnect the four connectors.
b. Move the selector lever to L range.
c. Remove the Transmission range sensor.
6. Remove the output speed sensor.
7. Remove the O-ring from the output speed sensor
8. Remove the vehicle speedometer sensor.
9. Remove the O-ring from the vehicle speedometer sensor.
10. Remove the oil pan and gasket. Examine any material found in the pan or on the magnet to determine the condition of the transaxle.
^ Clutch facing material: Drive plate and brake band wear
^ Steel (magnetic): Bearing, gear, and driven plate wear
^ Aluminum (nonmagnetic): Aluminum part wear
NOTE: If large amounts of material are found, replace the torque converter and carefully check the transaxle for the cause.
11. Remove the clip.
12. Loosen the indicated bolts evenly and gradually.
13. Remove the control valve body and solenoid harness as an assembly.
14. Remove the O-rings from the transaxle case.
15. Remove the low and reverse brake sleeve.
16. Remove the 2-3 accumulator return spring.
17. Remove the converter housing from the transaxle case.
18. Remove the differential.
19. Remove the O-ring from the input shaft.
20. Remove the O-ring from the differential lubrication hole of the transaxle.
21. Remove the oil pump and gasket.
22. While holding the anchor end bolt, loosen the locknut.
23. Remove the anchor end bolt.
24. Remove the 2-4 brake band, and hold it together with a piece of wire as shown in the illustration.
25. Pull out the input shaft, remove the reverse clutch, high clutch, high clutch hub and front sun gear as an assembly.
26. Remove the thrust bearings and bearing race.
27. Remove the band servo.
a. Remove the snap ring by using the SST.
b. Remove the servo retainer, servo piston and return springs.
28. Remove the low one-way clutch.
a. Remove the snap ring.
b. Remove the low one-way clutch by using a flat-tipped screwdriver.
CAUTION: Do not damage the contact surfaces.
29. Remove the side cover.
30. Remove the output gear and thrust bearing.
31. Remove the front planetary carrier and low and reverse brake piston.
a. Remove the snap ring by using the SST.
b. Pull out the front planetary carrier and low and reverse brake piston retainer as an assembly.
c. Remove the low and reverse brake spring and retainer.
32. Remove the thrust bearings from the front planetary carrier.
33. Remove the rear sun gear and rear planetary carrier.
34. Remove the thrust bearing from the rear planetary carrier.
35. Remove the rear internal gear and forward clutch hub.
36. Remove the overrunning clutch hub.
37. Remove the thrust washer and bearing race from the overrunning clutch hub.
38. Remove the forward clutch drum.
39. Remove the thrust bearing from the forward clutch drum.
NOTE: Do not remove the idler gear if not necessary.
40. Remove the idler gear and reduction gear.
a. Move the selector lever to park position.
b. Remove the locknut.
c. Remove the idler gear and reduction gear by using the SST.
NOTE: When bearing race and bearing are replaced during reassembly, adjust the preload.
d. Remove the idler gear bearing race and shims by using the SST.
NOTE: Do not remove the reduction gear outer race if not necessary.
41. Remove the reduction gear outer race.
42. Remove the parking lever and parking rod.
43. Remove the return spring, parking shaft, parking pawl and parking actuator support.
44. Remove the drum support.
NOTE: When bearing race and bearing are replaced during reassembly, adjust the preload.
45. Remove the differential bearing races by using the SST.