1. Transaxle Unit (Disassembly)

PRECAUTION

General notes:

1. 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.














Components

Disassembly 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. Full out the oil pump shaft by hand.





3. Remove the ATF dipstick and oil filler tube.
4. Remove the O-ring from the oil filler tube.
5. Remove the breather hose.





6. Assemble the SSTs.





7. Attach suitable hangers to the oil pump as shown.





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.





8. Lift the transaxle and mount it on the SST.





9. Remove the Input/Turbine speed sensor and Transmission range sensor.





10. Remove he connector bolt.
11. Remove the packings, oil pipe, spring and steel ball.





12. 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

If large amounts of material are found, replace the torque converter and carefully check the transaxle for the cause.





13. Remove the oil strainer and O-ring.





14. Remove the control valve body cover and gasket.





15. Disconnect the solenoid connectors and Transmission, fluid temperature sensor connector.
16. Remove the coupler assembly.
17. Remove the O-ring from the coupler assembly.





18. Loosen the indicated bolts evenly and gradually.
19. Remove the control valve body as an assembly.





20. Remove the oil pump and gasket.





21. Remove the clutch assembly.
1. Remove the turbine shaft snap ring.





2. Pull out the reverse and forward drum and remove the clutch assembly.





22. Remove,the small sun gear and one-way clutch 1.





23. Remove the 2-4 brake band, and hold it together with a piece of wire as shown in the image.





24. Pull out the anchor shaft while holding the strut, then remove the strut.





25. Remove the piston stem from the band servo.





26. Remove the band servo.
1. Remove the snap ring by using the SST.
2. Remove the band servo and spring.





27. Remove the one-way clutch 2 and carrier hub assembly.
1. Remove the snap ring.





2. Remove the one-way clutch 2 together with the carrier hub assembly.
3. Remove the friction plate.





28. Remove the internal gear.
1. Remove the snap ring.





2. Remove the internal gear from the output shelf.





29. Remove the 3-4 clutch assembly.
1. Remove the O-ring from the turbine shaft at the converter housing side.





2. Pull out the turbine shaft to remove the 3-4 clutch assembly.
3. Remove the 3-4 clutch assembly.





30. Remove the bolts, and remove the transaxle case by tapping lightly with a plastic hammer.





31. Remove the output shell from the output gear.





32. Remove the manual shaft and manual plate.
1. Remove the plug, packing, spring, and detent ball.





2. Remove the bracket.





3. Loosen the nut and pull out the manual shaft.
4. Remove the nut, washer, spacer, and manual plate.





33. Remove the differential assembly.





34. Remove the 2-3 accumulator.
35. Remove the orifice check valve spring and orifice check valve.





36. Remove the bearing housing.
1. Remove the bolt indicated in the figure for access to the roll pin.
2. Remove the roll pin by using a pin punch.
3. Remove the baffle plate.
4. Remove the bearing housing by tapping lightly with a plastic hammer.





37. Hold the idler gear and output gear, and remove them by tapping out from the torque converter side.





38. Remove the bearing cover assembly.
1. Remove the converter housing from the SST (transaxle hanger).
2. Remove the bearing cover bolts.





3. Hold the bearing cover assembly and press it out of the converter housing by using a suitable pipe.

Outer diameter of pipe: 80 mm (3.1 inch)





39. Press out the bearing races by using the SST.