Overhaul (Disassembly)

Disassembly





1. Drain ATF through drain plug. Refer to "Changing A/T Fluid".
2. Remove torque converter.





3. Check torque converter one-way clutch using check tool as shown.
a. Insert check tool into the groove of bearing support built into one-way clutch outer race.
b. When fixing bearing support with check tool, rotate one-way clutch spline using screwdriver.
c. Check that inner race rotates clockwise only. If not, replace torque converter assembly.





4. Remove A/T fluid charging pipe and fluid cooler tube.





5. Set manual shaft to position P.
6. Remove Park/Neutral Position (PNP) switch.





7. Remove oil pan using power tools, and oil pan gasket.

NOTE: Do not reuse oil pan bolts.

8. Check foreign materials in oil pan to help determine causes of malfunction. If the fluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and can inhibit pump pressure.

NOTE: If frictional material is detected, replace radiator after repair of A/T. Refer to "RADIATOR".





9. Remove control valve assembly.
a. Remove control valve assembly mounting bolts I, X and O.





b. Remove snap ring from terminal body.





c. Push terminal body into transaxle case and draw out terminal cord assembly.





10. Remove manual valve from control valve assembly.





11. Remove return spring from servo release accumulator piston.





12. Remove servo release accumulator piston with compressed air.
13. Remove O-rings from servo release accumulator piston.





14. Remove N-D accumulator piston and return spring with compressed air.





15. Remove O-rings from N-D accumulator piston.
16. Check accumulator pistons and contact surface of transaxle case for damage.





17. Check accumulator return springs for damage and free length.
18. Remove lip seals.





19. Remove L & R oil tube and oil sleeve.





20. Remove converter housing.
a. Remove converter housing mounting bolts using power tools.
b. Remove converter housing by tapping it lightly.





c. Remove O-ring from differential oil port.





21. Remove final drive assembly from transaxle case.





22. Remove differential side bearing outer race and side bearing adjusting shim from transaxle case using Tool.
Tool number: KV381053S0 (J-34286)





23. Remove differential side bearing adjusting shim from transaxle case.





24. Remove differential side bearing outer race from converter housing using Tool.
Tool number: KV381054S0 (J-34286)





25. Remove oil seal from converter housing using suitable tool.

CAUTION: Be careful not to damage case.





26. Remove differential lubricant tube from converter housing.





27. Remove oil pump.
a. Remove O-ring from input shaft.





b. Remove oil pump assembly, baffle plate and gasket from transaxle case.





c. Remove thrust washer and bearing race from oil pump assembly.





28. Remove brake band.
a. Loosen lock nut, then back off anchor end pin using suitable tool.

NOTE: Do not reuse anchor end pin.





b. Remove brake band and strut from transaxle case.





CAUTION: To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. When removing the brake band, always secure it with a clip as shown in the figure at left.

NOTE: Leave the clip in position after removing the brake band.





c. Check brake band facing for damage, cracks, wear or burns.





29. Remove input shaft assembly (high clutch) and reverse clutch.
a. Remove input shaft assembly (high clutch) with reverse clutch.





b. Remove input shaft assembly (high clutch) from reverse clutch.





c. Remove needle bearings from high clutch drum and check for damage or wear.





d. Remove high clutch hub and front sun gear from transaxle case.





e. Remove front sun gear and needle bearing from high clutch hub and check for damage or wear.
f. Remove bearing race from front sun gear and check for damage or wear.





30. Remove needle bearing from transaxle case and check for damage or wear.





31. Apply compressed air and check to see that low and reverse brake operates.





32. Remove low one-way clutch and front planetary carrier assembly.
a. Remove snap ring with flat-bladed screwdriver.





b. Remove low one-way clutch with a suitable hook made of wire.





c. Remove snap ring with flat-bladed screwdriver.





d. Remove front planetary carrier with low and reverse brake piston and retainer.





e. Remove low and reverse brake spring retainer.

NOTE: Do not remove return springs from spring retainer.





f. Check that low one-way clutch rotates in the direction of the clockwise arrow and locks in the opposite direction.





g. Remove needle bearing, low and reverse brake piston and retainer from front planetary carrier.
h. Check front planetary carrier, low one-way clutch and needle bearing for damage or wear.





i. Check clearance between planetary gears and planetary carrier with feeler gauge.
Standard clearance: 0.20 - 0.70 mm (0.0079 - 0.0276 inch)
Allowable limit: 0.80 mm (0.0315 inch)
Replace front planetary carrier if the clearance exceeds allowable limit.





33. Remove rear planetary carrier assembly and rear sun gear.
a. Remove rear planetary carrier assembly from transaxle case.





b. Remove rear sun gear from rear planetary carrier.





c. Remove needle bearings from rear planetary carrier assembly.
d. Check rear planetary carrier, rear sun gear and needle bearings for damage or wear.





e. Check clearance between pinion washer and rear planetary carrier with feeler gauge.
Standard clearance: 0.20 - 0.70 mm (0.0079 - 0.0276 inch)
Allowable limit: 0.80 mm (0.0315 inch)
Replace rear planetary carrier if the clearance exceeds allowable limit.





34. Remove rear internal gear and forward clutch hub from transaxle case.





35. Remove overrun clutch hub from transaxle case.





36. Remove needle bearing from overrun clutch hub and check for damage or wear.





37. Remove forward clutch assembly from transaxle case.





38. Remove needle bearing from transaxle case.





39. Remove output shaft assembly.
a. Remove side cover bolts.

NOTE:
^ Do not mix bolts A and B.
^ Always replace bolts A as they are self-sealing bolts.





b. Remove side cover by lightly tapping it with a soft hammer.

NOTE: Be careful not to drop output shaft assembly. It might come out when removing side cover.





c. Remove adjusting shim.





d. Remove output shaft assembly.





NOTE: If output shaft assembly came off with side cover, tap cover with a soft hammer to separate.





e. Remove needle bearing.





40. Disassemble reduction pinion gear.
a. Set manual shaft to position P to fix idler gear.
b. Unlock idler gear lock nut using a suitable punch.





c. Remove idler gear lock nut using suitable tool.

NOTE: Do not reuse idler gear lock nut.





d. Remove idler gear using Tool.
Tool number: ST27180001 (J-25726-A)





e. Remove reduction pinion gear.
f. Remove adjusting shim from reduction pinion gear.





41. Remove return spring from parking shaft with screwdriver.
42. Draw out parking shaft and remove parking pawl from transaxle case.
43. Check parking pawl and shaft for damage or wear.





44. Remove parking actuator support from transaxle case.
45. Check parking actuator support for damage or wear.





46. Remove side oil seal from transaxle case using suitable tool.