Part 2 of 5

Transaxle Case Removal Con't





50. Important: If the end play is not within 0.37 - 1.29 mm (0.0146 - 0.0508 inch), replace the thrust roller bearing.

Using a dial indicator, measure the end play of the input shaft.





51. Remove the 7 oil pump assembly retaining bolts.
52. Remove the oil pump assembly from the transaxle case.





53. Remove the differential gear assembly from the transaxle case.





54. Using a screwdriver, remove the 2 O/D brake gaskets from the transaxle case.





55. Remove the input shaft assembly from the transaxle.





56. Remove the stator shaft thrust roller bearing from the input shaft assembly.





57. Remove the forward clutch hub thrust roller bearing from the forward clutch hub.





58. Remove the forward clutch hub sub-assembly from the transaxle case.





59. Remove the 11 transaxle rear cover retaining bolts.
60. Tap on the circumference of the transaxle cover with a soft faced hammer to remove the transaxle rear cover from the transaxle case.





61. Remove the 4 transaxle case gaskets.





62. Using a magnet, remove the rear clutch drum thrust roller bearing.





63. Remove the intermediate shaft assembly from the transaxle case.





64. Remove the 2nd coast and overdrive brake flange, two 2nd coast and overdrive brake discs and two 2nd coast and overdrive brake flanges from the transaxle.





65. Check the 2nd coast and overdrive brake discs, plates and flanges. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flanges.





66. Using a magnet, remove the C-2 hub thrust bearing race, thrust roller bearing race from the direct clutch hub.





67. Remove the direct clutch hub from the transaxle case.





68. Using a magnet, remove the rear planetary sun gear No.2 thrust bearing from the rear planetary sun gear assembly.





69. Remove the rear planetary sun gear assembly from the transaxle case.





70. Remove the rear planetary sun gear thrust roller bearing and thrust washer No. 1 from the rear planetary sun gear.





71. Hold the rear planetary sun gear (1) and turn the 1 way clutch. The 1 way clutch should turn freely clockwise (2) and should lock if turned counterclockwise (3).





72. Remove the 1 way clutch assembly and planetary carrier thrust washer No. 2 from the rear planetary sun gear.





73. Using a screwdriver, remove the 2nd coast and overdrive brake flange snap ring from the transaxle case.





74. Using a screwdriver, remove the 2nd brake disc snap ring.
75. Remove the flange, 3 discs and 3 plates from the transaxle case.





76. Check the 2nd brake discs, plates and flanges. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flanges.





77. Remove the 2nd brake piston sleeve from the transaxle case.





78. Install the 1 way clutch and thrust washer on the rear planetary sun gear.
79. Hold the rear planetary sun gear and turn the 1 way clutch. The 1 way clutch should turn freely counterclockwise (1) and should lock counterclockwise (2).





80. Using a screwdriver, remove the rear planetary gear assembly snap ring.
81. Remove the rear planetary gear assembly from the transaxle case.





82. Remove the rear planetary gear rear thrust roller bearing and 2 bearing races from the rear planetary gear assembly.





83. Separate the 2nd brake cylinder, 1 way clutch and the planetary gear.





84. Remove the retainer from the 1 way clutch No.2.





85. Remove the front planetary sun gear and thrust roller bearing from the transaxle case.





86. Using a screwdriver, remove the 1st and reverse brake disc snap ring.





87. Check the 1st and reverse brake discs, plates and flange. If the sliding surfaces of the discs, plates and flanges are worn or discolored, replace all the discs, plates and flange.





88. Using a press and a screwdriver, remove 1st and reverse return spring sub-assembly snap ring.
89. Remove the 1st and reverse brake return spring sub-assembly from the transaxle case.





90. Using vernier calipers, or an equivalent, measure the free length of the spring together with the spring seat. The free length should be 13.96 mm (0.5496 inch). If the length is not as specified, replace the spring.
91. Using compressed air at low pressure 392 kPa (57 psi) push out the 1st and reverse brake piston No.2 from the transaxle case.





92. Remove the 2 O-rings from the 1st and reverse brake piston No.2.





93. Engage the counter driven gear with the parking lock pawl.





94. Using a punch and hammer, unstake the counter drive gear lock washer.





95. Remove the counter drive gear nut and lock washer.





96. Using a press, remove the planetary gear assembly.





97. Install 2 M6 bolts 40 - 80 mm in length with a 1.0 mm thread pitch into the counter drive gear.
98. Tighten the bolts to remove the counter drive gear and front planetary sun gear.
99. Remove the 2 radial ball bearings from the counter drive gear and front planetary sun gear.





100. Remove the 3 parking lock pawl bracket retaining bolts.