Part 4

Transmission Disassemble




145. Tighten the bolts evenly and make a clearance of approximately 20.0 mm (0.797 in) between the counter drive gear and the inner race.




146. Using a suitable puller (1), remove the tapered roller bearing inner race.




147. Remove the bearing inner race (rear side) (1) and angular ball (rear side).




148. Using a press (1), remove the bearing outer race (rear side) from the transaxle case.




149. Remove the angular ball.




150. Using a press (1), remove the bearing outer race (front side) from the transaxle case.
Remove the angular ball (front side).




151. Using a screwdriver, remove the snap ring from the transaxle case.




152. Compress the return spring with a press.

Note: Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove to prevent the spring seat from being deformed.

153. Using a snap ring expander, remove the snap ring (1).
154. Remove the return spring.




155. Remove underdrive brake piston (1).
156. Apply compressed air to the transaxle case to remove the underdrive brake piston.




157. Remove the O-rings (1) from the underdrive brake piston.




158. Using a suitable puller, remove the needle roller bearing from the transaxle case.




159. Remove the oil seal rings (1) from the transaxle case.




160. Remove the number 1 transaxle case plugs.
161. Remove the O-rings from the number 1 transaxle case plugs.




162. Using a suitable puller, remove the underdrive cylindrical roller bearing from the transaxle case.




163. Remove the oil seal ring (1) from the transaxle housing.




164. Remove the bolt (2), transaxle apply tube clamp (1) and differential gear lube apply tube from the transaxle housing.




165. Remove the clutch drum oil seal rings (1).




166. Remove the bolts (1-11) and stator shaft.
167. Keep the gears in the assembled order.




168. Remove the front oil pump drive gear (1).




169. Remove the front oil pump driven gear (1).




170. Using a screwdriver, remove the O-ring (1).




171. Mount the oil pump in a soft jaw vise.
172. Using a suitable puller (1), remove the oil seal from the oil pump body.




173. Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly.




174. Push the driven gear (2) to one side of the body.
175. Using a feeler gauge, measure the clearance.

* Standard body clearance - 0.10-0.17 mm (0.0039-0.0067 in)
* Side clearance - 0.02-0.05 mm (0.001-0.002 in)
* Maximum body clearance - 0.17 mm (0.0067 in)

If the body clearance is greater than the maximum, replace the oil pump body sub-assembly.




176. Using a feeler gauge, measure the tip clearance between the driven gear teeth and drive gear teeth.

* Standard tip clearance - 0.07-0.15 mm (0.0028-0.0059 in)
* Maximum tip clearance - 0.15 mm (0.0059 in)

If the tip clearance is greater than the maximum, replace the oil pump body sub-assembly.




177. Using a straightedge and feeler gauge, measure the side clearance of both gears.

* Standard side clearance - 0.02-0.05 mm (0.0008-0.0020 in)
* Maximum side clearance - 0.05 mm (0.0020 in)

Refer to Transmission General Specifications (Transmission General Specifications) for drive gear thickness.




178. Using a dial indicator, measure the inside diameter of the oil pump body bushing.

* Standard inside diameter - 38.113-38.138 mm (1.5005-1.5014 in)
* Maximum inside diameter - 38.188 mm (1.5034 in)

If the inside diameter is greater than the maximum, replace the oil pump and gear body sub-assembly.




179. Using a dial indicator, measure the inside diameter of the stator shaft.

* Standard inside diameter - 21.500-21.526 mm (0.8464-0.8474 in)
* Maximum inside diameter - 21.57 mm (0.8492 in)

If the inside diameter is greater than the maximum, replace the stator shaft.




180. Put matchmarks (1) on the front differential ring gear (2) and differential case.




181. Remove the bolts from the front differential ring gear (1).




182. Using a plastic hammer, tap on the front differential ring gear (1) to remove it from the case.




183. Using a suitable puller (1), remove the front differential case front tapered roller bearing from the differential case.




184. Using a suitable puller (1), remove the front differential case front tapered roller bearing outer race.




185. Using a suitable puller (1), remove the front differential case rear tapered roller bearing from the differential case.




186. Using a suitable puller (1), remove the front differential case rear tapered roller bearing outer race.





Note: Before removing the straight pin, unstake it with a pin punch.

187. Using a pin punch and hammer, remove the straight pin.




188. Remove the front number 1 differential pinion shaft (2) from the differential case.




189. Remove the front differential pinions, pinion thrust washers, front differential side gears (1) and side gear thrust washers from the differential case.




190. Using a suitable driver (1) and a hammer, remove the transaxle housing oil seal.




191. Using a suitable driver (1) and a hammer, remove the differential side bearing retainer oil seal.




192. Using a dial indicator, inspect the backlash of the side gear.

Standard backlash - 0.05-0.20 mm (0.0020-0.0079 in)
Refer to Transmission General Specifications (Transmission General Specifications)