Part 2

OVERHAUL





30. INSPECT INPUT SHAFT ENDPLAY
a. Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0103 - 0.0492 inch)





31. REMOVE TRANSAXLE CASE NO.1 PLUG [35104Q/98-3]
a. Remove the 2 transaxle case No 1 plugs.
b. Remove 2 O-rings from the 2 transaxle case No. 1 plugs.





32. REMOVE TRANSAXLE HOUSING [35111C/98-14]
a. Remove the 16 bolts.
b. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.

NOTICE: Differential may be accidentally removed when the transaxle housing is removed.





33. REMOVE OIL PUMP ASSY
a. Remove the 7 bolts and oil pump from the transaxle case.





34. REMOVE THRUST NEEDLE ROLLER BEARING [34736B/98-4]
a. Remove thrust needle roller bearing from the U/D planetary gear assy.





35. REMOVE THRUST BEARING UNDERDRIVE RACE NO.2 [34736A/98-4]
a. Remove thrust bearing U/D race No. 2 from the U/D planetary gear assy.





36. REMOVE DIFFERENTIAL GEAR ASSEMBLY
a. Remove the differential gear assy from the transaxle case.





37. REMOVE OVERDRIVE BRAKE GASKET [35179/98-3]
a. Remove 2 O/D brake gaskets from the transaxle case.
38. REMOVE FORWARD CLUTCH ASSY





a. Remove the forward clutch from the transaxle case.





b. Remove the thrust bearing from the forward clutch.





39. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB [35631/98-5]
a. Remove the thrust bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle case.





40. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB [35631/98-5]
a. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing
Standard inside diameter: 23.025 - 23.045 mm (0.9065 - 0.9073 inch)
Maximum inside diameter: 23.09 mm (0.9091 inch)

NOTICE:
- When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
- Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is Identified, replace the direct clutch sub-assy with new one.

If the inside diameter is greater than the maximum, replace the forward clutch hub.
41. REMOVE UNDERDRIVE PLANETARY GEAR ASSY





a. Remove the bolt and parking pawl shaft clamp.





b. Remove the parking lock pawl shaft.





c. Push the parking lock pawn.

HINT: Failure to do so will cause interference when the U/D planetary gear is removed.





d. Remove the U/D planetary gear assy from the transaxle case.

NOTICE: Be careful so that the U/D planetary gear assy will not fall out.





e. Remove the spring, pawl pin and parking lock pawl.





42. REMOVE UNDERDRIVE CLUTCH ASSY
a. Remove the U/D clutch assy, thrust bearing and bearing race from the transaxle case.
43. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY [34360/98-4]





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





b. Remove the 1-way clutch from the transaxle case.





c. Remove the outer race retainer from the 1-way clutch.





44. REMOVE UNDERDRIVE CLUTCH DISC NO.2 [34262/98-4]
a. Using a screwdriver, remove the snap ring.
b. 1MZ-FE:
Remove the flange, 4 discs and 4 plates from the transaxle case.
c. 2AZ-FE:
Remove the flange, 3 discs and 3 plates from the transaxle case.





45. INSPECT UNDERDRIVE CLUTCH DISC NO.2 [34262/98-4]
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.





46. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY [34207/98-4]
a. Using SST, a snap ring expander and a press, remove the snap ring and piston return spring.
SST 09387-00020





47. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY [34207/98-4]
a. Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 14.04 mm (0.5528 inch)





48. REMOVE TRANSAXLE CASE NO.1 PLUG [35104Q/98-3]
a. Remove 2 transaxle case No.1 plugs from the transaxle rear cover.
b. Remove 2 O-rings from the 2 transaxle case No.1 plugs.
49. REMOVE TRANSAXLE REAR COVER SUB-ASSY [35102/98-3]
a. Remove the 11 bolts.





b. Tap in the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.





c. Remove the 2 oil seal rings from the transaxle rear cover.





d. Using a torx socket wrench (T30), remove the 2 screws and transaxle rear cover plate.





e. Using SST, remove the needle-roller bearing from the transaxle rear cover.
SST 09387-00040 (09387-01010, 09387-01030, 09387-01040)





50. REMOVE BRAKE APPLY TUBE [35666D/98-9]
a. Remove a bolt, clamp and 2 brake apply tubes.
b. Remove the brake apply tube from the clamp.
51. REMOVE FRONT CLUTCH APPLY TUBE [35895/98-9]
a. Remove the front clutch apply tube from the clamp.





52. REMOVE GOVERNOR APPLY GASKET NO.1 [35148/98-3]
a. Using a screwdriver, remove the 2 apply gaskets.
53. REMOVE DIRECT CLUTCH ASSY





a. Remove the thrust bearing and the direct clutch assy from the transaxle case.





b. Remove the bearing race from the direct clutch.
54. REMOVE REAR PLANETARY SUN GEAR ASSY [35730/98-8]





a. Remove the rear planetary sun gear assy from the transaxle case.





b. Remove the thrust bearing from the rear planetary sun gear.





c. Remove the thrust washer No. 1 from the rear planetary sun gear.
55. REMOVE 1 WAY CLUTCH ASSY [35790/98-6]





a. Remove the 1-way clutch and the thrust bearing from the transaxle case.





b. Remove the inner race from the 1-way clutch.





56. REMOVE 1 WAY CLUTCH SLEEVE OUTER [35798A/98-6]





57. REMOVE 2ND BRAKE CLUTCH DISC [35677/98-6]
a. Using a screwdriver, remove the snap ring.
b. 1MZ-FE:
Remove the flange, 4 discs and 4 plates from the transaxle case.
c. 2AZ-FE
Remove the flange, 3 discs and 3 plates from the transaxle case.





58. INSPECT 2ND BRAKE CLUTCH DISC [35677/98-6]
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
- If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs.
- Before assembling new discs, soak them in ATF for at least 15 minutes.

59. REMOVE SECOND BRAKE PISTON ASSY





a. Using a screwdriver, remove the snap ring.





b. Remove the 2nd brake piston assy from the transaxle case.
60. REMOVE REAR PLANETARY GEAR ASSY [35760/98-8]





a. Using a screwdriver, remove the snap ring.





b. Remove the rear planetary gear from the transaxle case.





c. Remove the planetary carrier thrust washer No. 1 from the rear planetary gear.





d. Remove the bearing race from the rear planetary gear.