Part 1

DISASSEMBLY





1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
a. Remove the nut, washer and control shaft lever.





b. Using a screwdriver, unstake the nut stopper, and remove the lock nut and nut stopper.





c. Remove the 2 bolts and pull out the park/neutral position switch.
2. REMOVE BREATHER PLUG HOSE
a. Remove the breather plug hose from the transaxle case.





3. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION)
a. Remove the union.
b. Remove the O-ring from the union.





4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)
a. Remove the elbow.
b. Remove the O-ring from the elbow.





5. REMOVE SPEED SENSOR
a. Remove the 2 bolts and the 2 speed sensors from the transaxle assembly





6. REMOVE TRANSAXLE CASE NO.1 PLUG
a. Remove the 4 transaxle case No. 1 plugs from the transaxle case.
b. Remove the 4 O-rings from the 4 transaxle case No.1 plugs.





7. FIX AUTOMATIC TRANSAXLE ASSEMBLY
a. Fix the transaxle assembly





8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB ASSEMBLY
a. Remove the 18 bolts, oil pan and gasket.





b. Remove the 2 magnets from the oil pan.





9. INSPECT TRANSMISSION OIL CLEANER MAGNET
a. Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle:
Result:
Steel (magnetic): Wear of the bearing, gear and plate
Brass (non-magnetic): Wear of the bushing





10. DISCONNECT TRANSMISSION WIRE
a. Remove the 7 connectors from the shift solenoid valves.
b. Remove the bolt, lock plate and temperature sensor.





11. REMOVE TRANSMISSION WIRE
a. Remove the bolt and transmission wire from the transaxle case.





12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
a. Remove the 3 bolts and oil strainer.





b. Remove the O-ring from the oil strainer.





13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
a. Support the valve body assembly and remove the 17 bolts and valve body assembly.





14. REMOVE GOVERNOR APPLY GASKET NO.1
a. Remove the governor apply gasket No. 1 from the transaxle case.





15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
a. Remove the transaxle case 2nd brake gasket from the transaxle case.





16. REMOVE BRAKE DRUM GASKET
a. Remove the brake drum gasket from the transaxle case.





17. REMOVE CHECK BALL BODY
a. Remove the check ball body and spring from the transaxle case.





18. REMOVE C-3 ACCUMULATOR PISTON
a. Remove the spring from the C-3 accumulator piston.





b. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the C-3 accumulator piston.

NOTICE:
^ Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth.
^ Take care not to splash ATF when applying compressed air.





c. Remove the O-ring from the C-3 accumulator piston.





19. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON
a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the reverse accumulator piston and spring.

NOTICE:
^ Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth.
^ Take care not to splash ATF when applying compressed air.





b. Remove the 2 O-rings from the reverse clutch accumulator piston.





20. REMOVE B-3 ACCUMULATOR PISTON
a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.

NOTICE:
^ Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth.
^ Take care not to splash ATF when applying compressed air.





b. Remove the O-ring from the B-3 accumulator piston.





21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING
a. Using needle-nose pliers, remove the manual valve lever shaft retainer spring.





22. REMOVE MANUAL DETENT SPRING SUB ASSEMBLY
a. Remove the 2 bolts, the manual detent spring subassembly and cover.





23. REMOVE PARKING LOCK PAWL BRACKET
a. Remove the 2 bolts and parking lock pawl bracket.





24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
a. Using a chisel and hammer, cut off and remove the spacer.





b. Using a pin punch ([diameter] 35 mm) and hammer, drive out the pin.

HINT: Slowly drive out the pin so that it will not fall into the transaxle case.





c. Remove the manual valve lever shaft and manual valve lever.





25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
a. Remove the parking lock rod from the manual valve lever.





26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
a. Using a screwdriver, remove the oil seal from the transaxle case.

NOTICE: Do not apply excessive force when removing the oil seal.

27. FIX AUTOMATIC TRANSAXLE ASSEMBLY
a. Fix the transaxle case with the oil pump side facing up.
28. INSPECT INPUT SHAFT ENDPLAY





29. REMOVE TRANSAXLE HOUSING
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: The differential may be accidentally removed when the transaxle housing is removed.





30. REMOVE OIL PUMP ASSEMBLY
a. Remove the 7 bolts and oil pump from the transaxle case.





31. REMOVE THRUST NEEDLE ROLLER BEARING
a. Remove the thrust needle roller bearing from the underdrive planetary gear assembly





32. REMOVE THRUST BEARING UNDERDRIVE RACE NO.2
a. Remove the thrust bearing underdrive race No.2 from the underdrive planetary gear assembly.





33. REMOVE DIFFERENTIAL GEAR ASSEMBLY
a. Remove the differential gear assembly from the transaxle case.





34. REMOVE OVERDRIVE BRAKE GASKET
a. Remove the 2 overdrive brake gaskets from the transaxle case.





35. REMOVE FORWARD CLUTCH ASSEMBLY
a. Remove the forward clutch assembly from the transaxle case.





b. Remove the thrust needle roller bearing from the forward clutch.





36. REMOVE MULTIPLE DISC CLUTCH HUB
a. Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and thrust bearing race No.1 from the transaxle case.
37. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB





38. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY
a. Remove the bolt and pawl shaft clamp.





b. Remove the parking lock pawl shaft.





c. Push the parking lock pawl.

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





d. Remove the underdrive planetary gear assembly from the transaxle case.

NOTICE: Be careful so that the underdrive planetary gear assembly will not fall out.





39. REMOVE PARKING LOCK PAWL
a. Remove the spring, pawl pin and parking lock pawl.





40. REMOVE UNDERDRIVE CLUTCH ASSEMBLY
a. Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle case.