Disassembly And Assembly: Disassembly

CAUTION:

• Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
• The working area should be covered with a rubber mat to keep it clean at all times.
• Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
• Parts which have been disassembled should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
• Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
• If the transaxle body has been damaged, disassemble and clean the cooler system.

1. Remove the torque converter.
2. Use a dial gauge to measure the input shaft end play.
3. Remove control cable support bracket.
4. Remove the dipstick.
5. Remove the eye bolt, gaskets and the oil cooler feed tube.
   Fig 1: Measuring Input Shaft End Play Using Dial Gauge

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6. Remove the input shaft speed sensor and output shaft speed sensor.
   Fig 2: Input Shaft Speed Sensor And Output Shaft Speed Sensor

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   CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.
7. Loosen the manual control lever tightening nut, and then remove the manual control lever and the park/neutral position switch.
   Fig 3: Manual Control Lever And Park/Neutral Position Switch

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8. Remove the air breather by inserting a screwdriver into the air breather and prying it up.
   Fig 4: Inserting Screwdriver Into Air Breather

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9. Remove the valve body cover.
   Fig 5: Valve Body Cover Bolts

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10. Remove the manual control shaft detent.
    Fig 6: Manual Control Shaft Detent

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11. Disconnect the solenoid valve harness from the valve body by disconnecting the fluid temperature sensor and all the connectors.
    Fig 7: Fluid Temperature Sensor

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    CAUTION:

    • Make sure that the manual control lever and the park/neutral position switch are removed. See step  7.
    • Do not remove the bolts (four pieces) shown in the illustration.
12. Remove the valve body mounting bolts (twenty seven pieces).
    Fig 8: Locating Valve Body Mounting Bolts

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    CAUTION: Do not lose the two steel balls.
13. Remove the valve body and the steel balls (two pieces).
    Fig 9: Removing Valve Body And Steel Balls

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14. Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.
    Fig 10: Removing Snap Ring

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15. Remove the strainer and the second brake retainer oil seal.
    Fig 11: Removing Strainer

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16. Remove each accumulator piston and spring.
    Fig 12: Accumulator Piston

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    ACCUMULATOR PISTON REFERENCE
    
    

    NUMBER	NAME
    1	For low-reverse brake
    2	For underdrive clutch
    3	For second brake
    4	For overdrive clutch

17. Remove the reduction brake accumulator cover after removing the snap ring, then remove the spring and piston.
    Fig 13: Snap Ring Location

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18. Remove the manual control lever shaft roller.
    Fig 14: Manual Control Lever Shaft Roller

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19. Remove the manual control lever shaft and the parking pawl rod.
    Fig 15: Torque Converter Housing Mounting Bolts

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20. Remove the torque converter housing mounting bolts (twenty pieces), and then remove the torque converter housing.
21. Remove the O-rings (two pieces).
22. Remove the differential bearing outer race and spacer from the converter housing.
    Fig 16: Differential Bearing Outer Race

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23. Remove the differential.
    Fig 17: Differential

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24. Remove the oil filter.
    Fig 18: Removing Oil Filter

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25. Remove the pipe clamp bolts (two places).
    Fig 19: Locating Pipe Clamp Bolts

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26. Remove the oil pump mounting bolts (six pieces).
    Fig 20: Oil Pump Mounting Bolts

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27. Place special tool MD998333 as shown in the illustration.
28. Turn special tool MD998333 to remove the oil pump.
29. Remove the oil pump gasket.
    Fig 21: Removing Oil Pump

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30. Remove thrust washer number 1.
    Fig 22: Removing Thrust Washer

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31. Holding the input shaft, remove the underdrive clutch and input shaft.
    Fig 23: Removing Input Shaft

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32. Remove thrust bearing number 2.
    Fig 24: Removing Thrust Bearing

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33. Remove the underdrive clutch hub.
    Fig 25: Removing Underdrive Clutch Hub

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34. Remove the reduction brake piston cover after removing the snap ring.
35. Remove the reduction brake piston and spring after removing the snap ring.
    Fig 26: Locating Reduction Brake Piston Cover Snap Ring

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36. Remove the parking pawl shaft, and then remove the spacer and spring.
    Fig 27: Removing Parking Pawl Shaft

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37. Remove the parking roller support shafts (two pieces), and then remove the parking pawl and parking roller support.
    Fig 28: Removing Parking Roller Support Shafts

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38. Remove the direct planetary carrier assembly.
    Fig 29: Removing Direct Planetary Carrier Assembly

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39. Remove the anchor plug and O-ring.
    Fig 30: Locating Anchor Plug

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40. Remove the direct clutch.
    Fig 31: Removing Direct Clutch

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41. Remove the reduction brake band.
    Fig 32: Removing Reduction Brake Band

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42. Remove the thrust bearing number 11 and thrust race number 12.
    Fig 33: Removing Thrust Bearing Number 11 And Thrust Race Number 12

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43. Remove the rear cover.
44. Remove the thrust race number 8.
45. Remove the seal rings (four pieces).
46. Remove the input shaft rear bearing.
    Fig 34: Removing Input Shaft Rear Bearing

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47. Remove the O-rings (six pieces).
    Fig 35: O-Rings

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48. Remove the direct clutch accumulator piston and spring after removing the O-ring.
    Fig 36: Removing Direct Clutch Accumulator Piston

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49. Remove the reverse and overdrive clutch and thrust bearing number 7.
    Fig 37: Removing Thrust Bearing

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50. Remove overdrive clutch hub and thrust bearing number 6.
    Fig 38: Removing Overdrive Clutch Hub

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51. Remove thrust bearing number 5.
    Fig 39: Removing Thrust Bearing

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52. Remove the planetary reverse sun gear.
    Fig 40: Removing Planetary Reverse Sun Gear

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53. Remove the snap ring.
    Fig 41: Removing Snap Ring

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54. Remove the second brake piston and the return spring.
    Fig 42: Removing Second Brake Piston And Return Spring

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55. Remove the pressure plate, second brake discs (four pieces) and second brake plates (three pieces).
    Fig 43: Removing Pressure Plate Second Brake Discs And Second Brake Plates

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56. Remove the planetary carrier assembly.
    Fig 44: Removing Planetary Carrier Assembly

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57. Remove the snap ring.
    Fig 45: Removing Snap Ring

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58. Remove the reaction plate and the brake disc.
    Fig 46: Removing Reaction Plate

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59. Remove the snap ring.
    Fig 47: Removing Snap Ring

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60. Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.
    Fig 48: Removing Brake Plates

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    NOTE: *Includes the brake discs removed in step 57.
    Fig 49: Removing Wave Spring

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61. Remove the wave spring.
    Fig 50: Compressing One-Way Clutch Inner Race Using Special Tools

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62. Remove the one-way clutch inner race and low-reverse brake piston as follows:
    1. Using special tools MD999577 and MD998924, compress the one-way clutch inner race.
    2. Remove the snap ring.
    3. Remove the special tools.
    4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.
63. Remove the transfer drive gear bearing mounting bolts (four pieces). Then, turn the gear 1/8 turn (45 degrees) and remove the remaining bolts (four pieces).
    Fig 51: Removing Transfer Drive Gear Bearing Mounting Bolts

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    Fig 52: Transfer Drive Gear Bearing Mounting Bolts

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64. Remove the transfer drive gear.
    Fig 53: Removing Transfer Drive Gear

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65. Remove the snap ring.
    Fig 54: Removing Snap Ring

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66. Remove the one-way clutch.
67. Remove the seal rings (two pieces).
68. Remove the needle bearing.
69. Remove the differential bearing outer race from the transaxle case.

Fig 55: Removing Differential Bearing Outer Race From Transaxle Case

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