AUTOMATIC TRANSAXLE DISASSEMBLY

id051700502100


Precaution

The following are precautions that must be followed when performing removal/installation.

1.  Handle electronic parts with care

•  Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the lock first and pull the connector.
•  When connecting the connector, verify to insert it until it is properly locked. (Verify that a click sound is heard.)
•  Do not shock electronic parts. Replace with new parts if they have been dropped or subjected to shock.

2.  Prevent foreign matter from penetrating

•  Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing parts.
•  Protect removed parts from dust with an object such as a vinyl sheet.
•  Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Thus work with bare hands or use vinyl gloves.

3.  Prevent scratching

•  Do not pry with a screwdriver forcibly. Slightly hit the case with a plastic hammer when separating component cases at seams.
•  Do not pull the valve forcibly.
•  Be careful not to get the wire harness caught between parts during installation.

4.  Prevent incorrect installation and lack of or missing parts

•  Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings, bearings and races. Take great care for straightening parts and checking installation direction.
•  Be careful not to drop small parts such as check balls or lose them during installation.

5.  Wash parts and apply oil

•  Wash each part before installing and dry using compressed air, and then apply the specified ATF type JWS3309.
•  Soak disks in ATF type JWS3309 before installing. In particular, soak new disks for 2 h or more so that the oil seeps into the lining.
•  If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease.
•  Apply ATF type JWS3309 to contact and rotating surfaces.
•  Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one hour or more.
•  Do not wash aluminum parts or rubber parts with alkaline chemicals.
•  Do not wash the rubber parts with white gasoline.

6.  Handling ATF with care

•  If you spill ATF on the floor, wipe it off immediately, as it is quite slippery and dangerous.
•  Be sure to use JWS3309 type ATF.


Disassembly


Components

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1
Oil pipe and O-ring
2
Torque converter
3
Drain plug
4
Gasket
5
Filler plug
6
O-ring
7
TCM
8
Control valve body cover
9
Lock plate
10
Suction cover
11
Gasket
12
Control valve body component
13
Coupler component lock plate
14
Coupler component
15
O-ring
16
Gasket
17
Input/turbine speed sensor
18
Oil seal (converter housing side)
19
O-ring (converter housing side) (2WD)
20
Oil seal (transaxle case side)
21
O-ring (transaxle case side)
22
Oil seal (manual shaft)

*1  :The figure shows CX-7 specification.
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1
Breather pipe
2
O-ring
3
Transaxle case gasket
4
Gasket
5
Gasket
6
Oil Pump component
7
Oil strainer
8
C3 clutch component
9
Front planetary gear component and input shaft
10
Brake band anchor bolt
11
B1 brake band
12
Snap ring
13
Brake piston cover
14
B1 brake piston
15
Piston return spring
16
Thrust bearing
17
Bearing race
18
C1 clutch component
19
Thrust bearing
20
Bearing race
21
Sun gear input drum
22
Counter gear component
23
Differential component
24
Lock washer
25
Counter drive gear
26
Vehicle speed sensor (VSS)
27
Spacer
28
Snap Ring
29
Rear planetary gear component and one-way clutch component
30
Bearing race
31
Thrust bearing
32
Bearing race
33
Snap ring
34
Retaining plate
35
Drive plate
36
Driven plate
37
Retaining plate
38
C2 clutch component
39
Thrust bearing

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1
Tube clamp
2
Oil reservoir lock plate
3
Magnet
4
Oil pipe

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1
Stud bolt
2
Detent spring cover
3
Detent spring
4
Parking pawl shaft
5
Pawl return spring
6
Spring guide sleeve
7
Torsion spring
8
Parking pawl bracket
9
Parking pawl
10
Manual valve lever
11
Parking rod
12
Parking pin
13
Pipe clamp
14
Transaxle case No.1 plate
15
Wiring harness clip
16
Oil cooler outlet tube
17
O-ring
18
Seal ring
19
Transaxle case plate No.2
20
Transaxle case plate No.3


Disassembly procedure

1.  Remove the oil pipes and O-rings. (Refer to Workshop Manual.)

Caution
•  Do not damage the oil seal.
•  Do not drop the torque converter.

2.  Remove the torque converter.

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3.  Remove the drain plug and gasket.

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4.  Drain the ATF.

Caution
•  Do not repair the threads using a tap or other tools.

5.  Remove the stud bolts.

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Caution
•  Do not touch the terminals.
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6.  Remove the TCM.

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7.  Set the SST as shown in the figure.

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Caution
•  When installing the SST to the transaxle, use bolts (M12×1.25) with a thread length of 90 mm {3.54 in}.

8.  Install the SST to the position where the transaxle stud bolts were removed.

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9.  Remove the control valve body cover installation bolt.

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Caution
•  Do not damage the fitting surface of the transaxle case and the control valve body cover.
•  Do not deform the control valve body cover.

10.  Using a plastic hammer, tap the control valve body cover to remove it.

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Caution
•  Be careful not to damage the solenoid valves and connectors.
•  Do not pull the wiring harnesses when removing the connector.
Note
•  Disconnect the solenoid connector according to the following procedure:
(1)  Insert a precision screwdriver from the backside into the connector as shown in the figure.
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(2)  Pry the screwdriver in the direction of the arrow and disconnect the connector.
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Caution
•  Do not damage the solenoid valves and connectors with the screwdriver.
•  When disconnecting connectors, grasp the connectors, not the wiring harnesses. Otherwise, the wiring harnesses may be pulled out of the connector causing poor contact.

11.  Disconnect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.

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12.  Disconnect the coupler component from the clamp.

13.  Remove the lock plate, and pull out the TFT sensor from the control valve body.

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14.  Remove the O-ring from the TFT sensor.

Note
•  Be sure to secure the coupler component with tape so that it will not interfere with the control valve body component.

15.  Fix the coupler component with tape to the transaxle case as shown in the figure.

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16.  Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.

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Note
•  Be sure to secure the VSS and input/turbine speed sensor with tape so that they do not interfere with the control valve body component.

17.  Secure the VSS wiring harness and input/turbine speed sensor wiring harness with tape to the transaxle case as shown in the figure.

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18.  Remove the suction cover and the gasket.

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Caution
•  Loosen the bolts evenly a little at a time in the order shown in the figure.

19.  Remove the control valve body installation bolts.

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Caution
•  Do not drop the control valve body component.

20.  Disconnect the manual valve link and remove the control valve body component.

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21.  Remove the coupler component lock plate.

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Caution
•  Do not damage the wiring harness.
•  Do not pull hard on the wiring harness.

22.  Remove the coupler component from the transaxle case.

23.  Remove the O-ring and the gasket from the coupler component.

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Caution
•  Do not damage the input/turbine speed sensor.

24.  Remove the input/turbine speed sensor.

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25.  Remove the bolts as shown in the figure.

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Caution
•  Do not damage the fitting surface of the converter housing and the transaxle case.

26.  Using a plastic hammer, tap the converter housing to remove it.

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27.  Remove the transaxle case gaskets as shown in the figure.

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28.  Remove the gaskets as shown in the figure.

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Caution
•  Do not damage the oil reservoir lock plate.

29.  Remove the tube clamp and the oil reservoir lock plate.

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30.  Remove the magnets from the oil reservoir lock plate.

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Caution
•  Do not damage the differential gear lube apply tube.

31.  Using a flathead screwdriver, remove the oil pipe.

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Caution
•  Do not damage the converter housing.
•  If using a screwdriver, use a wooden block or equivalent to avoid damaging the fitting surface of the converter housing.

32.  Remove the oil seal lip using a razor.

33.  Using a tape-wrapped flathead screwdriver, remove the oil seal (converter housing side).

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34.  Remove the oil pump component.

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35.  Remove the oil seal and the oil strainer from the oil pump component.

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36.  Remove the C3 clutch component, input shaft and the front planetary gear component.

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Note
•  In some cases, the input shaft may be detached with the thrust roller bearing attached.

37.  Remove the C3 clutch component from the input shaft and the front planetary gear component.

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Note
•  In some cases, the C3 clutch component may be detached with the thrust washer attached.

38.  Remove the brake band anchor bolt.

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39.  Remove B1 the brake band.

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40.  Inspect the lining of the brake band.

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new brake band and C3 clutch. When replacing, inspect the contact surfaces between the C3 clutch drum and B1 brake band. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with a new B1 brake band, soak it at least 2 h in ATF.

41.  Remove the snap ring using snap ring pliers.

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Caution
•  The brake piston cover will fly off due to the force of the piston return spring.
•  Do not drop the brake piston cover.
•  Do not drop the B1 brake piston.

42.  Remove the brake piston cover, B1 brake piston and the piston return spring.

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43.  Remove the thrust bearing, bearing race and the C1 clutch component.

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Note
•  In some cases, the C1 clutch component may be detached with the thrust bearing attached.

44.  Remove the thrust bearing, bearing race and the sun gear input drum.

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45.  Remove the detent spring cover and detent spring.

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Caution
•  Be careful not to apply too much force to the pawl return spring.

46.  Remove the pawl return spring and the parking pawl shaft.

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Caution
•  Be careful not to apply too much force to the torsion spring.

47.  Remove the torsion spring and the spring guide sleeve.

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48.  Remove the parking pawl and the parking pawl bracket.

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49.  Disconnect the parking rod from the manual valve lever.

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50.  Remove the manual valve lever from the transaxle case.

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51.  Remove the parking rod from the transaxle case.

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52.  Remove the parking pin from the transaxle case.

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Note
•  Inspect the direction of the parking pin.

53.  Remove the counter gear component.

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Note
•  For easy removal, tilt the counter gear component slightly.

54.  Remove the differential component.

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Caution
•  Do not damage the VSS wiring harness.
•  Do not pull hard on the VSS wiring harness.

55.  Disconnect the VSS wiring harness from the tube wiring clamp.

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Caution
•  Do not damage the oil cooler outlet tube.

56.  Remove the pipe clamp, transaxle case No.1 plate, wiring harness clip and the oil cooler outlet tube.

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57.  Remove the O-rings from the oil cooler outlet tube.

58.  Using a flathead screwdriver and a hammer, pry back the crimp on the lockwashers.

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Caution
•  If the lockwasher crimp is not completely pried back, the tool cannot fit over the bolt properly and the bolt cannot be loosened.

59.  Remove the lockwashers, washers and the counter drive gear.

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Caution
•  Do not damage the VSS wiring harness.
•  Do not pull hard on the VSS wiring harness.
•  Do not damage the VSS.

60.  Remove the VSS and spacer from the counter drive gear.

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61.  Using a flathead screwdriver, remove the snap ring.

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Caution
•  Do not drop the sun gear.

62.  Remove the rear planetary gear component and the one-way clutch.

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Note
•  In some cases, the sun gear may be detached with the bearing race attached.
Note
•  Remove the sun gear in the center while holding it.
•  The thrust washer of the rear planetary gear on the rear side might remain on the transaxle case side when removing the rear planetary gear component.

63.  Remove the thrust bearing and the bearing races.

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64.  Using a flathead screwdriver, remove the snap ring.

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65.  Remove the retaining plates, drive and driven plates.

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Note
•  Inspect the number of drive plates and driven plates.

66.  Inspect the lining of all drive plates.

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with new drive plates, soak them at least 2 h in ATF.

67.  Remove the C2 clutch component and the thrust bearing.

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68.  Remove the seal rings from the transaxle case.

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69.  Remove the transaxle case plate No.2.

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70.  Remove the transaxle case plate No.3.

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Caution
•  Do not damage the transaxle case.
•  If using a screwdriver, use a wooden block or equivalent to avoid damaging the fitting surface of the transaxle case.

71.  Remove the oil seal lip using a razor.

72.  Using a tape-wrapped flathead screwdriver, remove the oil seal (transaxle case side).

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Caution
•  Do not damage the transaxle case.
•  If using a screwdriver, use a wooden block or equivalent to avoid damaging the fitting surface of the transaxle case.

73.  Using a tape-wrapped flathead screwdriver, remove the oil seal (manual shaft).

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