AUTOMATIC TRANSAXLE DISASSEMBLY
id051700660600
Structural View
Automatic transaxle 1
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1
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3 bolts*
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2
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Electric AT oil pump*
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3
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O-ring*
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4
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Stud bolt
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5
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Torque converter
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6
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3 bolts
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7
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Oil cooler
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8
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O-ring
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9
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Bolt
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10
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Dipstick
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11
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O-ring
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12
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Hose clamp
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13
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16 bolts
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14
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Oil pan
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15
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Magnet
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16
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Bolt
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17
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Oil strainer
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18
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O-ring
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19
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7 bolts
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20
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Control valve body
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21
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Dowel pin
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22
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Gasket
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23
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O-ring
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24
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Oil seal
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* :Only vehicles with i-stop
Automatic transaxle 2
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1
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21 bolts
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2
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Converter housing
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3
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O-ring (oil pump)
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4
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O-ring
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5
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3 bolts
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6
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Baffle plate
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7
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Oil seal
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8
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Bearing race
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9
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Shim
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10
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Snap ring
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11
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Roller bearing
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12
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Shim
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Automatic transaxle 3
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1
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7 bolts
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2
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Oil pump
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3
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Thrust washer
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4
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Clutch component
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5
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D-ring
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6
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Seal ring
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7
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Thrust needle bearing
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8
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High clutch hub
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9
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Thrust needle bearing
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10
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Low clutch hub
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11
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Thrust needle bearing
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12
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Ring gear and differential
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13
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Thrust needle bearing
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14
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Oil pipe
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15
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Secondary gear and output gear
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16
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Thrust needle bearing
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17
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Plug
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18
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Oil seal
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19
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Bearing race
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20
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Shim
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Automatic transaxle 4
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1
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12 bolts
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2
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End cover component
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3
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O-ring
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4
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Shim
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5
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Bearing race
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6
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Thrust needle bearing
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7
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Rear planetary gear
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8
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Rear sun gear
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9
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Front sun gear
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10
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Locknut
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11
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Front planetary gear
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12
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Snap ring
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13
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Retaining plate
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14
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Springs and retainer component
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15
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Drive plate
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16
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Driven plate
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17
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Low and reverse brake piston A
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18
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Snap ring
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19
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Dished plate
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20
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Low and reverse brake piston B2
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21
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Spacer
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22
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Snap ring
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23
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Low and reverse brake piston B1
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Automatic transaxle 5
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1
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2 bolts
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2
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Detent bracket component
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3
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Pawl return spring
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4
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Parking pawl shaft
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5
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Parking pawl
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6
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Parking pawl pin
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7
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Parking rod component
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8
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Roll pin
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9
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Parking shift lever component
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10
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Parking assist lever component
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11
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Manual plate component
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12
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Oil seal
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13
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Washer
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Automatic transaxle 6
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1
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Primary gear
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2
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Angular contact ball bearing
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3
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Transaxle case
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Disassembly Procedure
1. Clean the outside of the transaxle. (See AUTOMATIC TRANSAXLE CLEANING.)
2. Remove the electric AT oil pump using the following procedure: (Only vehicles with i-stop)
-
Caution
-
• Do not drop or apply a shock to the electric AT oil pump. Replace the electric AT oil pump with a new one if it was dropped or received an impact.
• Do not disassemble the electric AT oil pump. Replace the electric AT oil pump if it has been disassembled.
• Verify that there is no sealant or foreign matter in the electrical AT oil pump and transaxle. Otherwise, it could cause a malfunction.
• Be careful not to scratch or damage the aligning surfaces of the electric AT oil pump and end cover and the O-ring installation area so as not to cause ATF leakage.
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1
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3 bolts
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2
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Electric AT oil pump
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3
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O-ring
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- (1) Remove the bolts shown in the figure.
-
- (2) Remove the electric AT oil pump.
-
-
Note
-
• Shake the electric AT oil pump by hand as shown in the figure and remove it.
- (3) Remove the O-rings.
-
3. Remove the stud bolts.
4. Remove the torque converter.
5. Remove the oil cooler in the order shown in the figure.
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1
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Bolt
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2
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Oil cooler
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3
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O-ring
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6. Remove the dipstick in the order shown in the figure.
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1
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Bolt
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2
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Dipstick
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3
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O-ring
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7. Remove the hose clamp.
8. Install the transaxle to the SST (engine stand) using the following procedure:
-
Caution
-
• When installing the transaxle to the SST (engine stand) using chain hoists, be careful not to allow the transaxle to contact the SST (engine stand). If the transaxle contacts the SST, verify the areas which are contacted and replace damaged parts with new ones.
- (1) Install the SSTs to the transaxle using the following procedure.
-
-
Note
-
• When installing the SST (49 L010 1A0) to the transaxle (stud bolt holes), use new part number: 9YA02 1440 or M14 x 1.5 bolt, length 100 mm {3.94 in}.
• When installing the SST (49 UN30 3050) to the transaxle, use new part number: 9YA02 1015, or M10 x 1.5 bolts (length 35 mm {1.4 in}).
- 1) Temporarily install the arms (49 L010 102) using new part number: 9YA02 1440, or M14 x 1.5 bolts, length 100 mm {3.94 in}.
-
-
Note
-
• To adjust the installation position of the SST in Step 3), temporarily tighten the bolts.
A :Part number: 9YA02 1440, or M14 x 1.5 bolt, length 100 mm {3.94 in}
- 2) Assemble the SST (49 L010 1A0).
-
-
Note
-
• Use bolts (49 L010 105) with a length of 138 mm {5.43 in}.
A :Washer
B :Approx. 20 mm {0.79 in}
C :Approx. 18 mm {0.71 in}
D :Approx. 47 mm {1.9 in}
- 3) Install the SST assembled in Step 2).
-
-
Note
-
• Adjust so that the plate (49 L010 101) and arms (49 L010 102) are level, and install.
A :Washer
B :Level out
- 4) Verify that nothing other than the SST arms (49 L010 102) installation area contacts the transaxle.
-
-
Caution
-
• If something other than the SST arms (49 L010 102) installation area contacts the transaxle, readjust the SST to prevent damaging the part.
- 5) Tighten the nuts and bolts.
-
-
Tightening torque
-
• Bolt: Part number: 9YA02 1440, or M14 x 1.5 bolt, length 100 mm {3.94 in}
39.2—52.0 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}
• Nut: 49 L010 104
140—160 N·m {15—16 kgf·m, 104—118 ft·lbf}
- 6) Assemble the SSTs using part number: 9YA02 1015, or M10 x 1.5 bolt (length 35 mm {1.4 in}).
-
A :Part number: 9YA02 1015, or M10 x 1.5 bolt, length 35 mm {1.4 in}
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Tightening torque
-
37.3—52.0 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}
- (2) Using chain hoists, install the transaxle to the SST (engine stand) using part number: 9YA02 A220, or M12 x 1.75 bolt, length 40 mm {1.6 in}.
-
-
Caution
-
• When installing the transaxle to the SST (engine stand) using chain hoists, be careful not to allow the transaxle to contact the SST (engine stand). If the transaxle contacts the SST, verify the areas which are contacted and replace damaged parts with new ones.
-
Note
-
• Tighten the four locations with bolts and securely install the transaxle to the SST (engine stand).
A :Part number: 9YA02 A220, or M12 x 1.75 bolt, length 40 mm {1.6 in}
-
Tightening torque
-
88—118 N·m {9.0—12 kgf·m, 65—87 ft·lbf}
- (3) Remove the SSTs.
-
A :Part number: 9YA02 1015, or M10 x 1.5 bolt, length 35 mm {1.4 in}
9. Remove the oil pan and magnet using the following procedure:
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1
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16 bolts
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2
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Oil pan
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3
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Magnet
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- (1) Remove the bolts shown in the figure.
-
-
Caution
-
• If the removed bolts with spring washers are reused it could loosen the bolts due to spring weakness, therefore when performing the automatic transaxle assembly, use new bolts.
- (2) Remove the oil pan using the separator tool.
-
- (3) Remove the magnet.
-
10. Remove the oil strainer in the order shown in the figure.
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Caution
-
• To avoid damaging the control valve body, if there is a large amount of foreign material at the bottom of the oil pan when the oil pan is removed, replace the oil strainer with a new one.
• If there is not a large amount of foreign material at the bottom of the oil pan, the oil strainer does not have to be replaced.
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1
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Bolt
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2
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Oil strainer
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3
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O-ring
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11. Remove the control valve body using the following procedure:
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Caution
-
• If the control valve body is placed with the shift solenoid side facing down on a workbench, the wiring harness or connector of the coupler component may be damaged. When placing the control valve body on a workbench, always place it with the control valve body connector side facing down. However, if the control valve body is directly placed on the workbench, the control valve body connector area or the sensor may be damaged. Always place the control valve body on an impact-absorbing material, which is free of foreign matter, so that the connector area and the sensor do not contact the workbench directly.
• Do not drop or apply a shock to the control valve body. Replace the control valve body with a new one if it was dropped or received an impact.
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1
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7 bolts
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2
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Control valve body
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3
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Dowel pin
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4
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Gasket
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5
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O-ring
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- (1) Remove the bolts shown in the figure.
-
- (2) Remove the control valve body.
-
-
Caution
-
• Remove the control valve body straight so that force is not applied to the control valve body connector in the lateral direction.
- (3) Place the removed control valve body with the connector side pointing downward on a workbench.
-
-
Caution
-
• If the control valve body is placed with the shift solenoid side facing down on a workbench, the wiring harness or connector of the coupler component may be damaged. When placing the control valve body on a workbench, always place it with the control valve body connector side facing down. However, if the control valve body is directly placed on the workbench, the control valve body connector area or the sensor may be damaged. Always place the control valve body on an impact-absorbing material, which is free of foreign matter, so that the connector area and the sensor do not contact the workbench directly.
A :Control valve body
B :Impact-absorbing material which is free of foreign matter
C :Sensor
D :Control valve body connector
E :Shift solenoid
- (4) Remove the dowel pins.
-
- (5) Remove the gaskets.
-
- (6) Remove the O-ring.
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12. Remove the oil seal.
13. Remove the converter housing using the following procedure:
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1
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21 bolts
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2
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Converter housing
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3
|
O-ring (oil pump)
|
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4
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O-ring
|
- (1) Remove the bolts shown in the figure.
-
-
Caution
-
• Sealant has been applied to the removed bolts. If the bolts are reused it could cause ATF leakage, therefore when performing the automatic transaxle assembly, use new bolts.
- (2) Remove the bolts shown in the figure.
-
- (3) Lightly tap the converter housing evenly using a plastic hammer to remove it.
-
- (4) Remove the O-rings.
-
14. Remove the accessories from the converter housing using the following procedure:
- (1) Remove the baffle plate using the procedure shown in the figure.
-
- (2) Measure opening width A of the snap ring shown in the figure and verify the type of snap ring.
-
-
Snap ring type
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Dimension A is 19.4—20.6 mm: Type A
Dimension A is 16.4—17.6 mm: Type B
-
• If the snap ring is type A, go to Step (3) because the snap ring cannot be removed.
• If the snap ring is type B, remove the snap ring, roller bearing, and shim in the following order.
A :Snap ring
B :Roller bearing
C :Shim
- 1) Remove the snap ring using 2 flathead screwdrivers as shown in the figure.
-
- 2) Remove the roller bearing and shim.
- (3) Remove the oil seal.
-
- (4) Remove the bearing race and shim using the SSTs and procedure shown in the figure.
-
-
Caution
-
• Because the shim will deform when removing the bearing race, use a new shim when performing the automatic transaxle assembly.
15. Remove the oil pump using the following procedure:
- (1) Remove the bolts shown in the figure.
-
- (2) Remove the oil pump.
-
16. Remove the thrust washer.
17. Remove the clutch component.
18. Remove the D-rings from the clutch component.
19. Remove the seal ring from the clutch component.
-
Caution
-
• Only remove the seal ring when replacing it.
• Do not damage the shaft part of the clutch component.
• Collect all fragments if the seal ring is damaged.
-
Note
-
• Remove the seal ring using a precision driver (flathead).
20. Remove the thrust needle bearing.
21. Remove the high clutch hub.
22. Remove the thrust needle bearing.
23. Remove the low clutch hub.
24. Remove the thrust needle bearing.
25. Remove the ring gear and differential.
26. Remove the thrust needle bearing.
27. Remove the oil pipe.
28. Remove the secondary gear and output gear.
29. Remove the plug.
30. Remove the thrust needle bearing.
31. Remove the oil seal.
32. Remove the bearing race and shim using the following procedure:
- (1) When removing the bearing race and shim using the SST, place a rag as an impact-absorbing material on the oil catch area of the SST (engine stand) because the bearing race and shim will drop when removed.
-
A :Impact-absorbing material (rag)
- (2) Remove the bearing race and shim using the SSTs and procedure shown in the figure.
-
-
Caution
-
• Because the shim will deform when removing the bearing race, use a new shim when performing the automatic transaxle assembly.
- (3) Remove the rag placed on the oil catch area of the SST (engine stand) used as an impact-absorbing material.
33. Remove end cover component using the following procedure:
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1
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12 bolts
|
|
2
|
End cover component
|
|
3
|
O-ring
|
- (1) Remove the bolts shown in the figure.
-
-
Caution
-
• Sealant has been applied to the removed bolts. If the bolts are reused it could cause ATF leakage, therefore when performing the automatic transaxle assembly, use new bolts.
- (2) Remove the bolts shown in the figure.
-
- (3) Lightly tap the end cover component using a plastic hammer to remove it.
-
- (4) Remove the O-ring.
-
34. Remove the shim.
35. Remove the bearing race.
36. Remove the thrust needle bearing.
37. Remove the rear planetary gear.
38. Remove the rear sun gear.
39. Remove the front sun gear.
40. Inspect the transaxle case, primary gear, and the angular contact ball bearing using the following procedure:
- (1) Visually inspect the transaxle case and primary gear. (See VISUAL INSPECTION OF PARTS.)
- (2) Rotate the primary gear by hand and verify that there is no malfunction in the angular contact ball bearing (rotation sticking).
-
-
• If there is a malfunction, remove the primary gear in Step 67 and replace the malfunctioning parts with new ones as when performing the automatic transaxle assembly.
41. Remove the locknut using the following procedure:
-
Caution
-
• Rotate and adjust the rotation handle of the engine stand so that the end cover side is situated sideways and remove the locknut. If the locknut is removed with the end cover side pointed downward, the front planetary gear will drop.
• Torque greater than approx. 130 N·m {13 kgf·m, 96 ft·lbf} is required to loosen the locknut. For safety purposes, perform the procedure using two people, one loosens the locknut and the other supports the engine stand.
- (1) Rotate and adjust the rotation handle of the engine stand so that the end cover side is situated sideways.
-
- (2) Install the SSTs.
-
-
Note
-
• Engage the three projections of the SST (49 D019 015) with the three holes of the primary gear.
• When installing the SST (49 D019 016), use the bolts supplied with the SST (49 D019 016), or M8 × 1.25 bolt (length 18 mm {0.71 in}).
A :Extension bar
B :Bolt supplied with SST (49 D019 016) or M8 x 1.25 (length 18 mm {0.71 in})
A :Extension bar
B :Bolt supplied with SST (49 D019 016) or M8 x 1.25 (length 18 mm {0.71 in})
-
SST installation bolt tightening torque
-
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
- (3) Loosen the locknut and remove it.
-
-
Caution
-
• For safety purposes, perform the procedure using two people, one loosens the locknut and the other supports the engine stand.
- (4) Remove the SSTs.
-
A :Extension bar
B :Bolt supplied with SST (49 D019 016) or M8 x 1.25 (length 18 mm {0.71 in})
- (5) Remove the locknut from the front planetary gear.
-
42. Remove the front planetary gear.
43. Perform a simple inspection of the low and reverse brake using the following procedure:
- (1) Blow compressed air into the two oil passages shown in the figure and verify the operation condition of the low and reverse brake.
-
-
Warning
-
• Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
-
Caution
-
• To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
-
Compressed air pressure
-
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
-
• If there is a malfunction, verify the cause and repair the applicable part after disassembly.
44. Remove the snap ring using the following procedure:
- (1) Install the SSTs.
-
- (2) Tighten the SST (49 G019 029) until there is no longer any spring force from the springs and retainer component applied to the snap ring.
-
-
Caution
-
• If the SST (49 G019 029) is tightened with excessive force, surrounding parts could be damaged. Stop tightening if a gap appears between the snap ring and retaining plate.
-
Note
-
• Lock the SST (49 G019 027) against rotation using a flathead screwdriver and tighten the SST (49 G019 029).
A :Snap ring
B :Retaining plate
C :Gap
- (3) Remove the snap ring.
-
- (4) Loosen the SST (49 G019 029) and remove the SSTs.
-
-
Note
-
• Lock the SST (49 G019 027) against rotation using a flathead screwdriver and loosen the SST (49 G019 029).
45. Remove the retaining plate.
46. Remove the springs and retainer component.
47. Remove the drive plates and driven plates.
A :Drive plate
B :Driven plate
48. Remove low and reverse brake piston A using the following procedure:
- (1) Blow compressed air into the oil passage shown in the figure.
-
-
Warning
-
• Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
-
Caution
-
• To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
-
Compressed air pressure
-
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
- (2) Remove low and reverse brake piston A removed from the transaxle case.
-
49. Remove the snap ring.
-
Note
-
• When removing the snap ring, insert a flathead screwdriver into the position shown in the figure and the snap ring can be easily removed by prying it off.
50. Remove the dished plate.
51. Remove low and reverse brake piston B2 using the following procedure:
- (1) Blow compressed air into the oil passage shown in the figure.
-
-
Warning
-
• Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
-
Caution
-
• To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
-
Compressed air pressure
-
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
- (2) Remove low and reverse brake piston B2 removed from the transaxle case.
-
52. Insert a small flathead screwdriver into the oil passage shown in the figure and remove the spacer.
A :Spacer
53. Remove the snap ring using the following procedure:
- (1) Move the position of the snap ring end gap.
-
-
Caution
-
• Do not damage the piston friction surface. Otherwise, oil could leak.
- (2) Install the SSTs.
-
- (3) Insert a small flathead screwdriver into the oil passage and press the snap ring using the screwdriver.
-
- (4) Remove the snap ring.
-
- (5) Remove the SST.
-
-
Note
-
• Remove the SST in the lateral direction because the gap between the SST and part is small.
54. Remove low and reverse brake piston B1 using the following procedure:
- (1) Blow compressed air into the oil passage shown in the figure.
-
-
Warning
-
• Always wear protective eye wear when using the air compressor. Otherwise, ATF or dirt particles blown off by the air compressor could get into the eyes.
-
Caution
-
• To prevent damage to parts, always use an air compressor which is adjusted to the indicated pressure.
-
Compressed air pressure
-
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
- (2) Remove low and reverse brake piston B1 removed from the transaxle case.
-
55. Remove the detent bracket component in the order shown in the figure.
|
1
|
Bolt
|
|
2
|
Detent bracket component
|
56. Remove the pawl return springs.
57. Remove the parking pawl shaft.
58. Remove the parking pawl.
59. Remove the parking pawl pin.
60. Remove the parking rod component using the following procedure:
- (1) Rotate the parking rod component as shown in the figure and align the parking rod component projection with the keyhole of the manual plate component.
-
- (2) Remove the parking rod component.
-
61. Remove the roll pins shown in the figure using a pin punch.
-
Note
-
• Use a pin punch with an end outer diameter of 3 mm {0.1 in} or more and less than 4 mm {0.2 in}.
62. Remove the parking shift lever component.
63. Remove the parking assist lever component.
64. Remove the manual plate component.
65. Remove the oil seal.
66. Remove the washer.
67. Perform the following procedure only if there is a malfunction found in the Step 40 inspection.
- (1) Remove the primary gear using the following procedure:
-
-
Caution
-
• Because the angular contact ball bearing will be damaged if the primary gear is removed, remove the primary gear only if there is a malfunction found in the Step 40 inspection.
• Because the angular contact ball bearing is integrated with the transaxle case, if the primary gear is removed, replace the transaxle case with a new one when performing the automatic transaxle assembly.
- 1) When removing the primary gear using the SST, place a rag as an impact-absorbing material on the oil catch area of the SST (engine stand) because the primary gear will drop when removed.
-
A :Impact-absorbing material (rag)
- 2) Remove the primary gear using the SSTs.
-
-
Note
-
- 3) Remove the rag placed on the oil catch area of the SST (engine stand) used as an impact-absorbing material.
- (2) Remove the angular contact ball bearing from the primary gear using the following procedure:
-
-
Note
-
• If an angular contact ball bearing remains in the transaxle case and the only primary gear can be removed when removing the primary gear, the following removal procedure is not necessary.
- 1) Pry the angular contact ball bearing evenly using two flathead screwdrivers to create a gap between the primary gear end and the angular contact ball bearing end until the tab of the SST (49 0839 425C) is inserted.
-
-
Note
-
• If there is already a gap between the primary gear end and the angular contact ball bearing end in which the tab of the SST (49 0839 425C) is inserted when removing the primary gear, this procedure is not necessary.
A :Gap
- 2) Secure the primary gear in a vise.
-
-
Caution
-
• Insert a protective plate between the vise and the part so as not to damage the part.
A :Vise
- 3) Remove the angular contact ball bearing using the SSTs.
-
A :Vise
- 4) Remove the primary gear from the vise.
-
A :Vise
68. Remove the SST from the transaxle case using the following procedure:
- (1) Remove the transaxle case from the SST (engine stand).
-
-
Caution
-
• For safety purposes, perform the procedure using two people, one removes the transaxle case from the SST and the other supports the transaxle case.
A :Part number: 9YA02 A220, or M12 x 1.75 bolt, length 40 mm {1.6 in}
- (2) Remove the SST from the transaxle case.
-
- (3) Disassemble the SST.
-
A :Part number: 9YA02 1440, or M14 x 1.5 bolt, length 100 mm {3.94 in}
69. Disassemble the parts in the following order.
-
Note
-
• Disassemble the parts in the following order because the parts in the transaxle may be used for inspection, measurement, or adjustment.
- (1) Clutch component (See CLUTCH COMPONENT DISASSEMBLY.)
- (2) Oil pump (See OIL PUMP DISASSEMBLY.)
- (3) Secondary gear and output gear (See SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY.)
- (4) Ring gear and differential (See RING GEAR AND DIFFERENTIAL DISASSEMBLY.)
- (5) End cover component (See END COVER COMPONENT DISASSEMBLY.)
- (6) Control valve body (See CONTROL VALVE BODY DISASSEMBLY.)
70. Clean away the remaining silicone sealant on the transaxle case, converter housing, end cover, oil pan, and the electric AT oil pump*.
*:Only vehicles with i-stop
71. Clean the disassembled parts. (See AUTOMATIC TRANSAXLE CLEANING.)
72. Perform the following inspection and replace a malfunctioning part with a new one.
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