AUTOMATIC TRANSAXLE DISASSEMBLY

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Precaution


General notes

•  The oil pan could contain small chips, shavings, and other particles which may be helpful in inspecting the condition of the transaxle and diagnosing certain problems.
To ensure that all foreign particles stay in the oil pan, make sure that the transaxle is never tipped completely over while the oil pan is still installed.
1.  Disassemble the transaxle in a clean area (dustproof work space) to prevent entry of dust into the mechanisms.
2.  Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during disassembly.
3.  Use only plastic hammers when applying force to separate the light alloy case joints.
4.  Never use rags during disassembly; they may leave particles that can clog fluid passage.
5.  Several parts resemble one another; arrange them so that they do not get mixed up.
6.  Disassemble the control valve component and thoroughly clean it when the clutch or brake band has burned or when the ATF has degenerated.
Warning
•  Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.


Disassembly


Components

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1
Torque converter
2
Oil filler tube and oil dipstick
3
Input/turbine speed sensor
4
Oil pressure switch
5
Transaxle range switch
6
Vehicle speed sensor
7
Intermediate sensor
8
Connector pipe
9
Connector bolt
10
Oil pipe
11
Stud bolt
12
Connector bolt
13
Steel ball
14
Spring
15
Plug
16
Oil cover
17
Secondary control valve body
18
Oil pan
19
Hose
20
Joint pipe
21
Joint
22
Primary control valve body
23
Oil pump
24
Thrust washer
25
End cover
26
Bearing race

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1
2–4 brake band
2
Needle bearing
3
Clutch component
4
Snap ring
5
Rear planetary gear component
6
Needle bearing
7
Front sun gear
8
Needle bearing
9
Front planetary gear component
10
Front internal gear and one-way clutch
11
Lock nut
12
Bearing
13
Distance piece
14
Snap ring
15
Low and reverse brake
16
Snap ring
17
One-way clutch inner race
18
Piston return spring
19
Low and reverse brake piston
20
Band strut

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1
Manual shaft
2
Servo apply accumulator
3
Forward accumulator
4
Parking rod lever component
5
Band servo
6
Differential
7
Actuator plate
8
Support actuator
9
Parking pawl shaft
10
Parking pawl
11
Pawl return spring
12
Needle bearing
13
Bearing race
14
Output gear component
15
Secondary sun gear
16
Direct clutch component
17
One-way clutch No.2
18
Needle bearing
19
Seal rings
20
Spacer
21
Snap ring
22
Reduction brake
23
Snap ring
24
Springs and retainer component
25
Reduction brake piston
26
Forward clutch
27
Forward clutch hub
28
Primary gear
29
Bearing race
30
Oil seal
31
Transaxle case

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1
Bearing race
2
Bearing
3
Adjustment shim
4
Oil seal
5
Converter housing


Disassembly procedure

1.  Remove the torque converter, and immediately turn it so that the hole faces upward.

This will help to keep any remaining fluid from spilling.

2.  Remove the ATF dipstick and oil filler tube.

3.  Remove the O-ring from the oil filler tube.

4.  Remove the breather hose.

5.  Assemble the SST.

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6.  Lift the transaxle and mount it on the SST.

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7.  Remove the input/turbine speed sensor.

8.  Remove the O-ring from the input/turbine speed sensor.

9.  Remove the oil pressure switch.

10.  Remove the transaxle range switch.

11.  Remove the vehicle speed sensor.

12.  Remove the O-ring from the vehicle speed sensor.

13.  Remove the intermediate sensor.

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

15.  Remove the connector pipe, connector bolt and oil pipe.

Warning
•  Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
Caution
•  Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
•  If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil cover, and clean with cleaning fluids.

16.  Remove in the order shown in the figure. (vehicles with i-stop)

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1
Stud bolt
2
O-ring
3
Connector bolt
4
Packing
5
Steel ball
6
Spring
7
Plug

17.  Remove the oil cover.

Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause.

(1)  Clutch facing material
•  Drive plate and brake band wear
(2)  Steel (magnetic)
•  Bearing, gear, and driven plate wear
(3)  Aluminum (nonmagnetic)
•  Aluminum part wear

18.  Disconnect the solenoid valve connector.

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19.  Remove the bolts as shown in the figure.

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20.  Remove the secondary control valve body.

21.  Remove the coupler component.

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22.  Remove the O-rings and tubular pins from the transaxle case.

Warning
•  Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
Caution
•  Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal.
•  If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil pan, and clean with cleaning fluids.

23.  Remove the oil pan.

Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause.

(1)  Clutch facing material
•  Drive plate and brake band wear
(2)  Steel (magnetic)
•  Bearing, gear, and driven plate wear
(3)  Aluminum (nonmagnetic)
•  Aluminum part wear

24.  Remove in the order shown in the figure. (vehicles with i-stop)

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1
Hose
2
Joint pipe
3
O-ring
4
Joint

25.  Disconnect the solenoid valve connector, ground, and transaxle fluid temperature sensor.

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26.  Remove the oil strainer.

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

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28.  Remove the bolts as shown in the figure.

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Note
•  Remove the control valve body by removing the head of the manual valve from the port of the parking assist lever component.

29.  Remove the Primary control valve body.

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30.  Remove the coupler component.

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31.  Remove the accumulator component.

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32.  Remove the manual shaft.

(1)  Remove the roll pin using a pin punch.
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(2)  Remove the manual shaft.
(3)  Remove the O-ring from the manual shaft.
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33.  Remove the parking rod lever component.

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34.  Remove the band servo component.

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35.  Remove the oil pump.

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36.  Remove the converter housing by tapping lightly with a plastic hammer.

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37.  Remove the forward clutch component.

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38.  Remove the differential.

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39.  Remove the actuator plate.

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40.  Remove the support actuator.

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41.  Pull out the parking pawl shaft.

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42.  Remove the parking pawl.

43.  Remove the pawl return spring.

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44.  Remove the Output gear component.

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45.  Remove the Secondary sun gear.

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46.  Remove the direct clutch component and one-way clutch No.2.

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47.  Remove the Needle bearing, seal rings and spacer.

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48.  Remove the reduction brake.(See REDUCTION BRAKE DISASSEMBLY/ASSEMBLY.)

49.  Remove the end cover.

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50.  Remove the O-rings from the transaxle case.

51.  Remove the band strut.

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52.  Remove the 2–4 brake band, and hold it together using a piece of wire as shown in the figure.

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53.  Remove the clutch component.

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54.  Remove the snap ring.

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55.  Remove the rear planetary gear component.

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56.  Remove the front sun gear by tapping its end with a flathead screwdriver or similar tool. as shown in the figure.

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57.  Remove the forward clutch hub.

58.  Remove the front planetary gear component.

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59.  Remove the front internal gear and one-way clutch component.

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60.  Remove the locknut.

(1)  Knock the crimped portion of the locknut outward by using a small chisel and a hammer.
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(2)  Install the SST to the primary gear in the order shown.
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Tightening torque
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
(3)  Install the SST to the locknut in the order shown.
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(4)  Remove the locknut.
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61.  Remove the primary gear by tapping it with a flathead screwdriver, etc. as shown in the figure.

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62.  Remove the bearing and distance piece.

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Caution
•  Removing the bearing race using a flathead screwdriver can damage the inside of the bearing race. Handle the flathead screwdriver carefully.

63.  Remove torx screws from the converter housing side.

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64.  Remove the bearing race.

65.  Remove the bearing race using the SST as shown in the figure.

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66.  Remove the bearing using the SST as shown in the figure.

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