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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