AUTOMATIC TRANSAXLE DISASSEMBLY

id051700660600


Structural View


Automatic transaxle 1

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1
3 bolts*1
2
Electric AT oil pump*1
3
O-ring*1
4
Stud bolt
5
Torque converter
6
3 bolts
7
Oil cooler
8
O-ring
9
Bolt
10
Dipstick
11
O-ring
12
Hose clamp
13
16 bolts
14
Oil pan
15
Magnet
16
2 bolts
17
Oil strainer
18
11 bolts
19
Control valve body
20
Dowel pin
21
Gasket
22
Spool valve spring*2
23
Spool valve*2
24
Oil seal

*1  :Only vehicles with i-stop
*2  :Only vehicles with oil cooler No.2


Automatic transaxle 2

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1
25 bolts
2
Converter housing
3
O-ring
4
O-ring
5
3 bolts
6
Baffle plate
7
Oil seal
8
Bearing race
9
Shim
10
Bearing race
11
Shim


Automatic transaxle 3

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1
Baffle plate
2
7 bolts
3
Oil pump
4
Thrust needle bearing
5
High clutch component and low clutch component
6
Turbine shaft
7
D-ring
8
Seal ring
9
Thrust needle bearing
10
High clutch hub
11
Thrust needle bearing
12
Low clutch hub
13
Thrust needle bearing
14
Ring gear and differential
15
Oil pipe
16
Secondary gear and output gear
17
2 bolts
18
Baffle plate
19
Oil seal
20
Bearing race
21
Shim
22
Bearing race


Automatic transaxle 4

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1
12 bolts
2
End cover component
3
O-ring
4
Shim
5
Thrust needle bearing
6
Reduction sun gear
7
Thrust needle bearing
8
Rear planetary gear
9
Rear sun gear
10
Front sun gear
11
Locknut
12
Front planetary gear
13
Snap ring
14
One-way clutch
15
Drive plate
16
Driven plate
17
Springs and retainer component
18
Low and reverse brake piston


Automatic transaxle 5

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1
Connector
2
Gasket
3
Gasket
4
Oil pipe
5
O-ring
6
2 bolts
7
Detent bracket component
8
Pawl return spring
9
Support actuator
10
Parking pawl pin
11
Parking rod component
12
Plug
13
Gasket
14
Parking pawl shaft
15
Parking pawl
16
Roll pin
17
Parking shift lever component
18
Parking assist lever component
19
Manual plate component
20
Oil seal
21
Washer
22
Connector bolt *
23
Gasket *

*  :Only vehicles with oil cooler No.2


Automatic transaxle 6

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1
Primary gear
2
Angular contact ball bearing
3
Plug
4
Gasket
5
Transaxle case


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 an impact 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.
•  To prevent a malfunction, be careful not to allow sealant or foreign matter to penetrate the electric AT oil pump and the interior of the transaxle.
•  Be careful not to scratch or damage the aligning surfaces of the electric AT oil pump and end cover and the O-ring assembly area so as not to cause ATF leakage.
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1
3 bolts
2
Electric AT oil pump
3
O-ring

(1)  Remove the bolts shown in the figure.
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(2)  Remove the electric AT oil pump.
Note
•  Shake the electric AT oil pump by hand as shown in the figure and remove it.
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(3)  Remove the O-rings.
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3.  Remove the stud bolts.

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4.  Remove the torque converter.

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5.  Remove the oil cooler in the order shown in the figure.

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1
Bolt
2
Oil cooler
3
O-ring

6.  Remove the dipstick in the order shown in the figure.

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1
Bolt
2
Dipstick
3
O-ring

7.  Remove the hose clamp.

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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.
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Note
•  When installing the SST (49 L010 1A0) to the transaxle (stud bolt holes), use part number: 9YA02 1440, or M14×1.5 bolts, length 100 mm {3.94 in}.
•  When installing the SSTs (49 UN30 3050) to the transaxle, use part number: 9YA02 1015, or M10×1.5 bolt, length 35 mm {1.4 in}, and M10 bolt, nut.
1)  Temporarily install the arms (49 L010 102) using part number: 9YA02 1440, or M14×1.5 bolts, length 100 mm {3.94 in}.
Note
•  To adjust the installation position of the SST in Step 3), temporarily tighten the bolts.
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A  :Part number: 9YA02 1440, or M14×1.5 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}.
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A  :Washer
B  :Approx. 20 mm {0.79 in}
C  :Approx. 26 mm {1.0 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.
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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 M14×1.5 bolt, length 100 mm {3.94 in}
40—52 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 M10×1.5 bolt, length 35 mm {1.4 in}, and M10 bolt, nut.
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A  :Part number: 9YA02 1015, or M10×1.5 bolt, length 35 mm {1.4 in}
B  :M10 bolt, nut
Tightening torque
38—52 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 M12×1.75 bolts, 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).
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A  :Part number: 9YA02 A220, or M12×1.75 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.
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A  :Part number: 9YA02 1015, or M10×1.5 bolt, length 35 mm {1.4 in}
B  :M10 bolt, nut

9.  Remove the oil pan and magnet using the following procedure:

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1
16 bolts
2
Oil pan
3
Magnet

(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.
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(2)  Remove the oil pan using the separator tool.
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(3)  Remove the magnet.
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10.  Remove the oil strainer in the order shown in the figure.

Caution
•  If the oil strainer is reused while containing excessive foreign matter, it could cause an operation malfunction, therefore when performing the automatic transaxle assembly, use a new oil strainer.
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1
Bolt
2
Oil strainer

11.  Remove the control valve body using the following procedure:

Caution
•  Place the removed control valve body with the TCM side pointing upward on a workbench. If placing it with the TCM side pointing downward on a workbench, the TCM could be damaged.
•  Do not drop or apply an impact 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
11 bolts
2
Control valve body
3
Dowel pin
4
Gasket
5
Spool valve spring*
6
Spool valve*

*  :Only vehicles with oil cooler No.2
(1)  Remove the bolts shown in the figure.
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(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.
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(3)  Place the removed control valve body with the TCM side pointing upward on a workbench.
Caution
•  Place the removed control valve body with the TCM side pointing upward on a workbench. If placing it with the TCM side pointing downward on a workbench, the TCM could be damaged.
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A  :TCM
(4)  Remove the dowel pins.
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(5)  Remove the gaskets.
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(6)  Remove the spool valve spring (only vehicles with oil cooler No.2).
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(7)  Remove the spool valve (only vehicles with oil cooler No.2).
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12.  Remove the oil seal.

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13.  Remove the converter housing using the following procedure:

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1
25 bolts
2
Converter housing
3
O-ring (oil pump)
4
O-ring (oil cooler oil passage)

(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.
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(2)  Remove the bolts shown in the figure.
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(3)  Lightly tap the converter housing using a plastic hammer to remove it.
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(4)  Remove the O-rings.
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14.  Remove the accessories from the converter housing using the following procedure:

(1)  Remove the baffle plate using the procedure shown in the figure.
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1
Bolt
2
Baffle plate

(2)  Remove the oil seal.
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(3)  Remove the bearing race and shim using a pin punch and the 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.
•  Be careful not damage or scratch the converter housing when using a pin punch.
Note
•  Lightly tap around the shim using a pin punch and remove the bearing race with the shim.
•  Use a pin punch with an outer diameter on the end of approx.10 mm {0.39 in}. If the end of the pin punch is too thin it will put a hole in the shim and make it difficult to remove the bearing race.
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1
Bearing race
2
Shim

(4)  Remove the bearing race and shim using the following procedure:
Caution
•  Because the shim will deform when removing the bearing race, use a new shim when performing the automatic transaxle assembly.
1)  Disassemble the SST (49 W033 102).
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2)  Remove the bearing race, shim using the SSTs.
Note
•  The SST (49 W033 102) shown in the figure is the one disassembled in Step 1).
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1
Bearing race
2
Shim

3)  Assemble the SST (49 W033 102).
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15.  Remove the baffle plate.

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16.  Remove the oil pump using the following procedure:

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1
7 bolts
2
Oil pump

(1)  Remove the bolts shown in the figure.
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(2)  Remove the oil pump.
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17.  Remove the thrust needle bearing.

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18.  Remove the high clutch component and low clutch component.

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19.  Remove the turbine shaft.

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20.  Remove the D-ring and seal rings from the turbine shaft using the procedure in the figure:

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1
D-ring
2
Seal ring

21.  Remove the thrust needle bearing.

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22.  Remove the high clutch hub.

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23.  Remove the thrust needle bearing.

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24.  Remove the low clutch hub.

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25.  Remove the thrust needle bearing.

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26.  Remove the ring gear and differential.

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27.  Remove the oil pipe.

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28.  Remove the secondary gear and output gear.

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29.  Remove the baffle plate using the procedure shown in the figure.

Caution
•  The bolts for the baffle plate assembly are coated with thread-locking compound. If the bolts are reused it could loosen the bolts, therefore when performing the automatic transaxle assembly, use new bolts.
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1
Bolt
2
Baffle plate

30.  Remove the oil seal.

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31.  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.
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A  :Impact-absorbing material (rag)
(2)  Remove the bearing race and shim using a pin punch and the 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.
•  Be careful not damage or scratch the transaxle case when using a pin punch.
Note
•  Lightly tap around the shim using a pin punch and remove the bearing race with the shim.
•  Use a pin punch with an outer diameter on the end of approx.10 mm {0.39 in}. If the end of the pin punch is too thin it will put a hole in the shim and make it difficult to remove the bearing race.
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1
Bearing race
2
Shim

(3)  Remove the rag placed on the oil catch area of the SST (engine stand) used as an impact-absorbing material.

32.  Remove the bearing race using the SST.

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33.  Remove end cover component using the following procedure:

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1
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.
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(2)  Remove the bolts shown in the figure.
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(3)  Lightly tap the end cover component using a plastic hammer to remove it.
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(4)  Remove the O-rings.
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34.  Remove the shim.

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35.  Remove the thrust needle bearing.

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36.  Remove the reduction sun gear.

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37.  Remove the thrust needle bearing.

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38.  Remove the rear planetary gear.

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39.  Remove the rear sun gear.

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40.  Remove the front sun gear.

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41.  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).
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•  If there is a malfunction, remove the primary gear in Step 65 and replace the malfunctioning parts with new ones as when performing the automatic transaxle assembly.

42.  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 of approx. 500 N·m {51 kgf·m, 369 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.
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(2)  Install the SSTs.
Note
•  Engage the three projections of the SST (49 B019 028) to the three holes of the primary gear.
•  When installing the SST (49 B019 029), use the bolts supplied with the SST (49 B019 029), or M8×1.25 bolt, length 18 mm {0.71 in}.
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A  :Extension bar
B  :Bolt supplied with SST (49 B019 029), or M8×1.25 bolt, length 18 mm {0.71 in}
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A  :Extension bar
B  :Bolt supplied with SST (49 B019 029), or M8×1.25 bolt, 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
•  Torque of approx. 500 N·m {51 kgf·m, 369 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.
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(4)  Remove the SST.
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A  :Extension bar
B  :Bolt supplied with SST (49 B019 029), or M8×1.25 bolt, length 18 mm {0.71 in}
(5)  Remove the locknut from the front planetary gear.
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43.  Remove the front planetary gear.

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44.  Perform a simple inspection of the low and reverse brake using the following procedure:

(1)  Blow compressed air into the oil passage 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.
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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.

45.  Remove the snap ring using the following procedure:

(1)  Install the SSTs.
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(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 one-way clutch
Note
•  Lock the SST (49 G019 027) against rotation using a flathead screwdriver and tighten the SST (49 G019 029).
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A  :Snap ring
B  :One-way clutch
C  :Gap
(3)  Remove the snap ring.
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(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).
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46.  Remove the one-way clutch.

Caution
•  Do not disassemble the one-way clutch. If it has been disassembled, replace the one-way clutch with a new one.
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47.  Remove the drive plates and driven plates.

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A  :Drive plate
B  :Driven plate

48.  Remove the springs and retainer component.

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49.  Remove the low and reverse brake piston 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.
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Compressed air pressure
0.39—0.44 MPa {4.0—4.4 kgf/cm2, 57—63 psi}
(2)  Remove the low and reverse brake piston removed from the transaxle case.
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50.  Remove the connector, gaskets, oil pipe, and the O-rings in the order shown in the figure.

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1
Connector
2
Gasket
3
Oil pipe
4
O-ring

51.  Remove the detent bracket component in the order shown in the figure.

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1
Bolt
2
Detent bracket component

52.  Remove the pawl return springs.

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53.  Remove the support actuator.

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54.  Remove the parking pawl pin.

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55.  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.
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(2)  Remove the parking rod component.
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56.  Remove the parking pawl shaft in the order shown in the figure.

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1
Plug
2
Gasket
3
Parking pawl shaft

57.  Remove the parking pawl.

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58.  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 {0.119 in} or more and within 4 mm {0.157 in}.
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59.  Remove the parking shift lever component.

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60.  Remove the parking assist lever component.

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61.  Remove the manual plate component.

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62.  Remove the oil seal.

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63.  Remove the washer.

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64.  Remove the connector bolts and gaskets using the procedure shown in the figure (only vehicles with oil cooler No.2).

Caution
•  Perform a visual inspection of the connector bolt and transaxle case and if there is no malfunction, removal of the connector bolt is unnecessary. (See VISUAL INSPECTION OF PARTS.)
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1
Connector bolt
2
Gasket

65.  Perform the following procedure only if there is a malfunction found in the Step 41 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 41 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 as when performing the automatic transaxle assembly.
1)  When removing the primary gear using the SSTs, 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.
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A  :Impact-absorbing material (rag)
2)  Remove the primary gear using the SSTs.
Note
•  Use a plastic hammer.
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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
•  When removing the primary gear, if the angular contact ball bearing remains in the transaxle case and only the primary gear is removed, the following angular contact ball bearing 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.
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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.
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A  :Vise
3)  Remove the angular contact ball bearing using the SSTs.
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A  :Vise
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4)  Remove the primary gear from the vise.
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A  :Vise
(3)  Remove the plug and gasket in the order shown in the figure.
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1
Plug
2
Gasket

66.  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.
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A  :Part number: 9YA02 A220, or M12×1.75 bolt, length 40 mm {1.6 in}
(2)  Remove the SST from the transaxle case.
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(3)  Disassemble the SST.
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A  :Part number: 9YA02 1440, or M14×1.5 bolt, length 100 mm {3.94 in}

67.  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)  High clutch component and low clutch component
(2)  Oil pump (See OIL PUMP DISASSEMBLY)
(3)  Rear planetary gear (See REAR PLANETARY GEAR DISASSEMBLY)
(4)  Secondary gear and output gear (See SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY)
(5)  Ring gear and differential (See RING GEAR AND DIFFERENTIAL DISASSEMBLY)
(6)  End cover component (See END COVER COMPONENT DISASSEMBLY)
(7)  Reduction planetary gear (See REDUCTION PLANETARY GEAR DISASSEMBLY)
(8)  Control valve body (See CONTROL VALVE BODY DISASSEMBLY)

68.  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

69.  Clean the disassembled parts. (See AUTOMATIC TRANSAXLE CLEANING.)

70.  Perform the following inspection and replace a malfunctioning part with a new one.

•  Visual inspection of parts (See VISUAL INSPECTION OF PARTS)
•  Torque converter inspection (See TORQUE CONVERTER INSPECTION)
•  Thrust needle bearing inspection (See THRUST NEEDLE BEARING INSPECTION)
•  Front planetary gear inspection (See FRONT PLANETARY GEAR INSPECTION)
•  Rear planetary gear inspection (See REAR PLANETARY GEAR INSPECTION)
•  Reduction planetary gear inspection (See REDUCTION PLANETARY GEAR INSPECTION)
•  Secondary gear and output gear inspection (See SECONDARY GEAR AND OUTPUT GEAR INSPECTION)
•  Ring gear and differential inspection (See RING GEAR AND DIFFERENTIAL INSPECTION)
•  Low clutch inspection (See LOW CLUTCH INSPECTION)
•  High clutch inspection (See HIGH CLUTCH INSPECTION)
•  Low and reverse brake inspection (See LOW AND REVERSE BRAKE INSPECTION)
•  2-6 brake inspection (See 2-6 BRAKE INSPECTION)
•  R-3-5 brake inspection (See R-3-5 BRAKE INSPECTION)
•  One-way clutch inspection (See ONE-WAY CLUTCH INSPECTION)
•  Low clutch hub inspection (See LOW CLUTCH HUB INSPECTION)
•  High clutch hub inspection (See HIGH CLUTCH HUB INSPECTION)
•  Oil pump inspection (See OIL PUMP INSPECTION)
•  End cover inspection (See END COVER INSPECTION)
•  Oil cooler inspection (See OIL COOLER INSPECTION)