Part 1

DISASSEMBLY

Special Tools:




























1. Refer to the exploded views as necessary when performing the following steps.





2. Drain the CVT fluid from the transaxle assembly.
3. Remove the power transfer unit assembly and o-ring (4WD only).
4. Remove the torque converter (1)(Figure 3) from the transaxle.





5. Install Transmission Service Stand (1) to the belt side of the transmission case (3) using the upper transmission mount bolts (2).





6. Remove the output speed sensor (1)(Figure 5) from the converter housing. Remove and discard the o-ring from the output speed sensor.

CAUTION: Set aside and reuse any adjusting shim found between the output speed sensor and the converter housing.






7. Remove the input speed sensor (1)(Figure 6) from the transaxle case. Remove and discard the o-ring from the input speed sensor.





8. Remove the nut (1) holding the shift lever (2) to the manual shaft.
9. Remove the shift lever from the manual shaft(Figure 7).





10. Remove the bolts (2) holding the transmission range sensor (TRS) (1) to the transaxle case.
11. Remove the (TRS) transmission range sensor (1)(Figure 8) from the transaxle case and the manual shaft.





12. Remove the snap ring (1)(Figure 9) from the terminal body (2) and press the terminal body into the transaxle case.

CAUTION: Be careful not to cause damage to the terminal body.






13. Remove CVT fluid cooler (1)(Figure 10) from transaxle case. Remove and discard the CVT fluid cooler o-ring.





14. Remove the bolts holding the CVT fluid filter to the transaxle case.
15. Remove the CVT fluid filter (1)(Figure 11) from the transaxle case.





16. Remove the converter housing mounting bolts(Figure 12).





17. Remove the converter housing (1)(Figure 13) by tapping with plastic hammer.

CAUTION: There is a possibility that the drive sprocket adjusting shim may be dislodged and fall out.






18. Remove outer race of reduction gear bearing (1) from the converter housing using Puller and Puller.





19. Remove differential side oil seal (1)(Figure 15) from converter housing using a screwdriver. (2WD)





20. Remove converter housing oil seal (1)(Figure 16) from converter housing using a screwdriver.





21. Remove outer race (1) (Figure 17) of differential side bearing from converter housing using a suitable punch.

CAUTION: When removing the outer race, tap the outer race on both sides evenly. When removing the outer race, do not damage the converter housing.






22. Remove and discard the O-ring (1)(Figure 18) from the input shaft.





23. Remove the adjusting shim (1)(Figure 19) from the drive sprocket, if necessary.





24. Remove the nuts holding the baffle plate (1)(Figure 20) to the transaxle.
25. Remove the baffle plate.





26. Expand the snap ring (1)(Figure 21) and remove the driven sprocket (3), the oil pump chain (2), and the drive sprocket.





27. Remove the thrust washer (1)(Figure 22) from the oil pump cover.





28. Remove the snap ring (1)(Figure 23) from the oil pump.





29. Remove the reduction gear assembly (1)(Figure 24) from the transaxle case.





30. Remove the differential assembly (1)(Figure 25) from the transaxle case.





31. Remove the bolts holding the bracket (1)(Figure 26) to the oil pump cover and the transaxle.
32. Remove the bracket (1).





33. Remove the bolts holding the baffle plate (1)(Figure 27) to the transaxle.
34. Remove the baffle plate.





35. Remove the bolts holding the reaction shaft support (1)(Figure 28) to the transaxle.
36. Remove the reaction shaft support from the transaxle case.





37. Remove and discard the seal rings (1)(Figure 29) from the reaction shaft support.





38. Remove the bolts holding the oil pan (1)(Figure 30) to the transaxle case.
39. Remove the oil pan from the transaxle case.





40. Remove the oil pan gasket (1)(Figure 31) from the transaxle case.





41. Remove the bolts holding the oil strainer (1)(Figure 32) to the valve body.
42. Remove the oil strainer.
43. Remove and discard the oil strainer o-ring.





44. Remove the bolt (2)(Figure 33) holding the oil pump to the transaxle case from the rear of the transaxle.
45. Remove the bolts (1) holding the oil pump to the transaxle case from inside the transaxle.