Disassembly

DISASSEMBLY
GENERAL NOTE
1. Disassemble transaxle in a clean area (dust proof work space) to prevent entry of dust into mechanisms.
2. Inspect individual transaxle components.
3. Use only plastic hammers when applying force to separate light alloy case joints.
4. Never uses shop towels during disassembly; they may leave particles that can clog fluid passages.
5. Several parts resemble one another; organize them so that they do not get mixed up.
6. Disassemble control valve assembly and thoroughly clean it when a clutch or brake band has burned or when ATF has degenerated.

CLEANING NOTE
1. Clean transaxle exterior thoroughly with a steam cleaner or cleaning solvents before disassembly.
2. Clean removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and check that there are no obstructions.

CAUTION: Wear eye protection when using compressed air to clean components.

NOTE: Do not allow ATF to spill when removing torque converter.

DISASSEMBLE NOTE





1. Remove torque converter from converter housing.





2. Pull out oil pump shaft by hand.
3. Remove oil level gauge and oil filler tube
4. Remove input/turbine speed sensor.
5. Remove transaxle range switch.
6. Remove selector cable bracket.
7. Remove bracket.
8. Remove crankshaft position sensor.
9. Remove vehicle speed sensor and driven gear.
10. Remove inlet pipe.
11. Remove outlet pipe.





12. Assemble SST (OK130 175 011 A/OK130 990 007).





CAUTION: Do not lean transaxle to one side during disassembly. It may rotate suddenly and cause injury.

NOTE: Remove oil pan before turning transaxle over. This will ensure that any foreign material remains in pan.

13. Remove oil pan and gasket (19 bolts).





a. Examine any material found in pan or on magnet to determine condition of transaxle.





b. If large amounts of material are found, replace torque converter and carefully check transaxle for cause.
14. Remove clip (one bolt).





15. Disconnect solenoid connectors.
16. Remove strainer (three bolts).





17. Remove A, B and C bolts and brackets shown in figure.
Bolt length (Measured from below head):
A: 1.18 inch (30 mm)
B: 1.97 inch (50 mm)
C: 0.55 inch (14 mm)
18. Remove control valve body.
19. Remove manual shaft and manual plate.
a. Loosen nut and pull out manual shaft.
b. Remove nut, washer and manual plate.





20. Remove bolt and parking pawl lever holder.





21. Remove parking pawl lever (two bolts).





22. Remove detent lever and return spring.
23. Remove actuator support.





24. Remove oil pump assembly (10 bolts).
25. Remove reverse/forward clutch assembly.





a. Remove turbine shaft snap ring.





b. Pull reverse/forward drum and remove clutch assembly.





26. Remove small sun gear and one-way clutch No. 1.

NOTE: Use a piece of wire to secure brake band so that it is not damaged by being stretched.





27. Remove 2-4 brake band.
28. Pull anchor shaft while holding strut.





29. Remove strut.





30. Remove servo.
a. Compress servo piston and remove snap ring.
b. Remove servo retainer, servo piston and spring.
31. Remove one-way clutch No. 2 and planetary carrier assembly.





a. Remove snap ring.
b. Remove one-way clutch No. 2 together with planetary carrier assembly.





c. Remove friction plate.
32. Remove internal gear.





a. Remove snap ring.





b. Remove internal gear from output shell.
33. Remove 3-4 clutch assembly.





a. Remove O-ring from turbine shaft at converter housing side.





b. Pull out turbine shaft to remove 3-4 clutch assembly.
c. Remove 3-4 clutch assembly from turbine shaft.





34. Remove bolts (converter housing side: eight bolts transaxle case side: seven bolts) and remove transaxle case by tapping lightly with a plastic hammer.





35. Remove output shell from output gear.





36. Remove differential assembly.
37. Remove bearing housing.
a. Remove roll pin with a pin punch.
b. Remove (11) bolts securing bearing housing.





c. Remove bearing housing by tapping lightly with a plastic hammer.





38. Remove idler gear assembly and output gear assembly by tapping out from torque converter side.





39. Remove bearing cover.
a. Remove bearing cover bolts.
b. Remove converter housing from SST (OK130 175 011A).
c. Press bearing cover assembly out of converter housing.





NOTE: Install bearing outer race during reassembly to adjust preload.





40. Press out bearing outer races by using SST (OK130 170 012).

PRECAUTION
1. If drive plates or brake band are replaced with new ones, soak new part in ATF for at least two hours before installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
3. All O-rings, seals, and gaskets must be replaced with new ones.
4. Use petroleum jelly, not grease, during reassembly.
5. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
6. Assemble housing within 10 minutes after applying sealant and allow it to cure at least 30 minutes after assembly before filling transaxle with ATF.