Part 1

U660F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: DISASSEMBLY

1. REMOVE BREATHER PLUG HOSE

(a) Using a screwdriver, remove the breather plug hose from the transaxle case.

(b) Using a screwdriver, remove the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) from the breather plug hose.

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(c) Using a screwdriver, remove the O-ring from the No. 2 breather plug (ATM).

2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Remove the nut, washer and control shaft lever from the control shaft.

(b) Remove the 2 bolts and park/neutral position switch assembly from the transaxle case.

NOTICE:
Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch cannot be reinstalled correctly.

3. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION)

(a) Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case.

(b) Remove the O-ring from the oil cooler tube union (outlet oil cooler union).

4. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION)

(a) Loosen the nut while holding the oil cooler tube union (inlet oil cooler union).

(b) Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case.

(c) Remove the O-ring from the oil cooler tube union (inlet oil cooler union).

5. REMOVE NO. 1 TRANSAXLE CASE PLUG

(a) Remove the 3 No. 1 transaxle case plugs from the transaxle case.

(b) Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs.

(c) Using a hexagon wrench (6 mm), remove the 3 hexagon bolts from the transaxle housing.

(d) Remove the gasket from each of the 3 hexagon bolts.

6. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY

(a) Support the transaxle assembly on wooden blocks.

7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY

(a) Using a hexagon wrench (6 mm), remove the overflow plug from the automatic transaxle oil pan sub-assembly.

(b) Remove the gasket from the overflow plug.

(c) Using a hexagon wrench (6 mm), remove the No. 1 transmission oil filler tube from the automatic transaxle assembly.

(d) Remove the 18 bolts, automatic transaxle oil pan sub-assembly and automatic transaxle oil pan gasket from the automatic transaxle assembly.

(e) Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly.

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8. INSPECT TRANSMISSION OIL CLEANER MAGNET Transaxle Unit

9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Remove the 2 bolts and oil strainer assembly from the valve body assembly.

(b) Remove the O-ring from the oil strainer assembly.

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10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Remove the 11 bolts and valve body assembly from the transaxle case.

NOTICE:
When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere with each other.

11. REMOVE TRANSAXLE CASE GASKET

(a) Remove the 2 gaskets from the transaxle case.

12. INSPECT INPUT SHAFT SUB-ASSEMBLY Transaxle Unit

13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY

(a) Remove the refill plug from the rear transaxle cover sub-assembly.

(b) Remove the gasket from the refill plug.

(c) Remove the 2 No. 1 automatic transaxle case plugs from the rear transaxle cover sub-assembly.

(d) Using a screwdriver, remove the 2 O-rings from the 2 No. 1 automatic transaxle case plugs.

(e) Remove the 14 bolts from the rear transaxle cover sub-assembly.

(f) Using a brass bar and a hammer, tap on the circumference of the rear transaxle cover sub-assembly to remove the rear transaxle cover sub-assembly from the transaxle case.

(g) Using a screwdriver, remove the 3 O-rings from the transaxle case.

(h) Using a screwdriver, remove the 2 oil seal rings from the rear transaxle cover sub-assembly.

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(i) Remove the thrust needle roller bearing and thrust needle roller race from the rear transaxle cover sub-assembly.

(j) Using a "TORX" wrench (T30), remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly.

(k) Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly.

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SST : 09319-60020

14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY

(a) Remove the direct multiple disc clutch assembly from the transaxle case.

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(b) Remove the thrust needle roller bearing from the direct multiple disc clutch assembly.

15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING

(a) Using a screwdriver, remove the snap ring from the direct multiple disc clutch assembly.

(b) Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly.

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(d) Using a screwdriver, remove the O-ring from the direct multiple disc clutch assembly.

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16. REMOVE NO. 2 CLUTCH DISC

(a) Remove the clutch flange, 3 clutch discs and 3 clutch plates from the direct multiple disc clutch assembly.

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17. INSPECT NO. 2 CLUTCH DISC Transaxle Unit

18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

(a) Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly.

(b) Remove the rear planetary sun gear assembly from the direct multiple disc clutch assembly.

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19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY Transaxle Unit

20. REMOVE NO. 1 CLUTCH DISC

(a) Using 2 screwdrivers, remove the 2 snap rings from the direct multiple disc clutch assembly.

(b) Remove the clutch flange, 4 clutch discs and 4 clutch plates from the direct multiple disc clutch assembly.

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21. INSPECT NO. 1 CLUTCH DISC Transaxle Unit

22. REMOVE TRANSAXLE HOUSING

(a) Remove the 20 bolts from the transaxle housing.

(b) Using a brass bar and a hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case.

23. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE

(a) Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing.

SST : 09308-00010

24. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE

(a) Remove the bolt, clamp and differential gear lube apply tube from the transaxle housing.

25. REMOVE FRONT OIL PUMP ASSEMBLY

(a) Remove the 7 bolts and front oil pump from the transaxle case.

(b) Remove the O-ring from the front oil pump assembly.

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(d) Remove the O-ring from the transaxle case.

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26. REMOVE FRONT OIL PUMP BODY O-RING

27. REMOVE NO. 3 BRAKE DISC

(a) Using a screwdriver, remove the snap ring from the oil pump assembly.

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(b) Remove the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates from the oil pump assembly.

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28. INSPECT NO. 3 BRAKE DISC Transaxle Unit

29. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Remove the underdrive planetary gear assembly from the front oil pump assembly.

30. REMOVE NO. 3 BRAKE HUB

(a) Remove the No. 3 brake hub from the underdrive planetary gear assembly.

(b) Remove the thrust needle roller bearing and thrust needle roller race from the underdrive planetary gear assembly.

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31. REMOVE UNDERDRIVE PLANETARY RING GEAR

(a) Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear.

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(b) Remove the underdrive planetary ring gear from the underdrive planetary gear assembly.

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