Part 2

OVERHAUL
26. REMOVE MANUAL VALVE LEVER SUB-ASSY





a. Using a chisel and hammer, unstake and remove the spacer.





b. Using a pin punch and hammer, drive out the pin.

HINT: Slowly drive out the pin so that it will not fall into the transaxle case.





c. Remove the manual valve lever shaft and manual valve lever.





27. REMOVE PARKING LOCK ROD SUB-ASSY
a. Remove the parking lock rod from the manual valve lever.





28. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
a. Using a screwdriver, remove the oil seal from the transaxle case.
29. FIX AUTOMATIC TRANSAXLE ASSY
a. Fix the transaxle case with the oil pump side facing up.





30. INSPECT INPUT SHAFT ENDPLAY
a. Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0103 - 0.0492 inch)





31. REMOVE TRANSAXLE HOUSING
a. Remove the 16 bolts.
b. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.

NOTICE: Differential may be accidentally removed when the transaxle housing is removed.





32. REMOVE OIL PUMP ASSY
a. Remove the 7 bolts and oil pump from the transaxle case.





33. REMOVE THRUST NEEDLE ROLLER BEARING
a. Remove the thrust needle roller bearing from the U/D planetary gear assy.





34. REMOVE THRUST BEARING UNDERDRIVE RACE NO.2
a. Remove the thrust bearing U/D race No. 2 from the U/D planetary gear assy.





35. REMOVE DIFFERENTIAL GEAR ASSEMBLY
a. Remove the differential gear assy from the transaxle case.





36. REMOVE OVERDRIVE BRAKE GASKET
a. Remove the 2 O/D brake gaskets from the transaxle case.
37. REMOVE FORWARD CLUTCH ASSY





a. Remove the forward clutch assy from the transaxle case.





b. Remove the thrust bearing from the forward clutch.





38. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
a. Remove the thrust bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle case.





39. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
a. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing
Standard inside diameter: 23.025 - 23.046 mm (0.9065 - 0.9073 inch)
Maximum inside diameter: 23.09 mm (0.9091 inch)

NOTICE:
^ When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
^ Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, re place the direct clutch sub-assy with new one.

If the inside diameter is greater than the maximum, replace the forward clutch hub.
40. REMOVE UNDERDRIVE PLANETARY GEAR ASSY





a. Remove the bolt and parking pawl shaft clamp.





b. Remove the parking lock pawl shaft.





c. Push the parking lock pawl.

HINT: Failure to do so will cause interference when the U/D planetary gear is removed.





d. Remove the U/D planetary gear assy from the transaxle case.

NOTICE: Be careful so that the U/D planetary gear assy will not fall out.





41. REMOVE PARKING LOCK PAWL
a. Remove the spring, pawl pin and parking lock pawl.





42. REMOVE UNDERDRIVE CLUTCH ASSY
a. Remove the U/D clutch assy, thrust bearing and bearing race from the transaxle case.
43. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY





a. Using a screwdriver, remove the snap ring from the transaxle case.





b. Remove the 1-way clutch from the transaxle case.





c. Remove the outer race retainer from the 1-way clutch.
44. REMOVE UNDERDRIVE CLUTCH DISC NO.2





a. Using a screwdriver, remove the snap ring.





b. Remove the flange, 4 discs and 4 plates from the transaxle case.





45. INSPECT UNDERDRIVE CLUTCH DISC NO.2
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
^ If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.





46. REMOVE TRANSAXLE REAR COVER SUB-ASSY
a. Remove the 11 bolts.
b. Tap in the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.





47. REMOVE TRANSAXLE CASE NO.1 PLUG
a. Remove the 4 transaxle case No. 1 plugs from the transaxle rear cover.
b. Remove the 4 O-rings from the 4 transaxle case No. 1 plugs.





48. REMOVE REAR CLUTCH OIL SEAL RING OUTER
a. Remove the 3 oil seal rings from the transaxle rear cover.





49. REMOVE NEEDLE ROLLER BEARING
a. Using SST, remove the needle-roller bearing from the transaxle rear cover.
SST 09387-00041 (09387-01021, 09387-01030, 09387-01040)




50. REMOVE GOVERNOR APPLY GASKET NO.1
a. Using a screwdriver, remove the 3 apply gaskets.