Disassembly

DISASSEMBLY

CAUTION:
^ Because the automatic transaxle is manufactured from high-precision parts, care must be taken not to scratch or damage these parts during disassembly and assembly.
^ Work or a rubber mat and keep it clean at all times.
^ Do not wear any cloth gloves and do not use any shop towels during disassembly. Use only nylon cloth, paper towels or any other lint-free material.
^ Parts, which have been disassembled, should all be cleaned. Metal parts can be cleaned with normal detergent, but they should be dried completely using compressed air.
^ Clutch discs, plastic thrust plates and rubber parts should be cleaned with automatic transmission fluid (ATF).
^ If the transaxle body has been damaged, disassemble and clean the cooler system.





1. Remove the torque converter.
2. Remove each bracket
3. Remove the dipstick
4. Remove the eye bolt gauge, gaskets and the oil cooler feed tube.
5. Remove the input shaft speed sensor and output shaft speed sensor

CAUTION: The manual control lever tightening nut must be removed before removing the valve body. If the valve body is removed before the nut, the park/neutral position switch will be damaged.





6. Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.





7. Remove the sealing cap and o-ring.





8. Remove the valve body cover.





9. Remove the manual control shaft detent.





10. Disconnect the solenoid valve harness from the valve body by undoing the fluid temperature sensor and all the connectors.





CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.

11. Remove the valve body mounting bolts (27 pieces).





CAUTION: Do not lose the two steel balls.

12. Remove the valve body, gasket, and the two steel balls.





13. Remove the snap ring from the connector. Push the connector into the transaxle case and remove the solenoid valve harness.





14. Remove the strainer and the second brake retainer oil seal.








15. Remove each accumulator piston and spring.





16. Remove the manual control lever shaft roller.
17. Remove the manual control lever shaft and the parking pawl rod.





18. Remove the torque converter housing mounting bolts (18 bolts), and then remove the torque converter housing.
19. Remove the differential bearing outer race and spacer from the torque converter housing.





20. Remove the O-rings (two pieces).





21. Remove the differential.
22. Remove the differential bearing outer race from the transaxle case.





23. Remove the oil filter.





24. Remove the oil pump mounting bolts (six bolts).
25. Install special tool MD998333 in hole "A."





26. Turn special tools MD998333 to remove the oil pump.
27. Remove the oil pump gasket.





28. Remove thrust washer number 1.





29. Holding the input shaft, remove the underdrive clutch and input shaft.





30. Remove thrust bearing number 2.





31. Remove the underdrive clutch hub.





32. Remove the rear cover and input shaft rear bearing.
33. Remove thrust race number 8.
34. Remove the seal rings (four pieces).





35. Remove the O-rings (three pieces).





36. Remove the reverse and overdrive clutch and thrust bearing number 7.





37. Remove overdrive clutch hub and thrust bearing number 6.





38. Remove thrust bearing number 5.





39. Remove the planetary reverse sun gear.





40. Remove the snap ring.





41. Remove the second brake piston and the return spring.





42. Remove the pressure plate, brake discs and brake plate.





Number of brake discs and plates





43. Remove the planetary carrier assembly.





44. Remove the snap ring.





45. Remove the reaction plate and the brake disc.





46. Remove the snap ring.





47. Remove the brake plates (four pieces), brake discs (Eve pieces) and pressure plate.





48. Remove the wave spring.





49. Remove the parking pawl shaft, and then remove the spacer and spring.





50. Remove the two parking roller support shafts, and then remove the parking roller support.





51. Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 and MD998924, compress the one-way clutch inner race.
2. Remove the snap ring.
3. Remove the special tools.
4. Remove the one-way clutch inner race, O-ring, spring retainer, return spring and low-reverse brake piston.





52. Remove the four or three transfer drive gear bearing mounting bolts. Then, turn the gear 118 turn (45 degree angle) and remove the remaining bolts.





53. Remove the transfer drive gear.





54. Remove the cap by jabbing a screw driver in to the center of the cap and prying it up.





55. Using a chisel, straighten the staked portions from the output shaft nut.

CAUTION: The jam nut is reverse threaded.





56. Use special tools MB991625 and MB990607 to remove the output shaft jam nut.





57. Remove the bearing retainer mounting bolt.





58. Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.





59. Tap out the outer race and the spacer.
60. Remove the snap ring.