Transmission Disassembly
NOTE:
Thoroughly clean transaxle exterior prior to disassembly. Use special care in handling aluminum components. DO NOT turn transaxle case over when removing oil pan. Turning transaxle will contaminate valve body with material from bottom of oil pan.
- Remove torque converter. Remove engine mounting LH bracket. Remove oil level gauge and oil filler tube. Remove speedometer driven gear. Remove vehicle speed sensor. Remove PNP switch. Drain transmission fluid. Remove oil pan and gasket.
- Remove direct clutch and 2nd brake solenoid connectors. Using a screwdriver, carefully pry 2 oil tubes from lower valve body. Remove cable from throttle valve cam. Remove oil strainer (filter). Remove 11 lower valve body bolts. Remove valve body assembly. Ensure manual valve does not drop when removing valve body.
- Apply 15 psi (1 kg/cm2 ) of compressed air to apply hole (beside accumulator piston bore), and remove accumulator pistons into a shop towel. Remove pistons and springs. Remove 2nd brake band cover and gasket.
- Check 2nd brake piston stroke. Scribe mark on piston rod. Apply compressed air into oil hole. Measure 2nd brake piston rod stroke. See Fig 1. Piston stroke should be .060-.120" (1.52-3.05 mm). If piston stroke exceeds specification, inspect brake during disassembly.
- Remove 2nd brake piston. Using valve spring compressor tool, push in piston cover. Remove snap ring. Remove 2nd brake piston cover and piston. See Fig 2.
- Remove solenoid wire hold plate nut. Remove 2 wire harness clamps on transaxle. Remove solenoid wire. Remove 6 oil pump bolts. Using 2 slide hammers, remove oil pump. Ensure 2nd brake piston and piston rod have been removed prior to oil pump removal to prevent damage of 2nd brake band.
- Remove transaxle case housing while tapping lightly with a plastic hammer. Remove 2nd brake band pin. Remove direct and forward clutch together while holding input shaft. DO NOT lose ring gear race and bearing, which may sometimes stick to input shaft.
- Remove direct clutch from input shaft. Remove 2nd brake band. Remove front planetary ring gear and bearing. Remove front planetary gear. Remove planetary sun gear and front planetary gear bearing.
- Carefully remove one-way clutch snap ring. Remove one-way clutch and rear planetary gear. Remove rear planetary ring gear, ring gear bearing and washers.
- Check 1st and reverse brake clearance. Measure clearance between snap ring and flange. Clearance should be .023-.075" (.58-1.91 mm). See Fig 3. If clearance exceeds specification, inspect 1st and reverse brake discs and plates.
- Remove 2 snap rings, 1st and reverse brake flange, discs, plates and damper. Remove differential gear. Remove 10 bolts and 2 nuts from rear cover. Remove rear cover by lightly tapping with a plastic hammer.
- Unstake reduction driven gear lock nut. Place manual control lever in "P" position to lock output shaft. Carefully loosen nut so as not to damage reduction gear or parking lock pawl. Remove reduction gear.
- Drive out countershaft with a plastic hammer. Drive out output shaft by pushing outer race of internal output shaft bearing. To prevent damage, DO NOT hit output shaft or shaft end.
- Remove parking lock pawl shaft and spring. Remove parking lock pawl and sleeve. Remove detent spring and manual shift shaft. Push down return spring and remove snap ring. Remove return spring. Apply compressed air into case passage to remove 1st and reverse brake piston. Passage is beside clutch, in middle of case. If piston does not pop out with compressed air, use needle-nose pliers to remove.