Part 1
GENERAL NOTICEThe instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection. repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups.
Recommended fluid for the automatic transaxle: ATF TYPE T or equivalent
1. GENERAL CLEANING NOTICE:
a. All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air.
b. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transaxle fluid or kerosene in your face.
c. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
2. PARTS ARRANGEMENT:
a. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly.
b. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
c. New brakes and clutches that are to be used for replacement must be soaked in automatic transaxle fluid for at least 15 minutes before assembly.
3. GENERAL ASSEMBLY:
a. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with automatic transaxle fluid prior to reassembly.
b. All gaskets and rubber O-rings should be replaced.
c. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
d. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
e. Check thrust bearings and races for wear or damage. Replace if necessary.
f. Use petroleum jelly to keep parts in place.
COMPONENTS
COMPONENT PARTS REMOVAL
SEPARATE BASIC SUBASSEMBLY
1. REMOVE TRANSFER ASSEMBLY
a. Remove the breather hose from driven pinion bearing cage and transaxle case upper cover.
b. Remove the 5 nuts and 3 bolts.
c. Using a plastic hammer, remove the transfer assembly from the transaxle.
2. REMOVE APPLY GASKET
3. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Screw in a suitable bolt with washer into the side gear intermediate shaft.
b. Using SST, remove the side gear intermediate shaft.
SST 09520-32012
4. REMOVE UNION AND ELBOW
a. Using a open end wrench, remove the union and elbow.
b. Remove the O-rings from the union and elbow.
5. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Remove the manual shift lever.
b. Pry off the lock washer and remove the manual valve shaft nut.
c. Remove the 2 bolts and pull out the park/neutral position switch.
6. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE
7. REMOVE SOLENOID WIRE RETAINING BOLT AND PLATE
8. REMOVE VEHICLE SPEED SENSOR
a. Remove the bolt and speed sensor.
b. Remove the 0-ring from the speed sensor.
9. REMOVE TRANSAXLE CASE UPPER COVER
a. Using SST, remove the breather pipe.
SST 09631-22020
b. Remove the breather hose union.
c. Remove the breather pipe unions.
d. Remove the 0-rings from the unions.
e. Disconnect the breather hose from the filler pipe.
f. Remove the 9 bolts and transaxle case upper cover and gasket.
10. REMOVE OIL PAN AND GASKET
a. Remove the 17 bolts.
b. Remove the oil pan by lifting transaxle case.
NOTICE: Do not turn the transaxle over as this will contaminate the valve body with the foreign materials in the bottom of the oil pan.
c. Place the transaxle on wooden blocks to prevent damage to the oil pipe bracket.
11. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Look carefully at the chips and particles in the oil pan and on magnet to anticipate what type of wear you will find in the transaxle.
- Steel (magnetic): bearing, gear and plate wear
- Brass (non-magnetic): bushing wear
12. REMOVE OIL PIPE BRACKET AND STRAINER
13. REMOVE MANUAL VALVE BODY
a. Remove the 2 bolts and detent spring.
b. Remove the 5 bolts and manual valve body with the manual valve.
c. Remove the manual valve from the manual valve body.
14. REMOVE 8 OIL PIPES
a. Remove the bolt and retainer.
b. Pry up both pipe ends with a large screwdriver and remove the 8 pipes.
15. DISCONNECT 2 SOLENOID CONNECTORS
16. REMOVE CONNECTOR CLAMP AND PIPE RETAINER
17. REMOVE B3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.
18. REMOVE VALVE BODY
a. Remove the 10 bolts.
b. Disconnect the throttle cable from the cam and remove the valve body.
19. REMOVE THROTTLE CABLE AND SOLENOID WIRE
20. REMOVE 2ND BRAKE APPLY GASKET
21. REMOVE ACCUMULATOR PISTONS AND SPRINGS
a. Loosen the 4 bolts one turn at a time until the spring tension is released.
b. Remove the cover and gasket.
c. Remove the C1 accumulator piston and spring.
d. Remove the 2 O-rings from the piston.
e. Pop out pistons for C2 and B2 into a rag, using low pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi).
f. Remove the O-rings from the pistons.
22. MEASURE PISTON STROKE 2ND COAST BRAKE
a. Apply a small amount of paint to the piston rod at the point it meets the case.
b. Using SST, measure the piston stroke while blowing and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2 , 57 - 114 psi).
SST 09240-00020
Thrust clearance: 2.0 - 3.5 mm (0.079 - 0.138 inch)
If the piston stroke exceeds the limit, inspect the 2nd coast brake band.
23. REMOVE 2ND COAST BRAKE PISTON
a. Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)
b. Blow compressed air into the oil hole.
c. Remove the 2nd coast brake cover, piston assembly and spring.
d. Remove the 2 0-rings from the cover.
24. STAND TRANSAXLE ENGINE SIDE UPWARD
25. REMOVE OIL PUMP
NOTICE: Before removing the oil pump, remove the 2nd coast brake piston.
a. Remove the 7 bolts.
b. Using SST, pull out the oil pump from the transaxle case.
SST 09350-32014 (09351-32061)
26. REMOVE O-RING AND RACE FROM OIL PUMP
27. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH
28. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH
a. Separate the direct clutch and forward clutch.
b. Remove the thrust washer from direct clutch.
29. REMOVE BEARINGS AND RACES FROM FORWARD CLUTCH
30. REMOVE 2ND COAST BRAKE BAND
a. Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting.
b. Remove the brake band.
