Disassembly

DISASSEMBLY





1. INSTALL ENGINE HANGER
Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device.
Engine hanger part No.:
12281-67070, S1228-11781
Bolt part No.:
91642-81045
91642-81265 2 pieces
Nut part No.:
90178-10001
90179-12147 2 pieces

NOTICE:
- As the transaxle itself is heavy, place a wood block underneath to stabilize it and carry out the operation carefully.
- Do not pull or bend the high-voltage cable of the MG1 assembly.
- Drain the fluid before disassembly.

2. REMOVE MG1 ASSEMBLY





a. Remove the 21 bolts.





b. Using a screwdriver and a hammer, disconnect the MG1 assembly from the MG2 assembly.





HINT: When separating the MG1 assembly from the MG2 assembly, to prevent the drive sprocket from being removed with the MG1 assembly, push down the chain part with a taped screwdriver tip.





3. REMOVE COUNTER DRIVEN GEAR ASSEMBLY
Remove the counter driven gear assembly from the MG2 assembly.





4. REMOVE DIFFERENTIAL CASE ASSEMBLY
Remove the differential case assembly from the MG2 assembly.





5. REMOVE 2 RACE AND NEEDLE ROLLER BEARING





6. REMOVE DRIVE SPROCKET SUB-ASSEMBLY AND CHAIN
7. REMOVE INPUT SHAFT ASSEMBLY





a. Remove the input shaft assembly.





b. Remove the needle roller bearing and 2 bearing races.





8. REMOVE PLANETARY RING GEAR





9. REMOVE RING GEAR FLANGE AND SHIM





10. REMOVE COUNTER DRIVE GEAR AND SHIM

HINT: Remove the counter drive gear by tapping the case with a plastic hammer.





11. REMOVE OIL PAN AND GASKET
a. Remove the drain plug and its gasket.
b. Remove the 12 bolts.
c. Remove the oil pan and its gasket.





12. REMOVE MAGNET FROM OIL PAN





13. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips. Carefully examine the chips and particles in the oil pan and on the magnet to identify what type of wear has occurred in the transaxle.
- Steel (magnetic) bearing, gear and plate wear
- Brass (non-magnetic) bushing wear
14. REMOVE OIL STRAINER





a. Remove the bolt and oil strainer.





b. Remove the O-ring from the oil strainer.





15. SET MG2 ASSEMBLY
As illustrated, set the MG2 assembly and wood blocks.





16. REMOVE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.





17. REMOVE WIRING HARNESS CONNECTOR (MG2 side)
Remove the 2 bolts and the 2 wiring harness connectors.





18. REMOVE 2 WATER JACKET UNIONS (MG2 side)





19. REMOVE PARKING COVER
Remove the 6 bolts and parking cover.





20. REMOVE DETENT SPRING COVER AND DETENT SPRING
Remove the bolt, detent spring cover and detent spring.





21. REMOVE MOTOR WATER JACKET COVER
Remove the 6 bolts and motor water jacket cover.
22. REMOVE PARKING SHAFT COVER





a. Remove the 5 bolts and parking shaft cover.





b. Using a screwdriver, remove the oil seal from the cover.





23. REMOVE PARKING LOCK SHAFT ASSEMBLY
24. DISASSEMBLE PARKING LOCK SHAFT ASSEMBLY





a. Remove the washer.





b. Using a chisel and a hammer, cut the spacer.
c. Remove the spacer.





d. Using a pin punch and a hammer, drive out the pin.
e. Remove the parking lock lever No. 3 from the parking lock shaft.
25. REMOVE OIL PUMP





a. Remove the plug.
b. Remove the O-ring from the plug.





c. Remove the 5 bolts and oil pump cover.





d. Remove the O-ring.





e. Remove the oil pump driven rotor and drive rotor.





f. Remove the oil pump drive shaft.





26. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE LH AND SHIM (MG2 side)
Using SST, drive out the differential side bearing outer race and shim.
SST 09308-00010
27. REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE LH AND SHIM





a. Using SST, drive out the counter driven gear side bearing outer race and shim.
SST 09308-00010





b. Overturn the MG2 assembly and place a wood block under it stabilize.

NOTICE: Be careful not to bend the parking lock rod.





28. REMOVE DIFFERENTIAL OIL SEAL LH (MG2 side)
Using a screwdriver, drive out the oil seal.





29. REMOVE FILLER PLUG AND SCREW PLUG (MG2 side)
a. Remove the 2 screw plugs with a hexagon wrench.
b. Remove the 2 filler plugs and the 2 gaskets.





30. REMOVE BREATHER PLUG





31. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE
32. REMOVE HIGH-VOLTAGE CABLE





a. Remove the 4 bolts and power cable cover.





b. Remove the 6 bolts and the high-voltage cable.





33. REMOVE WIRING HARNESS CONNECTOR (MG1 side)
Remove the bolt and wiring harness connector.





34. REMOVE 2 WATER JACKET UNIONS (MG1 side)





35. REMOVE HOUSING TUBE





36. REMOVE INPUT SHAFT OIL SEAL
Using SST, drive out the input shaft oil seal.
SST 09612-30012





37. REMOVE DIFFERENTIAL OIL SEAL RH (MG1 side)
Using a screwdriver, drive out the differential oil seal RH.
38. TURN MG1 ASSEMBLY UPSIDE DOWN
39. REMOVE PARKING LOCK PAWL





a. Remove the bolt and the lock clamp.





b. Remove the parking lock pawl shaft.
c. Remove the parking lock pawl.
40. REMOVE PARKING LOCK SLEEVE





a. Remove the 2 bolts, sleeve bracket, torsion spring and parking lock sleeve.





b. Remove-the cam guide sleeve from the sleeve bracket.





41. REMOVE COUNTER DRIVEN GEAR SIDE BEARING OUTER RACE RH (MG1 side)
Using SST, drive out the counter driven gear side bearing outer race RH.
SST 09308-00010





42. REMOVE DIFFERENTIAL SIDE BEARING OUTER RACE RH (MG1 side)
Using SST, drive out the differential side bearing outer race RH.
SST 09308-00010





43. REMOVE DRAIN PLUG AND SCREW PLUG (MG1 side)
a. Remove the screw plug from the MG1 assembly with a hexagon wrench.
b. Remove the drain plug and the gasket.