Necessary equipment
- J-45053 Universal Clamp Press
- DT-47599 Anchor bolt wrench
- J-45161 Manual shift shaft bearing replacement tool
- J-45000 Seal remover
Disassembly order
1. Remove the gearbox assembly from the vehicle. See «Gearbox with final drive assembly» in this section.
2. Remove the torque converter.
- Remove the torque converter from the transaxle assembly.
3. Unscrew the drain plug.
- Unscrew the drain plug and drain the automatic transmission fluid.
- Remove the gasket from the drain plug.
4. Remove the oil level sensor.
- Unscrew 1 bolt and remove the oil level sensor.
5. Remove the output shaft speed sensor.
- Unscrew 1 bolt and pull out the output shaft speed sensor.
Important: Be careful not to damage the output shaft speed sensor and transaxle housing assembly.
6. Remove the input shaft speed sensor and the automatic transmission range switch.
- Remove 1 bolt and pull out the input shaft speed sensor.
Important: Be careful not to damage the input shaft speed sensor and transaxle housing assembly.
- Pry out the lock washer with a screwdriver.
- Remove the nut and lock washer.
- Unscrew 2 bolts and pull out the automatic transmission range switch.
7. Remove the rear transaxle case cover assembly.
- Remove the 9 Torx bolts and remove the transaxle case rear cover assembly.
Important: Be careful not to damage the transaxle case rear cover assembly and transaxle housing assembly.
8. Disconnect the transaxle wire connectors.
- Disconnect the 8 solenoid valve wire connectors.
- Unscrew 1 bolt and remove the clip, pull out the gearbox fluid temperature sensor.
Important: Be careful not to damage the connector.
9. Remove valve body.
- Unscrew 2 screws, remove suction cover and gasket.
- Remove 6 screws.
- While holding the valve block assembly, disconnect the range select valve connecting rod from the range select valve lever and remove the valve block assembly.
Important: Gearshift position - "N".
10. Dismantle the gasket.
- Remove 2 gaskets.
11. Remove the switch and sensor assembly from the transaxle housing assembly.
- Remove the transaxle wire assembly from the clips.
- Push the solenoid valve wire out of the inside and remove it.
Important: Be careful not to break the wire connector and the transmission fluid temperature sensor.
12. Remove the oil pump assembly.
- Remove 8 screws.
- Pull the oil pump assembly out of the transaxle housing assembly using J-45053.
Important: Care must be taken not to damage the reactor shaft sleeve.
13. Remove 2nd gear inertia brake (B1), 2nd brake (B2) and overrunning clutch No. 1 assy (F1).
- Remove the 2nd overrun brake hub and washer (B1) and 2nd gear brakes (B2).
14. Remove the gearbox housing with final drive assembly.
- Remove 17 screws.
- Using a plastic mallet, remove the transaxle housing with final drive assembly.
15. Remove the oil channel gasket.
16. Remove the lubricant supply pipe to the differential gear.
- Remove 1 bolt and remove clip.
- Using a screwdriver, remove the lubrication supply pipe to the differential gear.
Important: Be careful not to bend or damage the inlet tube.
17. Remove the fixing plate of the oil tank (gearbox housing with final drive assy).
- Unscrew 3 bolts and remove the fixing plate of the oil tank.
- Remove the 4 magnets from the fixing plate of the oil tank.
18. Remove differential assembly.
19. Remove oil filter.
- Unscrew 1 bolt and remove the oil filter.
20. Remove the transaxle housing plate assembly.
- Remove 2 bolts and remove transaxle housing plate assembly.
21. Remove the fixing plate of the oil tank (gearbox housing with final drive assy).
- Unscrew 3 bolts and remove the fixing plate of the oil tank.
22. Remove the downshift brake supply pipe (B4).
- Remove 2 screws and remove clip.
- Using a screwdriver, remove the supply pipe to the downshift brake (B4).
Important: Be careful not to bend or damage the inlet tube and O-ring. Be careful not to damage the transaxle housing assembly.
23. Remove the range select valve lever and park lock bar.
- Disconnect the lock spring from the range select valve lever.
- Disconnect the range select valve lever from the park lock rod.
- Remove the parking lock bar.
- Remove 2 screws.
- Remove lock spring.
- Remove the park lock pawl shaft and No. 1 torsion spring.
- Remove the cam plate and park lock pawl.
- Remove the pin of the parking lock mechanism.
- Remove 1 Torx bolt, guide bushing and torsion spring No. 2.
- Use a screwdriver to remove the range select valve seal.
- Using J-45161 and a plastic hammer, tap the manual shift shaft bearing through the hole in the transaxle housing and remove the bearing.
24. Remove the reduction gear assembly.
- Remove the thrust bearing and thrust bearing race from the underdrive assembly.
- Remove the reduction gear assembly from the transaxle housing assembly.
25. Remove the underdrive clutch assembly (C3).
- Remove the underdrive clutch assembly (C3).
26. Remove the underdrive brake band (B4).
- Remove the underdrive brake band (B4).
Important: Be careful not to damage the transaxle housing assembly.
27. Remove the rear planetary reduction gear assembly.
- Remove the rear planetary reduction gear assembly.
- Remove the rear reduction gear epicyclic gear assembly.
- Remove the thrust bearing and shim from the epicyclic gear of the rear planetary gear set.
28. Remove the underdrive brake piston (B4).
- Remove retaining ring with pliers.
- Remove the underdrive brake cover (B4) assembled from the gearbox housing with final drive assembly.
- Remove 2 o-rings from underdrive brake cover (B4).
- Remove the underdrive brake piston (B4) assembly and the spring from the gearbox housing with final drive assembly.
- Remove the o-ring from the underdrive brake piston (B4) assembled.
- Using the anchor bolt wrench DT-47599, unscrew the anchor bolt.
29. Remove the rear crankcase assembly.
- Remove 13 screws.
- Remove the rear crankcase assembly with a plastic hammer.
Important: Be careful not to damage the rear crankcase.
- Remove the rear crankcase assembly.
- Remove the 5 gaskets from the transaxle housing assembly.
30. Remove the supply tube.
- Remove 1 Torx bolt and remove clip.
- Remove the inlet tube with a screwdriver.
Important: Be careful not to bend or damage the inlet tube.
31. Remove forward clutch (C1) and direct transmission (C2).
- Remove forward clutch (C1) and direct transmission (C2) assembled.
32. Remove the planetary sun gear assembly.
- Remove the planetary sun gear assembly.
33. Remove the front planetary epicyclic wheel assembly.
- Remove the front planetary epicyclic wheel assembly.
34. Remove planetary gear assembly.
- Remove planetary gear assembly.
35. Remove the No. 2 freewheel front epicyclic gear (F2) and plate, disc and flange for 1st and reverse brakes (B3).
- Remove the bearing from the cage.
- Remove retaining ring with a screwdriver.
- Remove plate, disc and flange.
- Remove the front epicyclic gear and freewheel No. 2 (F2).
- Remove the retaining ring using a screwdriver.
- Remove the 1st gear and reverse brake return spring assembly (B3).
Attention! Protective goggles should be worn when working with compressed air to prevent injury to the eyes.
36. Remove the 1st gear and reverse brake piston (B3).
- By pressing the piston by hand, apply compressed air (4 kg/cm?) into the lubrication port of the transaxle housing as shown in the illustration, and remove the B3 piston.
- Remove o-rings from piston.
37. Check the condition of the brake disc and plate of the 1st gear and reverse (B3).
- Make sure that there is no wear or burnout of the sliding surface of the discs. Replace parts if necessary.
Important: Before replacing new discs, soak in the automatic transmission fluid for at least 2 hours.
38. Remove the thrust bearing race.
- Remove the cage from the countershaft drive gear.
39. Remove the countershaft drive gear.
- Remove retaining ring with pliers.
- Remove the countershaft drive gear.
40. Remove seal.
- Remove the oil seal from the crankcase side and the case side of the transaxle assembly using a J-45000 seal remover.
