Automatic Trans: Overhaul: Transaxle: 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.
The working area should be covered with a rubber mat to 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.

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

Fig 1: Locating 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.
Loosen the manual control lever tightening nut, and then remove the manual control lever, and the park/neutral position switch.

Fig 2: Locating Manual Control Lever And Park/Neutral Position Switch
Remove the speedometer gear.

Fig 3: Locating Speedometer Gear
Remove the valve body cover.

Fig 4: Locating Valve Body Cover
Remove the manual control shaft detent.

Fig 5: Locating Manual Control Shaft Detent
Disconnect the harness connectors from the solenoid valves and the fluid temperature sensor of the valve body.

Fig 6: Locating Valve Body Harness Connectors

CAUTION: Make sure that the manual control lever and the park/neutral position switch are removed. See step 8.
Remove the valve body mounting bolts (28 pieces).
Remove the fluid temperature sensor.

Fig 7: Locating Valve Body Mounting Bolts & Fluid Temperature Sensor

CAUTION: Do not lose the two steel balls.
Remove the valve body, gasket and the two steel balls.

Fig 8: Removing Valve Body
Remove the snap ring from the connector and then push the connector into the transaxle case and remove the solenoid valve harness.

Fig 9: Locating Snap Ring
Remove the strainer and the second brake retainer oil seal.

Fig 10: Locating Strainer And Second Brake Retainer Oil Seal

Remove each accumulator piston and spring.

Fig 11: Identifying Accumulator Pistons

ACCUMULATOR PISTON IDENTIFICATION

NUMBER	NAME
1	For low-reverse brake
2	For under drive clutch
3	For second brake
4	For overdrive clutch

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

Fig 12: Locating Manual Control Lever Shaft And Parking Pawl Rod
Remove the torque converter housing mounting bolts (18 pieces), and then remove the torque converter housing.

Fig 13: Locating Torque Converter Housing Mounting Bolts
Remove the differential bearing outer race and spacer from the torque converter housing.
Remove the O-rings (two pieces).

Fig 14: Locating O-Rings
Remove the differential.
Remove the differential bearing outer race from the transaxle case.

Fig 15: Locating Differential
Remove the oil filter.

Fig 16: Removing Oil Filter
Remove the oil pump mounting bolts (six pieces).
Install special tool MD998333 in hole "A".

Fig 17: Identifying Hole "A"
Turn special tools MD998333 to remove the oil pump.

Fig 18: Removing Oil Pump
Remove the oil pump gasket.
Remove thrust washer number 1.

Fig 19: Removing Thrust Washer #1
Holding the input shaft, remove the under drive clutch and input shaft.

Fig 20: Removing Underdrive Clutch
Remove thrust bearing number 2.

Fig 21: Removing Thrust Bearing #2
Remove the under drive clutch hub.

Fig 22: Removing Underdrive Clutch Hub
Remove the rear cover.
Remove thrust race number 8.
Remove the seal rings (four pieces).

Fig 23: Locating Thrust Race Number 8 & Seal Rings
Remove the O-rings (three pieces).

Fig 24: Locating O-Rings
Remove the reverse and overdrive clutch and thrust bearing number 7.

Fig 25: Removing Thrust Race Number 7
Remove overdrive clutch hub and thrust bearing number 6.

Fig 26: Removing Overdrive Clutch Hub And Thrust Bearing Number 6
Remove thrust bearing number 5.

Fig 27: Removing Thrust Bearing Number 5
Remove the planetary reverse sun gear.

Fig 28: Removing Planetary Reverse Sun Gear
Remove the snap ring.

Fig 29: Removing Snap Ring
Remove the second brake piston and the return spring.

Fig 30: Removing Second Brake Piston And Return Spring

Remove the pressure plate, brake discs and brake plate.

Fig 31: Removing Pressure Plate, Brake Discs And Brake Plate

NUMBER OF BRAKE DISCS AND PLATES

A/T MODEL	BRAKE DISC	BRAKE PLATE	PRESSURE PLATE
F4A42	3	2	1
F4A51	4	3	1

Remove the planetary carrier assembly.

Fig 32: Removing Planetary Carrier Assembly
Remove the snap ring.

Fig 33: Removing Snap Ring
Remove the reaction plate and the brake disc.

Fig 34: Removing Reaction Plate And Brake Disc
Remove the snap ring.

Fig 35: Removing Snap Ring
Remove the brake plates (five pieces), brake discs (six pieces) and pressure plate.

Fig 36: Removing Brake Plates, Brake Discs And Pressure Plate
Remove the wave spring.

Fig 37: Removing Wave Spring
Remove the parking pawl shaft, and then remove the spacer and spring.

Fig 38: Removing Parking Pawl Shaft
Remove the two parking roller support shafts, and then remove the parking roller support.

Fig 39: Removing Parking Roller Support
Remove the one-way clutch inner race and low-reverse brake piston as follows:
1. Using special tools MD998903 < F4A42 > or MD998338 < F4A51 > and MD998924, compress the one-way clutch inner race.
  NOTE: This illustration shows F4A51.
  
  Fig 40: Compressing One-Way Clutch Inner Race (F4A51 Shown)
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.
Remove the four < F4A51 > or three < F4A42 > transfer drive gear bearing mounting bolts.
Then, turn the gear 1/8 turn (45 degree angle) and remove the remaining bolts.

F4A42 = seven mounting bolts

F4A51 = eight mounting bolts

Fig 41: Removing Transfer Drive Gear Mounting Bolts
Remove the transfer drive gear.

Fig 42: Removing Transfer Drive Gear
Remove the cap.

Fig 43: Removing Cap
Using a chisel, remove the staked nut from the output shaft.

Fig 44: Unstaking Nut From Output Shaft

CAUTION: The jam nut is reverse threaded.
Use special tools MB991625 and MB990607 to remove the output shaft jam nut.

Fig 45: Removing Output Shaft Jam Nut
Remove the bearing retainer mounting bolt.

Fig 46: Removing Bearing Retainer Mounting Bolt
Tap on the rear end of the output shaft to remove the output shaft, taper roller bearing and collar.

Fig 47: Removing Output Shaft
Remove the outer race and the spacer.
Remove the snap ring.

Fig 48: Removing Snap Ring