Special Tools

DT-49189 Counter Gear Nut Wrench

1. Remove the nut (1), washer and control shaft lever.



2. Using a screwdriver, pry off the lock plate.
3. Remove the nut and lock plate.



4. Remove the bolts (1, 2) and pull out the PNP switch.
5. Remove the breather plug hose.



6. Remove the oil cooler outlet tube union.
7. Remove the O-ring from the union.



8. Remove the oil cooler inlet tube union.
9. Remove the O-ring from the union.



10. Remove the bolts and speed sensors from the transaxle.
11. Remove the O-rings from the sensors.



12. Remove the No. 1 transaxle case plugs.
13. Remove the O-rings from the plugs.



14. Place transaxle on wooden blocks.



15. Remove the bolts (1-18).
16. Remove the oil pan and magnets.
17. Remove the gasket from the oil pan.



18. Remove the bolts (1, 2, 3) and the oil strainer.



19. Remove the O-ring (1) from the oil strainer.



20. Disconnect the shift solenoid valve connectors.
21. Remove the bolt, lock plate (1) and ATF temperature sensor.



22. Remove the bolt (1) and transaxle wire.



23. Remove the O-ring from the transaxle wire (1).



24. Support the valve body and remove the bolts (1-16) and valve body.



25. Remove the No. 1 governor apply gasket (1) from the transaxle case.



26. Remove the 2nd brake gasket (1) from the transaxle.



27. Remove the brake drum gasket (1) from the transaxle.



28. Remove the check ball and spring from the transaxle.



29. Remove the spring from the C-3 accumulator piston.




Note: Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a cloth.

30. Apply compressed air to the oil hole and remove the C-3 accumulator piston.



31. Remove the O-ring (1) from the C-3 accumulator piston.




Note: Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a cloth.

32. Apply compressed air to the oil hole and remove the C-1 accumulator piston and spring.



33. Remove the O-rings (1, 2) from the C-1 accumulator piston.




Note: Applying compressed air may cause the piston to jump out. When removing the piston, hold it with your hand using a cloth.

34. Apply compressed air to the oil hole and remove the B-3 accumulator piston and springs.



35. Remove the O-ring (1) from the B-3 accumulator piston.



36. Remove the bolts (1, 2), manual detent spring and cover.



37. Remove the bolts (1, 2) and parking lock pawl bracket.



38. Using needle-nose pliers, remove the retainer spring.



39. Using a chisel and hammer, unstake and remove the spacer.



40. Using a pin punch and hammer, tap out the pin.

Slowly tap out the pin so that it will not fall into the transaxle.




41. Remove the manual valve lever shaft and manual valve lever.



42. Remove the parking lock rod from the manual valve lever.



43. Using a screwdriver, pry out the oil seal from the transaxle.
44. Mount the transaxle case with the oil pump side facing up.



45. Remove the No. 1 plugs.
46. Remove the O-rings from the plugs.



47. Remove the bolts (1-18).

Note: The differential may be removed when the transaxle housing is removed.

48. Tap on the circumference of the transaxle housing with a plastic-faced hammer to remove the transaxle housing from the transaxle case.



49. Remove the bolts (1-7) and oil pump from the transaxle.



50. Remove thrust needle roller bearing from the underdrive planetary gear.



51. Remove the No. 2 thrust bearing underdrive race from the underdrive planetary gear.



52. Remove the differential gear form the transaxle.



53. Remove the overdrive brake gaskets from the transaxle.



54. Remove the forward clutch from the transaxle.



55. Remove the thrust bearing from the forward clutch.



56. Using a screwdriver, remove the snap ring.



57. Remove the flange, discs, and plates from the input shaft.



58. Remove the forward clutch return spring sub-assembly.
59. Using a press (1), compress the return spring.
60. Using a snap ring expander, remove the snap ring.



61. Remove the piston return spring.



62. Place the forward clutch drum onto the oil pump.

Note: When the piston is slanted and cannot be removed, remove it by pushing down the protruding side and applying compressed air again, or using needlenose pliers (with its tips wrapped in tape).

63. Holding the forward clutch piston with your hand, apply compressed air to the oil pump to remove the forward clutch piston.



64. Remove the input shaft oil seal ring from the forward clutch drum.



65. Remove the thrust bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle.



66. Remove the bolt and parking pawl shaft clamp.



67. Remove the parking lock pawl shaft.



68. Push the parking lock pawl (1).




Note: Be careful so that the underdrive planetary gear assembly will not fall out.

69. Remove the underdrive planetary gear from the transaxle.



70. Remove the spring, pawl pin and parking lock pawl.



71. Loosen the staked part of the nut.



72. Clamp the underdrive planetary gear (1) in soft jaw vise.



73. Remove the lock nut from the underdrive planetary gear (1).



74. Using a suitable puller (1) remove the cylindrical roller bearing inner race.



75. Remove the underdrive planetary gear assembly.
76. Using a press and a suitable tool (1), remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.
77. Clamp the underdrive planetary gear in soft jaw vise.



78. Using a suitable puller (1) remove the rear angular ball bearing from the underdrive planetary gear.



79. Using snap ring pliers, remove the snap ring (1).



80. Remove the underdrive planetary ring gear (1) from the counter driven gear (2).



81. Remove the underdrive clutch, thrust bearing and bearing race from the transaxle.



82. Using a screwdriver, pry out the underdrive clutch flange snap ring.



83. Remove the flange, discs and plates from the underdrive clutch drum.



84. Remove the underdrive clutch drum O-ring from the clutch drum.



85. Remove the underdrive clutch piston set.
86. Using a press (1), compress the clutch balancer spring.
87. Using a snap ring expander, remove the snap ring.



88. Remove the clutch balancer from the underdrive clutch drum.



89. Remove the piston return spring from the underdrive clutch drum.



90. Install the underdrive clutch to the transaxle
91. Holding the underdrive clutch piston with your hand, apply compressed air to the transaxle case to remove the underdrive clutch piston.



92. Using a screwdriver, pry out the snap ring from the transaxle.



93. Remove the 1-way clutch from the transaxle.



94. Remove the outer race retainer from the 1-way clutch.



95. Using a screwdriver, pry out the snap ring.



96. Remove the flange, discs and plates from the transaxle.



97. Using a snap ring expander and press (1), remove the snap ring and piston return spring.



98. Remove the No. 1 plugs from the transaxle rear cover.
99. Remove the O-rings from the plugs.



100. Remove the bolts retaining the rear cover.



101. Tap in the circumference of the rear cover with a plastic-fased hammer to remove the transaxle rear cover from the transaxle.
102. Remove the oil seal rings from the transaxle rear cover.



103. Remove the bolts and transaxle rear cover plate.



104. Using a suitable puller (1), remove the needle-roller bearing from the transaxle rear cover.



105. Remove the bolt, clamp and brake apply tubes.
106. Remove the brake apply tube from the clamp.
107. Remove the front clutch apply tube from the clamp.



108. Using a screwdriver, remove the governor apply gaskets (1, 2).



109. Remove the thrust bearing and direct clutch from the transaxle.



110. Remove the bearing race from the direct clutch.



111. Using a screwdriver, pry out the snap ring from the direct clutch drum.



112. Remove the flange, discs and plates from the direct clutch drum.



113. Compress the clutch return spring with a press (1).
114. Using a snap ring expander, remove the snap ring from the direct clutch drum.



115. Remove the clutch balancer from the direct clutch drum.



116. Remove the piston return spring from the direct clutch drum.



117. Install the direct clutch drum on the transaxle rear cover.
118. Holding the direct clutch piston with your hand, apply compressed air to the transaxle rear cover (1) to remove the direct clutch piston.



119. Remove the rear planetary sun gear from the transaxle.



120. Remove the thrust bearing from the rear planetary sun gear.



121. Remove the No. 1 thrust washer from the rear planetary sun gear.



122. Remove the 1-way clutch and thrust bearing from the transaxle.



123. Remove the inner race from the 1-way clutch.



124. Remove the 1-way clutch outer sleeve.



125. Remove the 2nd brake clutch disc.
126. Using a screwdriver, remove the snap ring.
127. Remove the flange, discs and plates from the transaxle.



128. Using a screwdriver, remove the snap ring.



129. Remove the 2nd brake piston from the transaxle.



130. Using a press (1), compress the 2nd brake return spring.
131. Using a screwdriver, pry out the snap ring.



132. Remove the piston return spring.



133. Hold the 2nd brake piston and apply compressed air to the 2nd brake cylinder to remove the 2nd brake piston.



134. Remove the O-rings from the 2nd brake piston.



135. Using a screwdriver, pry out the snap ring.



136. Remove the rear planetary gear from the transaxle.



137. Remove the No. 1 planetary carrier thrust washer from the rear planetary gear.



138. Remove the bearing race from the rear planetary gear.



139. Remove the thrust bearings, bearing race and input sun gear from the transaxle.




Note: Push down all of the tabs on the washer.

140. Using a chisel and hammer, unstake the lock washer.



141. Using DT-49189 wrench  (1), remove the nut.



142. Using a press (1), remove the front planetary gear from the counter drive gear.



143. Remove the front planetary gear from the brake hub.



144. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.



145. Remove the flange, discs and plates from the transaxle case.



146. Using a press (1) and snap ring expander, remove the snap ring and piston return spring.



147. Apply compressed air to the transaxle case to remove the 1st and reverse brake piston.



148. Remove the O-rings (1) from the 1st and reverse brake piston.



149. Using a press (1), remove the counter drive gear from the transaxle case.



150. Tighten the bolts evenly and make a clearance of approximately 20.0 mm (0.797 in) between the counter drive gear and the inner race.



151. Using a suitable puller (1), remove the tapered roller bearing.



152. Using a brass bar and hammer, tap out the bearing outer races.



153. Remove the counter drive gear hole snap ring.
154. Using a screwdriver, pry out the snap ring from the transaxle.
155. Remove the No. 2 breather plug.



156. Remove the underdrive brake piston.
157. Apply compressed air to the transaxle case (1) to remove the underdrive brake piston.



158. Remove the O-rings (1) from the underdrive brake piston.



159. Using a suitable puller, remove the needle-roller bearing from the transaxle.



160. Remove the oil seal ring from the transaxle housing.



161. Remove the bolt, clamp and apply tube from the transaxle.

1. Using a dial indicator, measure the input shaft end play.

Specification
Standard end play - 0.262 to 1.249 mm (0.0103 to 0.0492 in)




2. Inspect pack clearance of forward clutch.
3. Install the forward clutch on the oil pump.
4. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (1).

Specification
Standard position stroke - 1.74 to 2.08 mm (0.0685 to 0.0819 in)

5. If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.

Note: As the opening is big, cover it with a shop rag to prevent the compressed air from being discharged

6. If the clearance is not as specified, select another flange.



7. Inspect the forward multiple disc clutch disc.

Note: 

•	If the lining of the disc is peeling off or discolored, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

8. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



9. Inspect the forward clutch return spring sub-assembly.
10. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 28.23 mm (1.1102 in)




11. Inspect the forward clutch piston subassembly.
12. Shake the piston to check that the check ball is not stuck.
13. Check that air does not leak from the valve when applying low compressed air.



14. Inspect the multiple disc clutch hub.

Note: 

•	When the diameter is over the maximum, replace the multiple disc clutch hub with a new one.

•	Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch subassembly with a new one.

15. Using a caliper gage, measure the inside diameter of the forward clutch hub bushing.

Specification

•	Standard inside diameter - 23.025 to 23.045 mm (0.9065 to 0.9073 in.)

•	Maximum inside diameter - 23.09 mm (0.9091 in.)

16. If the inside diameter is greater then the maximum, replace the forward clutch hub.



17. Inspect the underdrive clutch pack clearance.
18. Install the underdrive clutch to the transaxle.



19. Using a dial indicator, measure the underdrive clutch pack clearance while applying and releasing compressed air.

Specification
Standard pack clearance - 1.51 to 1.90 mm (0.0594 to 0.0748 in)

20. If the pack clearance is not as specified, inspect the discs, plates and flange.



21. Inspect the No. 1 underdrive clutch disc.

Note: 

•	If the lining of the discs is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

22. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



23. Inspect the underdrive clutch drum subassembly.

Specification

•	Standard drum bush - 37.06 to 37.08 mm (1.4591 to 1.4598 in.)

•	Maximum drum bush - 37.13 mm (1.4618 in.)

24. If the inside diameter is greater then the maximum, replace the underdrive clutch drum sub-assembly.



25. Inspect underdrive clutch return spring sub-assembly.
26. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 17.14 mm (0.6752 in.)




27. Inspect the No. 2 underdrive clutch disc.

Notice: 

•	If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

28. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



29. Inspect the underdrive brake return spring sub-assembly.
30. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 14.04 mm (0.5528 in)




31. Inspect the pack clearance of direct clutch.
32. Install the direct clutch and needle roller bearing on the transaxle rear cover.
33. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air.

Specification
Standard pack clearance - 0.515 to 0.825 mm (0.0203 to 0.0324 in.)

34. If the pack clearance is not as specified, inspect the discs, plates and flange.



35. Inspect the direct multiple disc clutch disc.

Note: 

•	If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

36. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



37. Inspect the direct clutch return spring sub-assembly.
38. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 22.58 mm (0.8898 in)




39. Inspect the 2nd brake clutch disc.

Note: 

•	If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

40. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



41. Inspect the 2nd brake piston return spring sub-assembly.
42. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 16.61 mm (0.6539 in)




43. Inspect the 1st and reverse brake clutch disc.

Note: 

•	If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

•	Before assembling new discs, soak them in ATF WS for at least 15 minutes.

44. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.



45. Inspect the 1st and reverse brake return spring sub-assembly.
46. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 15.5 mm (0.6106 in)




47. Inspect the underdrive 1-way clutch assembly.
48. Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.

1. Remove the clutch drum oil seal rings.



2. Remove the bolts (1-11) and stator shaft. Keep the gears in assembled order.



3. Remove the front oil pump drive gear (1).



4. Remove the front oil pump driven gear (1).



5. Using a screwdriver, pry out the O-ring.



6. Mount the oil pump in a soft jaw vise.
7. Using a suitable puller (1), tap out the oil seal from the oil pump body.



8. Turn the drive gear with two screwdrivers and make sure it rotates smoothly.



9. Push the driven gear to one side of the body. Using a feeler gage, measure the clearance.

Specification

•	Standard body clearance - 0.10 to 0.17 mm (0.0039 to 0.0067 in)

•	Maximum body clearance - 0.17 mm (0.0067 in)

10. If the body clearance is greater than the maximum, replace the oil pump body sub-assembly.



11. Measure the tip clearance between the driven gear teeth and drive gear teeth.

Specification

•	Standard tip clearance - 0.07 to 0.15 mm (0.0028 to 0.0059 in)

•	Maximum tip clearance - 0.15 mm (0.0059 in)

12. Using a straightedge and feeler gauge, measure the side clearance of both gears.

Specification

•	Maximum side clearance -0.05 mm (0.002 in.)

•	Standard side clearance - 0.02 to 0.05 mm (0.0008 to 0.002 in)




13. Inspect front oil pump and gear body subassembly.
14. Using a caliper gauge, measure the inside diameter of the oil pump body bushing.

Specification

•	Standard inside diameter - 38.113 to 38.138 mm (1.5005 to 1.5014 in)

•	Maximum inside diameter - 38.188 mm (1.5034 in)

15. If the inside diameter is grater than maximum, replace the oil pump body sub-assembly.



16. Inspect the stator shaft assembly.
17. Using a caliper gauge, measure the inside diameter of the stator shaft bushing.

Specification

•	Standard inside diameter - 21.500 to 21.526 mm (0.8464 to 0.8474 in)

•	Maximum inside diameter - 21.57 mm (0.8492 in)

18. If the indicator diameter is greater than the maximum, replace the stator shaft.



19. Place the matchmarks (1) on the ring gear and differential case.



20. Remove the bolts.



21. Using a plastic-faced hammer, tap on the ring gear to remove it from the case.



22. Using a suitable puller (3), tap out the front differential case front tapered roller bearing from the differential case.



23. Using a suitable puller (1), remove the front differential case front tapered roller bearing outer race.



24. Using a suitable puller (1), remove the front differential case rear tapered roller bearing from the differential case.



25. Using a suitable puller (1), tap out the front differential case front tapered roller bearing outer race.




Note: Before removing the straight pin, unstake it with a pin punch.

26. Using a pin punch and hammer, tap in the straight pin.



27. Remove the front differential pinion shaft from the differential case.



28. Remove the front differential pinions, pinion thrust washers, front differential side gears and side gear thrust washers from the differential case.



29. Using a suitable driver (1) and hammer, tap out the oil seal.



30. Using a suitale tool (1, 2) and hammer, tap out the oil seal.