Special Tools

DT-49190 Counter Gear Nut Wrench

1. Remove the bolt (1) and speedometer driven hole cover sub-assembly from the transaxle housing.
2. Remove the O-ring from the speedometer driven hole cover sub-assembly.



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



4. Using a screwdriver, pry out the lock plate and remove the manual valve shaft nut (1).



5. Remove the bolts (1, 2) and pull out the park/neutral position switch assembly.



6. Remove the bolt and remove the speed sensor from the transaxle case.



7. Remove the oil cooler tube unions from the transaxle case.
8. Remove the O-rings from the oil cooler tube unions.



9. Remove the No. 1 transaxle case plugs (1-4) from the transaxle housing and transaxle case.



10. Remove the No. 1 transaxle case plug (1) from the transaxle case.
11. Remove the O-rings from the No. 1 transaxle case plugs.



12. Remove the breather plug hose from the breather plug.
13. Remove the breather plug from the transaxle case.



14. Place the transaxle onto wooden blocks.



15. Remove the bolts and remove the oil pan and oil pan gasket.



16. Remove the oil cleaner magnets (1) from the oil pan.
17. Examine the particles in the oil pan.

•	Collect any steel chips with the removed magnets.

•	Carefully look at the foreign matter and particles in the oil pan and on the magnets to predict the type of wear which might be found in the transaxle.

-	Steel (magnetic): bearing, gear and clutch plate wear

-	Brass (non-magnetic): bearing wear




18. Remove the bolts (1) and remove the oil strainer assembly.



19. Remove the oil strainer gasket (1) from the oil strainer assembly.



20. Disconnect the solenoid connectors.
21. Remove the bolt (7) and lock plate and remove the ATF temperature sensor.



22. Remove the bolts (3) and remove the detent spring cover and detent spring (1).



23. Remove the bolts (1) and the valve body assembly from the transaxle case.



24. Remove the bolt and the transmission wire (1) from the transaxle case.



25. Remove the O-ring (1) from the transmission wire.



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



27. Remove the transaxle case gasket (1) from the transaxle case.



28. Remove the brake drum gasket from the transaxle case.



29. Remove the check ball body and spring from the transaxle case.




Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

30. Apply compressed air to the oil hole (1) and remove the B-2 accumulator piston and spring.



31. Remove the O-rings (1, 2) from the B-2 accumulator piston.




Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

32. Apply compressed air to the oil hole (1) and remove the C-3 accumulator piston and spring.



33. Remove the O-rings (1) from the C-3 accumulator piston.




Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

34. Apply compressed air to the oil hole (1) and remove the C-2 accumulator piston and spring.



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



36. Remove the bolts (1 14).

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

37. Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
38. Inspect the input shaft end play.



39. Measure the end play in the axial direction.

Specification
End Play - 0.38 to 1.29 mm (0.0149 to 0.0507 in)

40. If the end play is not as specified, replace the stator shaft thrust needle roller bearing and the forward clutch hub thrust needle roller bearing.



41. Remove the bolts and the oil pump assembly from the transaxle case.



42. Remove the differential gear assembly from the transaxle case.



43. Using a screwdriver, remove the overdrive brake gaskets (1, 2) from the transaxle case.



44. Remove the input shaft assembly from the transaxle case.



45. Remove the stator shaft thrust needle roller bearing from the input shaft.



46. Using a screwdriver, remove the snap ring.
47. Remove the flange, discs and plates from the input shaft.




Note: Do not compress the return spring excessively.

48. Compress the return spring with a press (1).
49. Using a snap ring expander, remove the snap ring.



50. Remove the clutch balancer and piston return spring.



51. Place the input shaft onto the oil pump.

Note: If the piston cannot be removed because it is tilted, either apply compressed air again while keeping the piston level or remove the piston using needle-nose pliers with their tips wrapped in protective tape.

52. Holding the forward clutch piston by hand, apply compressed air to the oil pump to remove the forward clutch piston.



53. Using a screwdriver, remove the clutch piston ring (1) from the forward clutch piston.



54. Using a screwdriver, remove the input shaft oil seal ring from the input shaft.



55. Remove the forward clutch hub thrust needle roller bearing from the forward clutch hub.



56. Inspect the intermediate shaft assembly.
57. Using a dial indicator, measure the intermediate shaft end play.

End Play
0.21 to 0.96 mm (0.0082 to 0.0377 in)

58. If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.



59. Remove the forward clutch hub from the transaxle case.



60. Remove the bolts.
61. Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.



62. Remove the rear transaxle cover plugs from the rear transaxle cover.
63. Using a screwdriver, remove the O-rings from the rear transaxle cover plugs.




Note: Stop pressing when the overdrive brake piston is 1-2 mm (0.0394-0.0787 in) from the snap ring groove to prevent the overdrive brake piston from being deformed.

64. Using a press and a screwdriver remove the snap ring.
65. Remove the overdrive brake return spring from the rear transaxle cover.




Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

66. Apply compressed air to the rear transaxle cover to remove the overdrive brake piston.



67. Using a screwdriver, remove the O-rings (1, 2) from the 2nd coast and overdrive brake piston.



68. Remove the clutch drum oil seal ring.
69. Remove the oil seal rings (1) from the rear transaxle cover.



70. Using the puller (1) remove the bearing from the rear transaxle cover.



71. Remove the transaxle case gaskets.



72. Using a magnetic pick-up tool, remove the rear clutch drum thrust needle roller bearing.



73. Remove the intermediate shaft assembly from the transaxle case.
74. Remove the reverse clutch disc.



75. Using a screwdriver, remove the snap ring.
76. Remove the flange, discs and plates.



77. Using a screwdriver, remove the snap ring.
78. Remove the direct clutch flange, plates and rear clutch flanges.



79. Using a press (1), remove the snap ring.
80. Remove the direct clutch return spring sub-assembly from the intermediate shaft.



81. Install the intermediate shaft onto the rear transaxle cover.

Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

82. Apply compressed air to the oil hole and remove the direct clutch piston from the intermediate shaft.



83. Install the intermediate shaft onto the rear transaxle cover.
84. Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly.

Note: 

•	Blowing air may cause the drum to jump out. When removing the drum, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

85. Apply compressed air to the oil hole and remove the direct clutch drum from the intermediate shaft.



86. Using a screwdriver, remove the piston O-rings (1) from the direct clutch piston.



87. Using a screwdriver, remove the direct clutch drum O-ring (1) from the direct clutch drum.



88. Remove the flange, discs and No. 2 flanges from the transaxle.



89. Using a magnetic pick-up tool, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the No. 3 thrust bearing race from the direct clutch hub.



90. Remove the direct clutch hub from the transaxle case.



91. Using a magnetic pick-up tool, remove the rear No. 2 planetary sun gear thrust needle roller bearing from the rear planetary sun gear assembly.



92. Remove the rear planetary sun gear from the transaxle case.



93. Remove the rear planetary sun gear thrust needle roller bearing and No. 1 planetary carrier thrust washer from the one-way clutch assembly.
94. Inspect the one-way clutch assembly.



95. Hold the rear planetary sun gear and turn the one-way clutch.
96. Make sure that the one-way clutch turns freely counterclockwise and locks when turned clockwise.



97. Remove the one-way clutch assembly and No. 2 planetary carrier thrust washer from the rear planetary sun gear.



98. Using a screwdriver, remove the snap rings (1).
99. Remove the flanges, discs and flanges from the transaxle.



100. Remove the 2nd brake piston sleeve from the transaxle case.
101. Inspect the No. 2 one-way clutch.



102. Turn the rear planetary gear assembly.
103. Make sure that the rear planetary gear assembly (1) turns freely counterclockwise and locks when turned clockwise.



104. Using a screwdriver, remove the snap ring.
105. Remove the rear planetary gear assembly from the transaxle case.



106. Remove the thrust needle roller bearing and bearing races from the rear planetary gear assembly.



107. Remove the No. 2 one-way clutch.
108. Separate the 2nd brake assembly, No. 2 one-way clutch and the rear planetary gear.



109. Remove the outer race retainer.
110. Remove the retainer from the No. 2 one-way clutch (1).



111. Remove the 2nd brake piston return spring sub-assembly.
112. Using a press (1), remove the snap ring from the 2nd brake piston.
113. Remove the 2nd brake return spring from the 2nd brake cylinder.



114. Remove the 2nd brake piston return spring subassembly from the 2nd brake cylinder.



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



116. Using a screwdriver, remove the O-rings from the 2nd brake cylinder.



117. Remove the front planetary sun gear and thrust needle roller bearing from the transaxle case.



118. Using a screwdriver, remove the snap ring.
119. Remove the flange, discs and plates from the transaxle case.



120. Using a press and a screwdriver, remove the snap ring.
121. Remove the 1st and reverse brake return spring sub-assembly.



122. Remove the No. 2 1st and reverse brake piston

Note: 

•	Blowing air may cause the piston to jump out. When removing the piston, hold it by hand using a shop rag or piece of cloth.

•	Do not splash ATF with compressed air.

123. Apply compressed air to the transaxle case to remove the No. 2 1st and reverse brake piston.



124. Remove the O-rings (1) from the No. 2 1st and reverse brake piston.



125. Secure the counter driven gear with the parking lock pawl.



126. Using a chisel (1) and a hammer, release the lock nut washer.



127. Using DT-49190 Counter Gear Nut Wrench  (1) , remove the nut and lock nut washer.



128. Using a press (1), remove the planetary gear assembly from the transaxle case.



129. Install the bolts to the counter drive gear.

Specification

•	Bolt (M6) Length - 40 to 80 mm (1.57 to 3.15 in)

•	Bolt (M6) Pitch - 1.0 mm (0.04 in)

130. Rotate the bolts and remove the counter drive gear and front planetary sun gear.
131. Remove the radial ball bearings from the counter drive gear and front planetary sun gear.



132. Remove the bolts, cam guide and parking lock pawl bracket from the transaxle case.



133. Remove the manual valve lever shaft retainer spring from the manual valve lever shaft.



134. Using a screwdriver, release and remove the spacer.



135. Using a pin punch and hammer, drive out the manual valve lever shaft spring pin.
136. Remove the manual valve lever shaft and manual valve lever.



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



138. Remove the manual valve lever shaft from the transaxle case.



139. Using a screwdriver, remove the parking lock pawl shaft from the transaxle case.
140. Remove the parking lock pawl torsion spring (1) and parking lock pawl from the transaxle case.



141. Remove the counter driven gear, drive pinion and thrust needle roller bearing from the transaxle case.



142. Using a brass bar and a hammer, remove the differential drive pinion plug.



143. Using a press (1), remove the differential drive pinion from the counter driven gear.



144. Remove the bolt (1) and the bearing lock plate.



145. Remove the differential gear lube apply tube (1) from the transaxle housing.



146. Using a puller (1), remove the front drive pinion front tapered roller bearing from the transaxle housing.



147. Using a puller (1), remove the front drive pinion rear tapered roller bearing from the transaxle case.
148. Remove the No. 1 transaxle case plate from the transaxle case.



149. Remove the left side counter drive gear bearing inner race and angular ball from the transaxle case.
150. Using a slide hammer (1), remove the left side counter drive gear bearing outer race from the transaxle case.
151. Remove the right side counter drive gear bearing.



152. Using a slide hammer (1), remove the right side counter drive gear bearing outer race from the transaxle case.



153. Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.



154. Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case.



155. Using a suitable tool (1, 2), remove the transaxle case oil seal from the transaxle case.
156. Remove the transaxle case oil seal from the transaxle housing.

1. Inspect the front clutch disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed number is damaged, replace all the discs.

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

2. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.



3. Inspect the forward clutch return spring sub-assembly.
4. Using vernier calipers, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 21.69 mm (0.853 in)




5. Inspect the overdrive brake return spring sub-assembly.
6. Using vernier calipers, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 17.88 mm (0.703 in)




7. Inspect the reverse clutch disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed mark is damaged, replace all the discs.

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

8. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.



9. Inspect the direct clutch disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed mark is damaged, replace all the discs.

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

10. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.



11. Inspect the direct clutch return spring sub-assembly.
12. Using vernier calipers, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 31.7 mm (1.248 in)




13. Inspect the direct clutch piston sub-assembly.
14. Shake the direct clutch pin and confirm that the check ball is not stuck.
15. Apply low pressure compressed air to the check ball and confirm that there is no air leakage.



16. Inspect the intermediate shaft sub-assembly.
17. Shake the direct clutch pin and confirm that the check ball is not stuck.
18. Apply low pressure compressed air to the check ball and confirm that there is no air leakage.



19. Inspect the 2nd coast and the overdrive brake disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed mark is damaged, replace all the discs.

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

20. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.
21. Inspect the 2nd brake disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed mark is damaged, replace all the discs.

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

22. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.



23. Inspect the 2nd brake piston return spring sub-assembly.
24. Using vernier calipers, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 14.65 mm (0.576 in)




25. Inspect the 1st and reverse brake disc.

Note: 

•	If the lining of any disc is peeled off or discolored, or even if part of the printed mark is damaged, replace all the discs.

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

26. Check whether the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.



27. Inspect the 1st and reverse brake return spring sub-assembly.
28. Using vernier calipers, measure the free length of the spring together with the spring seat.

Specification
Standard free length - 13.96 mm (0.5496  in)




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



30. Using a puller (1), remove the front differential case front tapered roller bearing outer race from the transaxle housing.



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



32. Using a suitable puller (1), remove the front differential case rear tapered roller bearing outer race from the transaxle case.



33. Remove the front differential ring gear.
34. Place matchmarks on the front differential ring gear and differential case.



35. Release the lock plate.



36. Remove the bolts and the ring gear lock plates.



37. Using a plastic hammer, remove the front differential ring gear from the differential case.



38. Remove the front differential pinion shaft straight pin.
39. Using a punch and a hammer, release the differential case.



40. Using a pin punch and a hammer, remove the straight pin.



41. Remove the front No. 1 differential pinion shaft from the front differential case.



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



43. Inspect the differential side gear backlash.
44. Measure the differential side gear backlash while holding one pinion gear toward the case.

Specification
Standard backlash - 0.05 to 0.20 mm (0.0019 to 0.0078 in)

45. If the backlash is not within the specified range, install the correct thrust washer to the side gear.
46. Select thrust washers which will ensure that the backlash is within the specified range for both sides. Refer to Transmission General Specifications for Differential Side Gear Thrust Washer Chart.

If the backlash is not within the specified range, install a thrust washer of a different thickness.