Special Tools

DT-49189 Counter Gear Nut Wrench

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



2. Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper.



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



4. Remove the number 2 breather plug (1) from the transaxle case.



5. Remove the hose and O-ring (2) from the number 2 breather plug.



6. Remove the inlet oil cooler tube union (1).
7. Remove the O-ring (2) from the union.



8. Remove the outlet oil cooler tube union (1).
9. Remove the O-ring (2) from the union.



10. Remove the bolts and the speed sensors (1) from the transaxle assembly.



11. Remove the number 1 transaxle case plugs from the transaxle case.
12. Remove the O-rings from the number 1 transaxle case plugs.



13. Remove the drain plug and drain plug gasket from the oil pan.



14. Remove the bolts (1), oil pan, and gasket.



15. Remove the transmission magnets (1) from the oil pan.



16. Disconnect the connectors (1) from the shift solenoid valves.
17. Remove the bolt, lock plate, and ATF temperature sensor.



18. Remove the bolt and transmission wire from the transaxle case.



19. Remove the bolts (1) and oil strainer.



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



21. Support the valve body assembly and remove the bolts (1) and valve body assembly.



22. Remove the number 1 governor apply gasket (1) from the transaxle case.



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



24. Remove the brake drum gasket (1) from the transaxle case.



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



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



27. Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.



28. Remove the O-ring (2) from the C-3 accumulator piston (1).




Note: 

•	Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth.

•	Take care not to splash ATF when applying compressed air.

29. Apply compressed air to the oil hole (1) and remove the reverse accumulator piston and spring.



30. Remove the O-rings (2) from the reverse clutch accumulator piston.




Note: 

•	Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a waste cloth.

•	Take care not to splash ATF when applying compressed air.

31. Apply compressed air to the oil hole (1) and remove the B-3 accumulator piston and springs.



32. Remove the O-ring (2) from the B-3 accumulator piston (1).



33. Using needle-nose pliers, remove the manual valve lever shaft retainer spring.



34. Remove the bolts (1, 2) and manual detent spring sub-assembly.



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



36. Using a screwdriver, slide the spacer (1).



37. Using a pin punch and hammer, drive out the pin.

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




38. Remove the manual valve lever shaft, manual valve lever, and spacer.



39. Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.

Align the dial with the notches on the manual valve lever sub-assembly to remove the parking lock rod sub-assembly.




40. Using a screwdriver, remove the oil seal from the transaxle case.
41. Rotate the transaxle case with the oil pump side facing up.



42. Remove the bolts (1-18).

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

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



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



45. Remove the thrust needle roller bearing (2) from the underdrive planetary gear assembly.



46. Remove the number 2 thrust bearing underdrive race from the underdrive planetary gear assembly (3).



47. Remove the differential gear assembly (1) from the transaxle case.



48. Remove the overdrive brake gaskets from the transaxle case.



49. Remove the forward clutch assembly (1) from the transaxle case.



50. Remove the thrust needle roller bearing (1) from the forward clutch.
51. Inspect the pack clearance of the forward clutch.



52. Using a screwdriver, remove the snap ring (1).



53. Remove the flange, discs and plates from the input shaft assembly.



54. Compress the return spring with a press.

Note: 

•	Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove. This prevents the spring seat from being deformed.

•	Do not expand the snap ring excessively.

55. Using a snap ring expander, remove the snap ring (2).



56. Remove the clutch balancer (1) from the input shaft.



57. Remove the forward clutch return spring (1) from the input shaft.



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

Note: If the piston is slanted and cannot be removed, either blow air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped.

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



60. Remove the input shaft oil seal ring from the input shaft.



61. Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and number 1 thrust bearing race (3) from the transaxle case.



62. Remove the bolt and pawl shaft clamp (1) from the transaxle case.



63. Remove the parking lock pawl shaft from the transaxle case.



64. Push the parking lock pawl.



65. Remove the underdrive planetary gear assembly (1) from the transaxle case.



66. Using a punch and a hammer, loosen the staked part of the lock nut.



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



68. Using a socket wrench (1), remove the lock nut.



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



70. Using a press (1), remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.



71. Clamp the underdrive planetary gear in a soft jaw vise.
72. Using a suitable puller (1), remove the rear angular ball bearing from the underdrive planetary gear.



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



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



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



76. Remove the underdrive clutch assembly, thrust bearing (1), and bearing race from the transaxle case.



77. Using a screwdriver, remove the number 2 underdrive clutch flange hole snap ring (1).



78. Remove the flange, discs, and plates from the underdrive clutch drum (1).



79. Using a press (1), remove underdrive clutch return spring.

Note: Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove. This prevents the spring seat from being deformed.

80. Using a snap ring expander, remove the snap ring.



81. Remove the clutch balancer (1) from the underdrive clutch drum.



82. Remove the return spring (1) from the underdrive clutch drum.



83. Remove the underdrive clutch from the transaxle case.
84. Holding the underdrive clutch piston by hand, apply compressed air to the transaxle case to remove the underdrive clutch piston.



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



86. Using a screwdriver, remove the snap ring (1) from the transaxle case.



87. Remove the underdrive one-way clutch (1) from the transaxle case.



88. Remove the outer race retainer (1) from the one-way clutch.



89. Using a screwdriver, remove the snap ring (1).



90. Remove the flange (1), discs and plates from the transaxle case.



91. Remove the bolts (1-11).
92. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.



93. Remove the number 1 transaxle case plugs from the transaxle rear cover.
94. Remove the O-rings from the number 1 transaxle case plugs.



95. Remove the rear clutch oil seal rings (1) from the transaxle rear cover.



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



97. Using a screwdriver, remove the governor apply gaskets (1, 2, 3).



98. Remove the bolt (2), clamp and brake apply tube (2).
99. Remove the clutch apply tube (3).
100. Remove the brake apply tube from the clamp.



101. Remove the thrust bearing (2) and the direct clutch assembly (1) from the transaxle case.



102. Using a screwdriver, remove the snap ring (1) from the intermediate shaft.



103. Remove the flange, discs, plates and cushion plate from the intermediate shaft.



104. Using a screwdriver, remove the snap ring from the intermediate shaft.
105. Remove the flange, discs and plates from the intermediate shaft.



106. Using a press (1), remove overdrive clutch return spring.

Note: 

•	Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove. This prevents the spring seat from being deformed.

•	Do not expand the snap ring excessively.

107. Using a snap ring expander, remove the snap ring from the direct clutch drum.



108. Remove the clutch balancer (1) from the overdrive direct clutch drum.



109. Remove the overdrive clutch return spring (1) from the overdrive direct clutch drum.



110. Install the intermediate shaft on the transaxle rear cover.
111. Holding the direct clutch piston by hand, apply compressed air to the transaxle rear cover (1) to remove the direct clutch piston.



112. Holding the direct clutch drum by hand, apply compressed air to the transaxle rear cover (1) to remove the direct clutch drum.



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



114. Remove the thrust bearing race (1), thrust bearing (2), and overdrive direct clutch hub (3) from the planetary gear assembly.



115. Remove the rear planetary sun gear assembly (1) from the transaxle case.



116. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.



117. Remove the number 2 planetary carrier thrust washer (1) from the rear planetary sun gear assembly (2).



118. Remove the one-way clutch assembly (2) and the thrust needle roller bearing (1) from the transaxle case.



119. Remove the one-way clutch inner race (1) from the one-way clutch assembly.



120. Remove the one-way clutch sleeve (1) from the transaxle case.



121. Remove the number 1 planetary carrier thrust washer (1) from the planetary gear assembly.



122. Using a screwdriver, remove the snap ring (1).
123. Remove the flange, discs and plates from the transaxle case.



124. Using a screwdriver, remove the snap ring (1).



125. Remove the 2nd brake piston assembly (1) from the transaxle case.



126. Using a suitable tool (1), remove the 2nd brake piston return spring.



127. Remove the 2nd brake piston return spring sub-assembly (1).



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



129. Remove the O-rings (1, 2) from the 2nd brake piston.



130. Using a screwdriver, remove the snap ring (1).



131. Remove the rear planetary gear assembly (1) from the transaxle case.



132. Remove the thrust needle roller bearings (4), number 2 thrust bearing races, number 3 thrust bearing race, and input sun gear (2) from the transaxle case.



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



134. Using a chisel and hammer, unstake the lock washer (1).



135. Using a DT-49189 counter gear nut wrench  (1, 2), remove the nut and washer.



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



137. Remove the front planetary gear assembly (1) from the brake hub.



138. Using a screwdriver, remove the snap ring (1) and front planetary ring gear from the brake hub.



139. Using a press (1), compress the 1st and reverse brake return spring.

Note: 

•	Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove to prevent the spring seat from being deformed.

•	Do not expand the snap ring excessively.

140. Using snap ring pliers, remove the snap ring.
141. Remove the return spring.




Note: 

•	Applying compressed air may cause the piston to jump-out. When removing the piston, hold it by hand using a piece of cloth.

•	Take care not to splash ATF when applying compressed air.

142. Apply compressed air to the transaxle case (2) to remove the 1st and reverse brake piston.



143. Remove the O-rings (1, 2) from the 1st and reverse brake piston.



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



145. 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.



146. Using a suitable puller (1), remove the tapered roller bearing inner race.



147. Remove the bearing inner race (rear side) (1) and angular ball (rear side).



148. Using a press (1), remove the bearing outer race (rear side) from the transaxle case.



149. Remove the angular ball.



150. Using a press (1), remove the bearing outer race (front side) from the transaxle case.

Remove the angular ball (front side).




151. Using a screwdriver, remove the snap ring from the transaxle case.



152. Compress the return spring with a press.

Note: Stop pressing when the spring seat is 1-2 mm (0.039-0.078 in) from the snap ring groove to prevent the spring seat from being deformed.

153. Using a snap ring expander, remove the snap ring (1).
154. Remove the return spring.



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



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



158. Using a suitable puller, remove the needle roller bearing from the transaxle case.



159. Remove the oil seal rings (1) from the transaxle case.



160. Remove the number 1 transaxle case plugs.
161. Remove the O-rings from the number 1 transaxle case plugs.



162. Using a suitable puller, remove the underdrive cylindrical roller bearing from the transaxle case.



163. Remove the oil seal ring (1) from the transaxle housing.



164. Remove the bolt (2), transaxle apply tube clamp (1) and differential gear lube apply tube from the transaxle housing.



165. Remove the clutch drum oil seal rings (1).



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



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



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



170. Using a screwdriver, remove the O-ring (1).



171. Mount the oil pump in a soft jaw vise.
172. Using a suitable puller (1), remove the oil seal from the oil pump body.



173. Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly.



174. Push the driven gear (2) to one side of the body.
175. Using a feeler gauge, measure the clearance.

Specification

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

•	Side clearance - 0.02-0.05 mm (0.001-0.002 in)

•	Maximum body clearance - 0.17 mm (0.0067 in)

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



177. Using a feeler gauge, measure the tip clearance between the driven gear teeth and drive gear teeth.

Specification

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

•	Maximum tip clearance - 0.15 mm (0.0059 in)

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



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

Specification

•	Standard side clearance - 0.02-0.05 mm (0.0008-0.0020 in)

•	Maximum side clearance - 0.05 mm (0.0020 in)

180. Refer to Transmission General Specifications for drive gear thickness.



181. Using a dial indicator, measure the inside diameter of the oil pump body bushing.

Specification

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

•	Maximum inside diameter - 38.188 mm (1.5034 in)

182. If the inside diameter is greater than the maximum, replace the oil pump and gear body sub-assembly.



183. Using a dial indicator, measure the inside diameter of the stator shaft.

Specification

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

•	Maximum inside diameter - 21.57 mm (0.8492 in)

184. If the inside diameter is greater than the maximum, replace the stator shaft.



185. Put matchmarks (1) on the front differential ring gear (2) and differential case.



186. Remove the bolts from the front differential ring gear (1).



187. Using a plastic hammer, tap on the front differential ring gear (1) to remove it from the case.



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



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



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



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




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

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



193. Remove the front number 1 differential pinion shaft (2) from the differential case.



194. Remove the front differential pinions, pinion thrust washers, front differential side gears (1) and side gear thrust washers from the differential case.



195. Using a suitable driver (1) and a hammer, remove the transaxle housing oil seal.



196. Using a suitable driver (1) and a hammer, remove the differential side bearing retainer oil seal.



197. Using a dial indicator, inspect the backlash of the side gear.

Specification
Standard backlash - 0.05-0.20 mm (0.0020-0.0079 in)

198. Refer to Transmission General Specifications