For 1990-2009 cars

#### Tools Required

• | DT 46451 (DW240-020) Brake/Clutch Spring Compressor

• | DT 46454 (DW240-050) Overdrive Brake Adapter

• | DT 46455 (DW240-060-01) Brake Spring Compressor Bolt/Nut

• | DT 46457 (DW240-070) 1st and Reverse Brake Adapter

• | DT 46463 (DW240-150) Transaxle Case Side Bearing Outer Race Adapter

• | DT 46465 (DW240-170) Adapter Handle

• | DT 46469-2 (DW260-021) Automatic Transaxle Overhaul Fixture

• | DT 46472 (DW260-041) Planetary Ring Gear Nut Removal/Installation Socket

### Disassembly Procedure

1. Remove the transaxle assembly from the vehicle. Refer to Transmission Replacement .
2. Install the transaxle assembly to the transaxle support stand using the DT 46453 (1).
3. Remove the nut, washer and control lever.
4. Using a screwdriver, unstake the lock washer.
5. Remove the 2 bolts and nut and pull out the park/neutral position (PNP) switch.
6. Remove the 2 unions the transaxle case.
7. Remove the 2 O-rings from the unions.
8. Remove the screw plug from the transaxle case.
9. Remove the O-ring from the screw plug.
10. Remove the bolt and the input shaft speed (ISS) sensor.
11. Remove the breather plug.
12. Remove the O-ring from the breather plug.
13. Remove the bolt and the output shaft speed (OSS) sensor.
14. Remove the 18 bolts.
15. Remove the oil pan and gasket.
16. Remove the drain plug from the oil pan.
17. Remove the 3 bolts and oil strainer.
18. Remove the gasket from the oil strainer.
19. Remove the bolt and transmission fluid temperature sensor with the clamp.
20. Disconnect the 5 solenoid connectors.

• | Lock-up control solenoid (5)

• | Pressure control solenoid (1)

• | No. 2 shift solenoid (2)

• | No. 1 shift solenoid (3)

• | Timing solenoid (4)

21. Support the valve body assembly and remove the 14 bolts.
22. Disconnect the manual valve control rod from the manual valve lever, then remove the valve body assembly.
23. Remove the check valve and spring.
24. Remove the brake drum gasket.
25. Remove the apply gasket.

Notice: Refer to Compressed Air Should Not Exceed 98 kPa (14 psi) Notice in the Preface section.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash automatic transaxle fluid (ATF) when air-blowing.

26. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the direct clutch accumulator piston and spring.
27. Remove the spring.
28. Remove the 2 O-rings (1) from the direct clutch accumulator piston.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash ATF when air-blowing.

29. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the forward clutch accumulator piston and spring.
30. Remove the spring.
31. Remove the 2 O-rings (1) from the forward clutch accumulator piston.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash ATF when air-blowing.

32. Apply 392 kPa (57 psi) of compressed air to the oil hole (1) and remove the over drive (O/D) and 2nd brake clutch accumulator piston and spring.
33. Remove the 2 O-rings (1) from the O/D and 2nd brake accumulator piston.
34. Remove the bolt and the transaxle wire from the transaxle case.
35. Remove the O-ring (1) from the transaxle wire.

Important: Be careful not to drop the differential gear assembly when the transaxle housing is removed.

36. Remove the 16 bolts and tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
37. Using a dial indicator, measure the input shaft end play.

Specification
The end play is 0.3-0.9 mm (0.012-0.035 in).

38. Remove the 6 bolts and oil pump.
39. Remove the differential gear assembly from the transaxle case.
40. Remove the apply gasket.
41. Remove the direct clutch assembly from the transaxle case.
42. Remove the thrust needle roller bearing from the direct clutch assembly.
43. Remove the direct clutch hub, thrust needle roller bearing and thrust bearing race from the transaxle case.
44. Remove the counter driven gear assembly from the transaxle case.
45. Remove the 9 bolts and tap on the circumference of the transaxle rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
46. Remove the 4 apply gaskets.
47. Remove 2nd coast and O/D brake flange (1), 2 discs (2), and 2 plates (3) from the transaxle case.
48. Remove the thrust needle roller bearing and forward and reverse clutch assembly.
49. Remove the thrust needle roller bearing and thrust bearing race from the forward and reverse clutch assembly.
50. Remove the forward clutch hub from the transaxle case.
51. Remove the thrust bearing race and thrust needle roller bearing from the forward clutch hub.
52. Remove rear planetary sun gear and 1-way clutch assembly.
53. Remove the thrust bearing race from the rear planetary sun gear and 1-way clutch assembly.
54. Remove the thrust needle roller bearing and planetary carrier thrust washer from the rear planetary sun gear and 1-way clutch assembly.
55. Remove the 1-way clutch assembly and thrust washer from the rear planetary sun gear.
56. Remove the front planetary sun gear from the transaxle case.
57. Remove the thrust bearing race from the front planetary sun gear.
58. Using the DT 46455 (1) and DT 46458 (2), remove the 2 snap rings, 2nd brake piston, and 2nd brake piston return spring.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash ATF when air-blowing.

59. Apply 392 kPa (57 psi) of compressed air to the 2nd brake to remove the 2nd brake piston from the 2nd brake clutch cylinder.
60. Remove the 2 O-rings (1) from the 2nd brake piston.
61. Remove the 2 plates, 2 discs, and flange.
62. Remove the No. 2 1-way clutch and planetary gear from the transaxle case.
63. Remove the No. 2 1-way clutch from the planetary gear and remove the anti-rattle clip.
64. Fix the counter drive gear with the parking lock pawl.

Notice: Do not chisel and remove the planetary ring gear nut staking before removing the nut. Damage to the planetary ring gear could result if force is applied . Remove the nut without unstaking the planetary ring gear. If force is used to unstake the planetary ring gear nut, damage the bearing could result.

65. Remove the planetary ring gear nut using planetary ring gear nut removal/installation socket DT 46472 (1).
66. Remove the 2 bolts and parking lock pawl bracket.
67. Remove the parking lock pawl shaft, torsion spring and parking lock pawl.
68. Remove the bolt and manual detent spring.
69. Using a chisel and hammer, unstake and remove the spacer.
70. Using a pin punch and hammer, drive out the pin.
71. Remove the manual valve lever shaft and manual valve lever.
72. Remove the parking lock rod from the manual valve lever.
73. Using a screwdriver, remove the oil seal.

Caution: Use extreme care when removing snap rings. Always wear adequate eye protection in order to avoid personal injury.

74. Using the DT 46455 (1) and DT 46457 (2), remove the snap ring of 1st and reverse brake.
75. Remove the flange, 4 discs, 4 plates, and return spring.
76. Using the DT 46455 (2), DT 46457 (3), and DT 46459 (1), remove the planetary ring gear.
77. Install the 3 bolts to the counter drive gear.

Specification

• | The bolt (M6) L is equal to 40-80 mm (1.57-3.15 in).

• | The bolt (M6) pitch is equal to 1.0 mm (0.04 in).

78. Rotate 3 bolts in order and remove the counter drive gear and planetary ring gear.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash ATF when air-blowing.

79. Apply 392 kPa (57 psi) of compressed air to the transaxle case to remove the 1st and reverse brake piston.
80. Remove the 2 O-rings (1) from the 1st and reverse brake piston.
81. Remove the bolt and No. 1 transaxle case plate from the transaxle case.
82. Using a suitable puller, remove the counter driven gear outer tapered roller bearing race and shim from the transaxle case.
83. Using a driver, remove the oil seal from the transaxle case.
84. Using the DT 46463 (2) and DT 46465 (1), remove the transaxle case side bearing outer race and shim.
85. Remove the 3 bolts and oil reservoir lock plate from the transaxle housing.
86. Remove the bolt and No. 1 transaxle apply pipe clamp from the transaxle housing.
87. Remove the transaxle lube apply pipe and differential gear lube apply pipe from the transaxle housing.
88. Using a suitable puller, remove the counter driven gear outer tapered roller bearing race from the transaxle housing.
89. Using a driver, remove the oil seal from the transaxle housing.
90. Using a suitable puller, remove the side bearing outer race from the transaxle housing.

Caution: Use extreme care when removing snap rings. Always wear adequate eye protection in order to avoid personal injury.

91. Using the DT 46451 (1), DT 46454 (2) and a driver, remove the snap ring.
92. Remove the O/D brake return spring.

Important:

• | Air pressure may cause the pistons to jump out. When removing the piston, hold it in place with your hand using a waste cloth.

• | Take care not to splash ATF when air-blowing.

93. Apply 392 kPa (57 psi) of compressed air to the transaxle rear cover to remove the O/D brake piston.
94. Remove the 2 O-rings (1) from the O/D brake piston.

Important: Do not expand the seal ring excessively.

95. Remove the 2 seal rings from the transaxle rear cover.
96. Remove the 4 screw plugs and 4 O-rings from the transaxle rear cover.