Disassembly

Disassembly Of Transmission Part 1:

Disassembly Of Transmission Part 2:

Disassembly Of Transmission Part 3:

COMPONENTS

SEPARATE BASIC SUBASSEMBLY




1. REMOVE THE TWO OIL COOLER PIPES
2. REMOVE SHIFT LEVER




3. REMOVE NEUTRAL START SWITCH




4. REMOVE SOLENOID
a. Disconnect connector.
b. Remove the two bolts and solenoid.

5. REMOVE OIL FILLER GAUGE AND TUBE




6. REMOVE FOLLOWING PARTS:
a. Throttle cable retaining plate
b. (A140E)
Solenoid wiring retaining bolt




7. (A140E)
REMOVE SPEED SENSOR
a. Disconnect the connector.
b. Remove the two bolts and cover bracket.
c. Remove the speed sensor and O-RING.




8. A140U
REMOVE GOVERNOR BODY
a. Remove the two bolts and cover bracket.
b. Remove the governor cover and O-RING.
c. Remove the governor body with thrust washer.
d. Remove the plate washer and governor body adaptor.




9. REMOVE OIL PAN AND GASKET
a. Remove the fifteen bolts.
b. Remove oil pan by lifting the transmission case.

CAUTION: Do not turn the transmission over as this will contaminate the valve body with foreign material in the bottom of the pan.

c. Place the ATM on wooden blocks to prevent damage to the tube bracket.




10. EXAMINE PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transmission.

Steel (magnetic)...bearing, gear and clutch plate wear
Brass (non-magnetic)...bushing wear




11. TURN TRANSMISSION OVER AND REMOVE FOLLOWING:
a. Tube bracket
b. Oil strainer
c. (A140E)
Solenoid connectors




12. REMOVE FOUR OIL TUBES
Pry up both tube ends with a large screwdriver and remove the four tubes.




13. REMOVE MANUAL DETENT SPRING
14. REMOVE MANUAL VALVE AND MANUAL VALVE BODY
15. REMOVE VALVE BODY




a. (A140E)
Remove the twelve bolts.




b. (A140L)
Remove the fourteen bolts.




c. Disconnect the throttle cable from the cam and remove the valve body.




16. REMOVE THROTTLE CABLE AND SOLENOID WIRING FROM CASE




17. REMOVE SECOND BRAKE APPLY GASKET AND GOVERNOR OIL STRAINER

NOTE: Governor oil strainer. ..A140L only




18. REMOVE ACCUMULATOR PISTON AND SPRINGS
a. Loosen the five bolts one turn at a time until spring tension is released.
b. Remove the cover and the gasket.
c. Remove the piston and spring for C1 and C2.
d. Pop out piston 82 into a rag, using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa). Force air into the hole shown and remove the piston and spring.

19. MEASURE PISTON STROKE OF SECOND COAST BRAKE




a. Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.




b. Using SST, measure the piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.
SST 09240 - 00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 in.)

If the piston stroke exceed the limit, replace the piston rod or brake band.




20. REMOVE THE SEVEN BOLTS HOLDING OIL PUMP TO TRANSMISSION CASE
21. PULL OIL PUMP FREE WITH SST FROM TRANSMISSION CASE
SST 09350 - 32013 (09351 - 32061)




22. REMOVE OIL PUMP AND DIRECT CLUTCH
While holding the input shaft, grasp the pump stator shaft and pull the oil pump and direct clutch together out the transmission case.

CAUTION: Push the 2nd coast brake band into the case, being careful not to catch it on the direct clutch drum.




23. REMOVE DIRECT CLUTCH FROM OIL PUMP
24. BE CAREFUL WHEN REMOVING RACE BEHIND OIL PUMP




25. REMOVE CLUTCH DRUM THRUST WASHER
26. REMOVE FORWARD CLUTCH




27. BE CAREFUL WHEN REMOVING BEARINGS AND RACES




28. REMOVE SECOND COAST BRAKE BAND
a. Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting.
b. Remove the brake band.




29. REMOVE FRONT PLANETARY RING GEAR




30. BE CAREFUL WHEN REMOVING RACES ON RING GEAR




31. REMOVE PLANETARY GEAR




32. BE CAREFUL WHEN REMOVING RACES AND BEARINGS ON PLANETARY GEAR




33. REMOVE BEARING FROM PLANETARY SUN GEAR
34. REMOVE SUN GEAR, SUN GEAR INPUT DRUM, SECOND BRAKE HUB AND NO. 1 ONE-WAY CLUTCH




35. STAND TRANSMISSION CASE UP AND REMOVE SECOND COAST BRAKE BAND GUIDE




36. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE




37. REMOVE SECOND BRAKE DRUM
If the brake drum is difficult to remove, lightly tap it with a wooden block.

38. REMOVE SECOND BRAKE DRUM GASKET




39. REMOVE SECOND BRAKE PISTON RETURN SPRING




40. REMOVE PLATES, DISCS AND FLANGE




41. BLOW OUT PISTON WITH COMPRESSED AIR
Use compressed air to remove the piston.

NOTE: Hold the piston so it does not slant and then blow with the gun slightly away from the oil hole.




42. REMOVE SNAP RING HOLDING NO. 2 ONE-WAY CLUTCH OUTER RACE TO CASE




43. REMOVE NO. 2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR




44. BE CAREFUL WHEN REMOVING THRUST WASHERS FROM BOTH SIDES OF PLANETARY CARRIER




45. REMOVE REAR PLANETARY RING GEAR, BEARING AND RACE




46. BE CAREFUL WHEN REMOVING RACES AND BEARING ON RING GEAR




47. REMOVE SNAP RING HOLDING FLANGE TO CASE




48. REMOVE FLANGES, PLATES AND DISCS




49. TURN TRANSMISSION CASE AROUND
50. REMOVE THE ELEVEN BOLTS HOLDING OVERDRIVE UNIT TO TRANSMISSION CASE




51. REMOVE OVERDRIVE UNIT WITH ALL PARTS
a. Tap on the overdrive case circumference with a plastic hammer to remove the unit from the transmission case.
b. Remove the overdrive planetary gear and counter gear if they remained in the transmission.

NOTE: The overdrive unit is heavy, so be careful not to drop it.




52. REMOVE CASE GASKET
53. REMOVE OVERDRIVE CLUTCH APPLY GASKET AND OVERDRIVE BRAKE APPLY GASKET




54. REMOVE PARKING LOCK PAWL BRACKET
55. REMOVE PARKING LOCK ROD




56. REMOVE PIN
57. REMOVE SPRING AND PARKING LOCK PAWL