Part 1 of 3

COMPONENT PARTS REMOVAL

Components











Separate Basic Subassembly
1. REMOVE 2 OIL COOLER PIPES
2. REMOVE TRANSAXLE DIPSTICK AND FILLER TUBE





3. REMOVE PARK / NEUTRAL POSITION SWITCH
a. Remove the manual shift lever.
b. Pry off the lock washer and remove the manual valve shaft nut.
c. Remove the 2 bolts and pull out the park / neutral position switch.





4. REMOVE UNION
a. Using the open end wrench, remove the union.
b. Remove the O-ring from union.





5. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE
6. REMOVE SOLENOID WIRE RETAINING BOLT AND PLATE





7. REMOVE VEHICLE SPEED SENSOR AND SENSOR ROTOR
a. Remove the retaining plate and pull out the speed sensor.
b. Remove the O-ring from speed sensor.





c. Remove the 2 bolts and sensor cover bracket.





d. Using a screwdriver, remove the sensor cover.

HINT: Tape the screwdriver tip before use to avoid damaging the cover or transaxle.





e. Remove the O-ring from the sensor cover.





f. Remove the sensor rotor.





g. Remove the 3 bolts and sensor adaptor.





8. REMOVE PAN AND GASKET
a. Remove the 18 bolts.
b. Remove the pan by lifting the transaxle case.

NOTICE: Do not turn the transaxle over as it will contaminate the valve body with the foreign materials in the bottom of the pan.

c. Remove the gasket.
d. Place the transaxle on wooden blocks to prevent damage to the pipes.





9. EXAMINE PARTICLES IN PAN
Remove the magnets and use them 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 transaxle:
Steel (magnetic) .. bearing, gear and plate wear
Brass (non-magnetic) .. bushing wear
10. TURN TRANSAXLE OVER





11. REMOVE OIL STRAINER
a. Remove the 3 bolts and oil strainer.





b. Remove the gasket.





12. REMOVE OIL TUBES
a. Remove the 2 bolts and tube bracket.
b. Remove the tube clamp bolt and clamp.





c. Remove the oil tube bracket.
d. Pry up both ends with a large screwdriver and remove the 5 tubes.





13. REMOVE MANUAL DETENT SPRING





14. DISCONNECT SOLENOID CONNECTORS





15. REMOVE VALVE BODY
a. Remove the wire retainer.





b. Remove the solenoid wire.





c. Remove the 11 bolts.





d. Disconnect the throttle cable from the cam.





e. Using a shop rag and screwdriver, remove the E -ring.

HINT: Carefully remove the E-ring so it does not fall into the transaxle case.





f. While disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body.
g. Remove the manual valve from the valve body.





16. REMOVE THROTTLE CABLE FROM CASE
Pull out the throttle cable.





17. REMOVE SECOND BRAKE APPLY GASKET





18. REMOVE SECOND BRAKE DRUM SEAL
Using a needle-nose pliers, pull out the second brake drum seal.





19. REMOVE C3 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the piston into a rag.





20. REMOVE ACCUMULATOR PISTONS AND SPRINGS
a. Loosen the 5 bolts one turn at a time until the spring tension is released.
b. Remove the cover and gasket.





c. Remove the C1, piston and 2 springs.





d. Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the C, piston into a rag.





e. Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the 132 piston into a rag.





21. 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.





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2 , 57 - 114 psi).
SST 09240-00020

Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)

If the piston stroke exceeds the limit, inspect the brake band.





22. REMOVE SECOND COAST BRAKE PISTON
a. Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)





b. Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the cover into a rag.





c. Remove the cover, piston and spring.
d. Remove the 2 O-rings from the cover.





23. REMOVE OIL PUMP
a. Remove the 6 bolts holding the oil pump to the transaxle case.





b. Using SST, pull the oil pump free from the transaxle case.
SST 09350-32014 (09351-32061)





c. Remove the oil pump with SST.
SST 09350-32014 (09351-32061)

NOTICE: Be careful not to drop or damage the races and bearing behind oil pump.

d. Remove SST from the oil pump.





e. Remove the race from the oil pump.





f. Remove the O-ring from the oil pump.