Part 1 of 2
COMPONENT PARTS REMOVALComponents
3-Speed Gear Unit Removal
1. REMOVE 2 OIL COOLER PIPES
2. REMOVE TRANSAXLE DIPSTICK AND FILLER TUBE
3. REMOVE MANUAL SHIFT LEVER
Remove the nut, washer and manual shift lever.
4. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Using a screwdriver, pry off the lock washer.
b. Remove the nut and lock washer.
c. Remove the 2 bolts and pull out the park/neutral position switch.
5. REMOVE THROTTLE CABLE RETAINING PLATE
Remove the bolt and plate.
6. REMOVE SOLENOID WIRE RETAINING PLATE
Remove the bolt and plate.
7. REMOVE GOVERNOR BODY
a. Remove the 2 bolts and cover bracket.
b. Using a screwdriver, remove the governor cover.
HINT: Tape the screwdriver tip before use to avoid damaging the cover or transaxle.
c. Remove the O-ring from the cover.
d. Remove the governor body with thrust washer.
e. Remove the 3 bolts and governor body adapter with gasket.
f. Remove the governor oil strainer.
8. REMOVE OIL PAN AND GASKET
a. Remove the 18 bolts.
b. Remove the oil 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 clips. 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 the oil strainer.
b. Remove the gasket.
12. REMOVE OIL PIPES
a. Remove the 2 bolts and pipe gasket.
b. Remove the pipe clamp bolt and clamp.
c. Pry up both ends with a large screwdriver and remove the 5 pipes.
13. REMOVE MANUAL DETENT SPRING
14. DISCONNECT SOLENOID CONNECTORS
15. REMOVE VALVE BODY
a. Remove the 12 bolts and wire retainer.
b. Disconnect the throttle cable from the cam.
c. Wire disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body.
d. Remove the manual valve from the valve body.
16. REMOVE THROTTLE CABLE FROM CASE Pull out the throttle cable.
17. REMOVE SOLENOID WIRE
18. REMOVE SECOND BRAKE APPLY GASKET
19. REMOVE SECOND BRAKE DRUM SEAL
Using needle-nose pliers, pull out the second brake drum seal.
20. REMOVE C3 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kg-cm2, 14 psi) pop out the piston into a rag.
21. 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 kg-cm2, 14 psi), pop out the C2 piston into a rag.
e. Using low-pressure compressed air (98 kPa, 1 kg-cm2, 14 psi), pop out the B2 into a rag.
22. 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 the compressed air (392 - 785 kPa, 4 - 8 kg-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.
23. 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 kg-cm2, 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.
24. 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 rear race from the oil pump.
f. Using a screwdriver, remove the O-ring from the oil pump.
25. REMOVE DIRECT CLUTCH