Part 1

Part 1:

Part 2:

Part 3:

COMPONENTS

SEPARATE BASIC SUBASSEMBLY

1. REMOVE THE TWO OIL COOLER PIPES
2. REMOVE TRANSMISSION DIPSTICK AND FILLER TUBE
3. REMOVE MANUAL SHIFT LEVER

4. REMOVE NEUTRAL START SWITCH

5. REMOVE THROTTLE CABLE RETAINING PLATE

6. REMOVE SOLENOID AND KICK-DOWN SWITCH WIRE RETAINING PLATE

7. REMOVE SPEED SENSOR AND SENSOR ROTOR

a. Remove the retaining plate and speed sensor.
b. Remove the two bolts and sensor cover.

c. Remove the sensor rotor.
d. Remove the sensor rotor adaptor.

8. REMOVE PAN AND GASKET
a. Remove the eighteen bolts.
b. Remove the pan by lifting the transmission case.

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

c. Place the transmission on wooden blocks to prevent damage to the pipe.

9. 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 plate wear
Brass (non-magnetic) . . . bushing wear

10. TURN TRANSMISSION OVER AND REMOVE OIL TUBE BRACKET

11. REMOVE OIL STRAINER

12. REMOVE OIL TUBES
a. Remove the tube clamp bolt.
b. Pry up both tube ends with a large screwdriver and remove the five tubes.

13. REMOVE MANUAL DETENT SPRING

14. DISCONNECT SOLENOID CONNECTORS
Disconnect the three solenoid connectors.

15. REMOVE VALVE BODY

a. Remove the twelve bolts.

b. Disconnect the throttle cable from the cam.
c. Disconnect the manual valve connecting rod from the manual valve lever and remove the valve body.

16. REMOVE THROTTLE CABLE FROM CASE

17. REMOVE SOLENOID WIRE

18. REMOVE SECOND BRAKE APPLY GASKET

19. REMOVE C3 ACCUMULATOR PISTON AND SPRING Using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa), pop out the piston into a rag. Force air into the hole shown and remove the piston and spring.

20. REMOVE ACCUMULATOR PISTONS AND SPRINGS
a. Loosen the five bolts one turn at a time until the spring tension is released.
b. Remove the cover and the gasket.
c. Remove the piston and spring for C1.
d. Using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa), pop out piston B2 and C2 into a rag. Force air into the hole shown and remove the piston and springs.

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 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 exceeds the limit, replace the piston rod or brake band.

22. REMOVE SECOND COAST BRAKE PISTON
a. Remove the snap ring.
b. Remove the cover.
c. Remove the piston and the outer return spring.

23. REMOVE OIL PUMP
a. Remove the six bolts.
b. Using SST, pull out the oil pump.

SST 09350-32013 (09351-32061)

24. REMOVE OIL PUMP
25. WATCH FOR RACE AND BEARING BEHIND OIL PUMP

26. REMOVE DIRECT CLUTCH

27. REMOVE FORWARD CLUTCH
28. WATCH FOR RACES AND BEARINGS

29. 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.