Component Parts Removal (Part 1)

Part 1:

Part 2:

Part 3:

COMPONENTS

SEPARATE BASIC SUBASSEMBLY
1. REMOVE TWO OIL COOLER PIPES
2. REMOVE TRANSMISSION DIPSTICK AND FILLER TUBE




3. REMOVE PARK/NEUTRAL SWITCH
a. Remove the manual shift lever.
b. Pry off the lock washer and remove the manual valve shaft nut.
c. Remove the two bolts and pull out the park/neutral 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 PULSE GENERATOR AND SENSOR ROTOR




a. Remove the retaining plate and pull out the pulse generator.
b. Remove the O-ring from pulse generator.




c. Remove the two bolts and sensor cover bracket.




d. Using a screwdriver, remove the sensor cover.

HINT: Tape the screwdriver tip before use so as not to damage the cover or transaxle.




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




f. Remove the sensor rotor.




g. Remove the three bolts and sensor adaptor.




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

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

c. Remove the gasket.
d. Place the transmission 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. Lock 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

11. REMOVE OIL STRAINER




a. Remove the three bolts and oil strainer.




b. Remove the gasket.

12. REMOVE OIL TUBES




a. Remove the two 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 five 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 eleven bolts.




d. Disconnect the throttle cable from the cam.




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

HINT: Slowly 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 C(3) ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/sq.cm, 14 psi) 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 gasket.




c. Remove the C(1) piston and two springs.




d. Using low-pressure compressed air (98 kPa, 1 kgf/sq.cm, 14 psi), pop out the C2 piston into a rag. Force air into the hole shown and remove the piston and spring.




e. Using low-pressure compressed air (98 kPa, 1 kgf/sq.cm, 14 psi), pop out the B2 piston into a rag. Force air into the hole shown and remove the piston and spring.

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 (392 - 785 kPa, 4 - 8 kgf/sq.cm, 57 - 114 psi) as shown.

SST 09240 - 00020

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

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/sq.cm, 14 psi), pop out the cover into a rag. Force air into the hole shown.




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

23. REMOVE OIL PUMP




a. Remove the six bolts holding the oil pump to the transmission case.




b. Using SST, pull the oil pump free from the transmission case.

SST 09350 - 32014 (09351 - 32061)




c. Remove the oil pump with SST.

SST 09350 - 32014 (09351 - 32061)

NOTE: 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.

24. REMOVE DIRECT CLUTCH WITH FORWARD CLUTCH




a. Remove the direct clutch with forward clutch from the case.




b. Remove the direct clutch from the forward clutch.




c. Remove the thrust washer, bearings and races from the forward clutch.




25. 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.

26. REMOVE FRONT PLANETARY RING GEAR




a. Remove the front planetary ring gear with race.




b. Remove the races from the ring gear.

27. REMOVE FRONT PLANETARY GEAR




a. Remove the front planetary gear with bearing and race.




b. Remove the races and bearings from the planetary gear.




28. REMOVE SUN GEAR, SUN GEAR INPUT DRUM AND THRUST WASHER




29. REMOVE SECOND BRAKE HUB AND NO.1 ONE-WAY CLUTCH




30. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.




31. REMOVE SECOND COAST BRAKE BAND GUIDE




32. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE




33. REMOVE SECOND BRAKE DRUM

HINT: If the brake drum is difficult to remove, lightly tap it with a wooden block.

34. REMOVE SECOND BRAKE PISTON RETURN SPRING




a. Remove the thrust washer.
b. Remove the return spring.




35. REMOVE PLATES, DISCS AND FLANGE




36. REMOVE SNAP RING HOLDING NO.2 ONE-WAY CLUTCH OUTER RACE TO CASE
Using a screwdriver, remove the snap ring.

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




a. Remove the No.2 one-way clutch and rear planetary gear with thrust washer.




b. Remove the two thrust washers from the gear.

38. REMOVE REAR PLANETARY RING GEAR




a. Remove the rear planetary ring gear with bearing and races.




b. Remove the bearing and races from the ring gear.




39. CONFIRM THAT FIRST AND REVERSE BRAKE PISTON MOVES
Using compressed air, confirm that the first and reverse brake piston moves smoothly.




40. REMOVE SNAP RING HOLDING FLANGE TO CASE
Using a screwdriver, remove the snap ring.