Part 1
DISASSEMBLY1. REMOVE 2 OIL COOLER PIPES
2. REMOVE TRANSAXLE DIPSTICK AND FILLER PIPE
3. REMOVE BREATHER HOSE
4. 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.
5. REMOVE UNION
a. Using an open end wrench, remove the 2 unions.
b. Remove the O-rings from the unions.
6. REMOVE THROTTLE CABLE RETAINING BOLT
7. REMOVE SOLENOID WIRE RETAINING BOLT
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.
Lock carefully at the chips and particles inch 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. DISCONNECT SOLENOID CONNECTORS
13. REMOVE MANUAL DETENT SPRING
14. REMOVE VALVE BODY
a. Remove the bolt and wire retainer.
b. Remove the solenoid wire.
c. Remove the 17 bolts.
d. Disconnect the throttle cable from the cam.
e. While disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body.
f. Remove the manual valve from the valve body.
15. REMOVE THROTTLE CABLE FROM CASE
Pull out the throttle cable.
16. REMOVE CHECK BALL BODY
Remove the check ball body and spring.
17. REMOVE 2ND BRAKE APPLY GASKET
18. REMOVE 2ND BRAKE DRUM SEAL
Using a needle-nose pliers, pull out the 2nd brake drum seal.
19. REMOVE B2 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm2'14 psi), pop out the piston into a rag and remove the spring.
20. REMOVE C2 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm2,14 psi), pop out the C2 piston into a rag and remove the spring.
21. REMOVE C1 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm2,14 psi), pop out the C, piston into a rag and remove the spring.
22. REMOVE C3 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm2,14 psi), pop out the C3 piston into a rag and remove the spring.
23. REMOVE 2ND COAST BRAKE BAND GUIDE
24. REMOVE MANUAL VALVE SHAFT
a. Using a screwdriver and hammer, unstake the spacer and remove it.
b. Using a punch and hammer, drive out the pin.
HINT: Slowly drive out the spring pin so it does not fall into the transaxle case.
c. Remove the retaining spring.
d. Slide out the manual valve shaft and remove the manual valve lever and washer.
25. IF NECESSARY, REPLACE OIL SEAL OF MANUAL SHAFT
a. Using a screwdriver, remove the oil seal.
b. Using a 14 mm socket wrench and hammer, drive in a new oil seal.
c. Apply MP grease to the seal lip.
26. REMOVE TRANSAXLE HOUSING
Remove the 17 bolts and transaxle housing.
27. REMOVE DIFFERENTIAL ASSEMBLY
28. REMOVE APPLY GASKET
29. REMOVE OIL PUMP
a. Remove the 6 bolts and holding the oil pump to the transaxle case.
b. Pull the oil pump from the transaxle case.
c. Remove the race from the oil pump.
d. Using a screwdriver, remove the O-ring from the oil pump.
30. REMOVE APPLY PIPE
a. Remove the bolt and apply pipe bracket.
b. Using a screwdriver, remove the apply pipe.
HINT: Tape the screwdriver tip before use.
NOTICE: Be careful not to bend or damage the pipe.
31. MEASURE PISTON STROKE OF 2ND 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 - 3.5 mm (0.059 - 0.138 inch)
If the piston stroke exceeds the limit, inspect the brake band.
32. REMOVE 2ND 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/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.
33. REMOVE DIRECT CLUTCH WITH FORWARD CLUTCH
a. Remove the direct clutch with the forward clutch from the case.
b. Remove the direct clutch from the forward clutch.
c. Remove the thrust washer and 2 assembled bearings and races from the forward clutch.
34. REMOVE 2ND COAST BRAKE BAND
a. Pull out the pin.
b. Remove the brake band.
35. REMOVE FRONT PLANETARY RING GEAR
a. Remove the front planetary ring gear.
b. Remove the bearing and race from the ring gear.
36. REMOVE FRONT PLANETARY GEAR
a. Remove the front planetary gear with the bearing and race.
b. Remove the bearing and race from the planetary gear.
37. REMOVE SUN GEAR, SUN GEAR INPUT DRUM AND THRUST WASHER
38. REMOVE 2ND BRAKE HUB AND NO.1 ONE-WAY CLUTCH
39. CONFIRM THAT 2ND BRAKE PISTON MOVES
Using compressed air, confirm that the 2nd brake piston moves smoothly.
40. REMOVE 2ND BRAKE
a. Using a screwdriver, remove the snap ring.
HINT: Tape the screwdriver tip before use.
b. Remove the 2nd brake drum.
HINT: If the brake drum is difficult to remove, lightly tap it with a wooden block.
c. Remove the return spring.
d. Remove the plates, discs and flange.
41. REMOVE REAR PLANETARY GEAR
a. Using 2 screwdrivers, remove the snap ring.
HINT: Tape the screwdriver tip before use.
b. Remove the No.2 one-way clutch and rear planetary gear with the 2 thrust washers.
c. Remove the 2 thrust washers from the gear.
d. Remove the bearing and race from the planetary ring gear.