Disassembly

SEPARATE BASIC SUBASSEMBLY




1. REMOVE TWO OIL COOLER PIPES
2. REMOVE MANUAL SHIFT LEVER




3. REMOVE NEUTRAL START SWITCH
4. REMOVE OIL FILLER GAUGE AND TUBE




5. REMOVE THROTTLE CABLE RETAINING PLATE




6. REMOVE GOVERNOR BODY
a. Remove the two bolts and cover bracket.
b. Remove the governor cover and O-ring.
c. Remove the governor body with thrust washer.
d. Remove the plate washer and governor body adaptor.




7. REMOVE PAN AND GASKET
a. Remove the fifteen bolts.
b. Remove the pan by lifting transmission case.

CAUTION: Do not turn the transmission over as this 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 tube bracket.




8. 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




9. TURN TRANSMISSION OVER AND REMOVE OIL TUBE BRACKET AND OIL STRAINER




10. REMOVE THE FOUR OIL TUBES
Pry up both tube ends with a large screwdriver and remove the four tubes.




11. REMOVE MANUAL DETENT SPRING
12. REMOVE MANUAL VALVE AND MANUAL VALVE BODY

13. REMOVE VALVE BODY




a. Remove the fourteen bolts.




b. Disconnect the throttle cable from the cam.




14. REMOVE THROTTLE CABLE FROM CASE




15. REMOVE SECOND BRAKE APPLY GASKET (GOVERNOR APPLY GASKET)
16. REMOVE GOVERNOR OIL STRAINER




17. REMOVE ACCUMULATOR PISTON 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 and C2.
d. Pop out piston B2 into a rag. using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa). Force air into the hole shown and remove the piston and spring.

18. 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 exceed the limit, replace the piston rod or brake band.




19. REMOVE SECOND COAST BRAKE PI$TON
a. Remove the snap ring.
b. Remove the cover.
c. Remove the piston and the outer return spring.




20. REMOVE SEVEN BOLTS HOLDING OIL PUMP TO TRANSMISSION CASE
21. PULL OIL PUMP FREE WITH SST FROM TRANSMISSION CASE
SST 09350-32013 (09351-32061)




22. REMOVE OIL PUMP AND DIRECT CLUTCH
While holding the input shaft, grasp the pump stator shaft and pull the oil pump and direct clutch together Out of the transmission case.

NOTE: Push the 2nd coast brake band into the case, being careful not to catch it on the direct clutch drum.




23. REMOVE DIRECT CLUTCH FROM OIL PUMP
24. WATCH FOR RACE BEHIND OIL PUMP




25. REMOVE CLUTCH DRUM THRUST WASHER AND FORWARD CLUTCH




26. WATCH FOR BEARINGS AND RACES




27. 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.




28. REMOVE FRONT PLANETARY RING GEAR




29. WATCH FOR RACES ON RING GEAR




30. REMOVE PLANETARY GEAR




31. WATCH FOR RACES AND BEARING ON PLANETARY GEAR




32. REMOVE SUN GEAR, SUN GEAR INPUT DRUM. SECOND BRAKE HUB AND NO.1 ONE-WAY CLUTCH




33. STAND TRANSMISSION CASE UP AND REMOVE SECOND COAST BRAKE BAND GUIDE




34. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE




35. REMOVE SECOND BRAKE DRUM
If the brake drum is difficult to remove, lightly tap it with a wooden block.




36. REMOVE SECOND BRAKE PISTON RETURN SPRING




37. REMOVE PLATES, DISCS AND FLANGE




38. BLOW OUT PISTON WITH COMPRESSED AIR
Use compressed air to remove the piston.

NOTE: Hold the piston so it is not horizontal and blow with the gun slightly away from the oil hole.




39. REMOVE SECOND BRAKE DRUM GASKET
Using a pin punch, drive out the gasket.




40. REMOVE SNAP RING HOLDING NO.2 ONE-WAY CLUTCH OUTER RACE TO CASE




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




42. WATCH FOR THRUST WASHERS OF PLANETARY CARRIER ON BOTH SIDES




43. REMOVE REAR PLANETARY RING GEAR, BEARING AND RACES




44. WATCH FOR RACES AND BEARING ON RING GEAR




45. REMOVE SNAP RING HOLDING FLANGE TO CASE




46. REMOVE FLANGES, PLATES AND DISCS




47. TURN TRANSMISSION CASE AROUND
48. REMOVE THE ELEVEN BOLTS HOLDING TRANSAXLE REAR COVER TO TRANSMISSION CASE




49. REMOVE TRANSAXLE REAR COVER, INTERMEDIATE SHAFT AND GASKET
a. Tap on the circumference of the cover with a plastic hammer to remove the cover from the transmission case.
b. Remove the intermediate shaft it remain in the transmission.




50. REMOVE PARKING LOCK PAWL BRACKET
51. REMOVE PARKING LOCK ROD




52. REMOVE PIN
53. REMOVE SPRING AND PARKING LOCK PAWL