Disassembly

Part 1:

Part 2:

Part 3:

COMPONENTS

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 thrust washer from the governor body.
d. Remove the governor body.
e. Remove the plate washer and governor body adaptor.




7. REMOVE PAN AND GASKET
a. Remove the fifteen 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.




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 (nonmagnetic) . . bushing wear




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




10. REMOVE 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 and remove the valve body.




14. REMOVE THROTTLE CABLE FROM CASE




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




17. REMOVE ACCUMULATOR PISTON AND SPRINGS
a. Loosen the five bolts ore 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. Using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa), pop out piston B2 into a rag. 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 (48 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 PISTON
a. Remove the snap ring.
b. Remove the cover.
c. Remove the piston and the outer return spring.




20. REMOVE OIL PUMP
a. Remove the seven bolts.
b. Using SST, pull out the oil pump. SST 09350-32013 (09351-32061)




21. REMOVE DIRECT CLUTCH FROM OIL PUMP
22. WATCH FOR RACE BEHIND OIL PUMP




23. REMOVE CLUTCH DRUM THRUST WASHER
24. REMOVE FORWARD CLUTCH




25. WATCH FOR BEARINGS AND RACES




26. 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.




27. REMOVE FRONT PLANETARY RING GEAR




28. WATCH FOR RACES ON RING GEAR




29. REMOVE PLANETARY GEAR




30. WATCH FOR RACES AND BEARINGS ON PLANETARY GEAR




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




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




33. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE




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




35. REMOVE SECOND BRAKE PISTON RETURN SPRING




36. REMOVE PLATES, DISCS AND FLANGE




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

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




38. REMOVE SECOND BRAKE DRUM GASKET




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




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




41. WATCH FOR THRUST WASHER OF PLANETARY CARRIER ON BOTH SIDES




42. REMOVE REAR PLANETARY RING GEAR AND BEARING




43. WATCH FOR RACES AND BEARING ON RING GEAR




44. REMOVE SNAP RING HOLDING FLANGE TO CASE




45. REMOVE FLANGES, PLATES AND DISCS




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




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

49. REMOVE CASE GASKET




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




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