Part 1

1. REMOVE UNION AND ELBOW
a. Using the open end wrench, remove the union and elbow.
b. Remove the O-rings from the union and elbow.




2. REMOVE NEUTRAL START 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 neutral start switch.




3. REMOVE SOLENOID
a. Disconnect connector.
b. Remove the two bolts and solenoid.




4. REMOVE THROTTLE CABLE RETAINING PLATE
5. REMOVE SOLENOID WIRE RETAINING BOLT




6. (A140E) REMOVE SPEED SENSOR
a. Disconnect the speed sensor connector.
b. Remove the two bolts and cover bracket.




c. Remove the speed sensor.




7. (A140L) REMOVE GOVERNOR BODY
a. Remove the two bolts and cover bracket.




b. Remove the governor cover.
c. Remove the governor body and thrust washer.
d. Remove the plate washer and governor body adaptor.




8. REMOVE OIL PAN AND GASKET
a. Remove the fifteen bolts.
b. Remove the oil 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 oil pan.

c. Place the transmission on wooden blocks to prevent damage to the tube bracket.




9. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the oil pan and on the magnets 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. REMOVE TUBE BRACKET AND OIL STRAINER




11. (A140E) DISCONNECT SOLENOID CONNECTORS




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




13. REMOVE MANUAL DETENT SPRING
14. REMOVE MANUAL VALVE AND MANUAL VALVE BODY

15. REMOVE VALVE BODY




a. (A140E) Remove the twelve bolts.




b. (A140L) Remove the fourteen bolts.




c. Disconnect the throttle cable from the cam and remove the valve body.




16. REMOVE THROTTLE CABLE AND SOLENOID WIRE FROM CASE




17. REMOVE SECOND BRAKE APPLY GASKET AND GOVERNOR OIL STRAINER

NOTE: Governor oil strainer...A140L only

18. 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 gasket.




c. Remove the piston and spring for C(1) and C(2).
d. Remove the O-rings.




e. Pop out piston B(2) 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.
f. Remove the two O-rings from the B(2) piston.




19. 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.

20. REMOVE SECOND COAST BRAKE PISTON



a. Using SST, remove the snap ring.
SST 09350-32014 (09351-32050)




b. Remove the cover.
c. Remove the piston and outer return spring.
d. Remove the O-ring from the cover.




21. REMOVE OIL PUMP AND DIRECT CLUTCH

CAUTION: Before removing the oil pump, remove the second coast brake piston.

a. Remove the seven bolts.




b. Using SST, pull out the oil pump from the transmission case.
SST 09350-32014 (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 the transmission case.

CAUTION: 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. BE CAREFUL WHEN REMOVING RACE BEHIND OIL PUMP




25. REMOVE CLUTCH DRUM THRUST WASHER
26. REMOVE FORWARD CLUTCH




27. REMOVE BEARINGS AND RACES FROM FORWARD CLUTCH




28. 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.




29. REMOVE FRONT PLANETARY RING GEAR