Part 1 of 3

COMPONENT PARTS REMOVAL

Components











3-Speed Gear Unit Removal
1. REMOVE 2 OIL COOLER PIPES
2. REMOVE TRANSAXLE DIPSTICK AND FILLER TUBE
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 UNIONS
a. Using an open end wrench, remove the 2 unions.
b. Remove the O-rings from 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. 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 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 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 SECOND BRAKE APPLY GASKET





18. REMOVE SECOND BRAKE DRUM SEAL
Using a needle-nose pliers, pull out the second brake drum seal.





19. REMOVE B2 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm, 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/cm, 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/cm, 14 psi), pop out the C1, piston into a rag and remove the spring.





22. REMOVE C3 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (98 kPa, 1 kgf/cm, 14 psi), pop out the C3 piston into a rag and remove the spring.





23. REMOVE SECOND 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 oil 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.