Part 1

COMPONENT PARTS REMOVAL

Components

External Components:

Valve Body Assembly, Accumulators And Manual Valve Lever:

Differential Assembly:

Internal Components:

Separate Basic Subassembly

1. REMOVE SHIFT CONTROL CABLE BRACKET
2. REMOVE UNION AND ELBOW

a. Remove the manual shift lever.

b. Using the open and wrench, remove the union an elbow.
c. Remove the O-rings from the union and elbow.

3. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Pry off the lock washer and remove the manual valve shaft nut.
b. Remove the 2 bolts and pull out the park/neutral position switch.

4. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE

5. REMOVE TRANSMISSION (T/M) REVOLUTION SENSOR
a. Remove the bolt and T/M revolution sensor.
b. Remove the O-ring from the T/M revolution sensor.

6. REMOVE TRANSAXLE CASE UPPER COVER

7. REMOVE OIL PAN AND GASKET
a. Remove the 17 bolts.
b. Remove the oil pan by lifting transaxle case.

NOTICE: Do not turn the transaxle over as this will contaminate the valve body with the foreign materials in the bottom of the oil pan.

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

8. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on 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

9. REMOVE OIL PIPE BRACKET AND STRAINER
10. REMOVE MANUAL VALVE BODY

a. Remove the 2 bolts and detent spring.

b. Remove the 5 bolts and manual valve body with the manual valve.
c. Remove the manual valve from the manual valve body.

11. REMOVE OIL PIPES
a. Remove the bolt.
b. Pry up both pipe ends with a large screwdriver and remove the 6 pipes.

12. DISCONNECT SOLENOID CONNECTORS

13. REMOVE CONNECTOR CLAMP AND PIPE RETAINER

14. REMOVE B, APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.

15. REMOVE VALVE BODY

a. Remove the 9 bolts.

b. Remove wire harness clamp.

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

16. REMOVE THROTTLE CABLE

17. REMOVE SOLENOID WIRING
Remove the bolt and the solenoid wiring.

18. REMOVE SECOND BRAKE APPLY GASKET
19. REMOVE ACCUMULATOR PISTONS AND SPRINGS

a. Loosen the 4 bolts one turn at a time until the spring tension is released.
b. Remove the cover and gasket.

c. Remove the C, accumulator piston and spring.
d. Remove the 2 O-rings from the piston.

e. Pop out pistons for C2 and B2 into a rag, using low pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi).
f. Remove the O-rings from the pistons.

20. MEASURE PISTON STROKE SECOND COAST BRAKE

a. Apply a small amount of paint to the piston rod at the point it meets the case.

b. Using Special Service Tool (SST), measure the piston stroke while applying and releasing compressed air (392-785 kPa, 4-8 kgf/cm2, 57 - 114 psi).

Maximum thrust clearance: 2.0 - 3.5 mm (0.079 - 0.138 inch)

If the piston stroke exceeds the limit, inspect the second coast brake band.

21. REMOVE SECOND COAST BRAKE PISTON

a. Using SST, remove the snap ring.
SST 09350-32014

b. Applying compressed air to the oil hole, remove the second coast brake cover, piston assembly and spring.
c. Remove the 2 O-rings from the cover.

22. STAND TRANSAXLE ENGINE SIDE UPWARD
23. REMOVE OIL PUMP

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

a. Remove the 7 bolts.

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

24. REMOVE O-RING FROM OIL PUMP

25. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH

26. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH
a. Separate the direct clutch and forward clutch.
b. Remove the thrust washer from direct clutch.

27. REMOVE BEARING 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
30. REMOVE FRONT PLANETARY GEAR

a. Remove the front planetary gear.

b. Remove the 2 bearings from the planetary gear.

31. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM

a. Remove the sun gear and the sun gear input drum.

b. Remove the thrust washer from sun gear input drum.

32. CHECK OPERATION OF SECOND BRAKE PISTON
Apply compressed air into the case passage and con firm that the piston moves.
If the piston does not move, disassemble and inspect.