Part 1 of 2

COMPONENT PARTS REMOVAL

COMPONENTS

External Components:

Valve Body And Accumulators:

Internal Components:

SEPARATE BASIC SUBASSEMBLY





1. REMOVE SHIFT CONTROL CABLE BRACKET





2. REMOVE UNION AND ELBOW
a. Remove the manual shift lever.





b. Using a open and wrench, remove the union and 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 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 pipe 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 B3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.


15. REMOVE VALVE BODY



a. Remove the 9 bolts.





b. Remove the 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 C1 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).
(SST) 09240-00020

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.