Part 1

DISASSEMBLY





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





a. Remove the nut, washer and manual shift lever.





b. Using a open end 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, pull out the park/neutral position switch and lock washer.





4. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE





5. REMOVE DIRECT CLUTCH SPEED SENSOR
a. Remove the bolt and direct clutch speed sensor.
b. Remove the O-ring from the direct clutch speed sensor.





6. REMOVE TRANSAXLE CASE UPPER COVER
a. Remove the 9 bolts and transaxle case upper cover.
b. Remove the gasket.





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

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.

d. 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
a. Remove the 3 bolts and strainer.
b. Remove the gasket from the gasket.
c. Remove the 3 bolts and oil pipe bracket.
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 PIPE
a. Remove the bolt.
b. Using a large screwdriver, pry up both pipe ends and remove the 6 pipes.





12. DISCONNECT 3 SOLENOID CONNECTORS





13. REMOVE CONNECTOR CLAMP AND B3 APPLY PIPE RETAINER
a. Remove the bolt and connector clamp.
b. Remove the bolt and pipe retainer.





14. REMOVE B3 APPLY PIPE
Using a screwdriver, pry up the pipe and remove the pipe.
15. REMOVE VALVE BODY





a. Remove the 9 bolts.





b. Remove the bolt and wire harness clamp.





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





16. REMOVE THROTTLE CABLE
a. Using a socket driver, remove the throttle cable.
b. Remove the O-ring.





17. REMOVE SOLENOID WIRE
a. Remove the bolt and solenoid wire.
b. Remove the O-ring.





18. REMOVE 2ND BRAKE APPLY GASKET
19. REMOVE ACCUMULATOR PISTON AND SPRING





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





c. Remove the C1 accumulator piston and spring.
d. Remove the 2 O-rings from the piston.





e. Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) to the oil hole and remove the C2 and 132 accumulator pistons and 3 springs.

NOTICE:
^ Blowing off the air may cause the piston's jump-out. When removing the piston, hold it with your hand using a waste cloth.
^ Take care not to splash ATF when air-blowing.

f. Remove the O-rings from the pistons.
20. MEASURE PISTON STROKE OF 2ND COAST BRAKE





a. Using a water proof pen, place a mark on the 2nd coast brake piston rod at the point it meets the case, as shown in the illustration.





b. Using SST, measure the piston stroke while applying and releasing compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi).
SST 09240-00020
Piston stroke: 2.0 - 3.5 mm (0.079 - 0.138 inch)
If the piston stroke non-standard, inspect the 2nd coast brake band.
21. REMOVE 2ND COAST BRAKE PISTON





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





b. Apply compressed air (392 - 785 kPa, 4 - 8 kgf/cm2, 57 - 114 psi) to the oil hole and remove the 2ns coast brake cover, piston and spring.

NOTICE:
^ Blowing off the air may cause the piston's jump-out. When removing the piston, hold It with your hand using a waste cloth.
^ Take care not to splash ATF when air-blowing.





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 2nd coast brake piston.





a. Remove the 7 bolts.





b. Using SST, remove the oil pump from the transaxle case.
SST 09350-32014 (09351-32061)





c. Remove O-ring from the oil pump.
d. Remove the thrust washer from the oil pump.





24. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH
25. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH
a. Separate the direct clutch and forward clutch.





b. Remove the thrust washer from the direct clutch.





c. Remove the assembled bearing & race, bearing and race from the forward clutch.





26. REMOVE 2ND COAST BRAKE BAND
a. Using a small screwdriver, push the pin and remove it from the bolt hole of the oil pump mounting.
b. Remove the 2nd coast brake band.





27. REMOVE FRONT PLANETARY RING GEAR
28. REMOVE FRONT PLANETARY GEAR





a. Remove the front planetary gear.





b. Remove the 2 bearings from the front planetary gear.
29. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM





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





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