Part 1

COMPONENTS


















SEPARATE BASIC SUBASSEMBLY




1. (A540H) REMOVE TRANSFER ASSEMBLY
a. Remove the five nuts and three bolts.
b. Using a plastic hammer, remove the transfer assembly form the transaxle.




2. (A540H) REMOVE APPLY GASKET




3. (A540H) REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
a. Screw in suitable bolt with washer into the side gear intermediate shaft.
b. Using SST, remove the side gear intermediate shaft.
SST 09520-32012




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




5. 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.




6. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE
7. REMOVE SOLENOID WIRE RETAINING BOLT




8. (A540E) REMOVE NO.2 SPEED SENSOR
a. Disconnect the connector.
b. Remove the bolt and pull out the speed sensor.
c. Remove the O-ring from speed sensor.




9. (A540H) REMOVE VEHICLE SPEED SENSOR
a. Remove the bolt and pull out the speed sensor.
b. Remove the O-ring from speed sensor.




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

CAUTION: 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.




11. EXAMINE PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips. Look carefully at the chips and particles in the oil 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




12. REMOVE OIL TUBE BRACKET AND STRAINER

13. REMOVE MANUAL VALVE BODY



a. Remove the two bolts and detent spring.




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




14. REMOVE OIL TUBES
(A540E) Pry up both tube ends with a large screwdriver and remove the six tubes.

(A540H)
a. Remove the bolt.
b. Pry up both tube ends with a large screwdriver and remove the seven tubes.




15. DISCONNECT SOLENOID CONNECTORS




16. REMOVE CONNECTOR CLAMP AND TUBE RETAINER




17. REMOVE B3 APPLY TUBE
Pry up the tube with a screwdriver and remove the tube.

18. REMOVE VALVE BODY




a. Remove the ten bolts.




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




19. REMOVE SECOND BRAKE APPLY GASKET




20. REMOVE THROTTLE CABLE AND SOLENOID WIRE




21. REMOVE ACCUMULATOR PISTONS 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 C(1) accumulator piston.
d. Remove the O-ring.




e. Pop out pistons for C(2) and B(2) into a rag, using low- pressure compressed air (1 kg/Sq. cm, 14 psi or 98 kPa). Force air into the holes shown and remove the pistons and springs.
f. Remove the O-rings from the pistons.

22. 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: 2.0 - 3.5 mm (0.079 - 0.138 in.)

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

23. 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 two O-rings from the cover.

24. STAND TRANSAXLE ENGINE SIDE UPWARD
25. REMOVE OIL PUMP

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 transaxle case.
SST 09350-32014 (09351-32061)




26. REMOVE O-RING FROM OIL PUMP




27. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH




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




29. REMOVE BEARINGS FROM FORWARD CLUTCH




30. 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.




31. REMOVE FRONT PLANETARY RING GEAR
32. REMOVE FRONT PLANETARY GEAR



a. Remove the front planetary gear.




b. Remove the two bearings from the planetary gear.

33. 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.