Component Parts Removal (A240L) (Part 1)

Part 1:

Part 2:

Part 3:

COMPONENTS

SEPARATE BASIC SUBASSEMBLY




1. REMOVE MANUAL SHIFT LEVER
Remove the nut, washer and manual shift lever.

2. REMOVE NEUTRAL START SWITCH




a. Using a screwdriver, unstake the nut stopper.




b. Remove the nut, nut stopper and packing.




c. Remove the two bolts and neutral start switch.




3. REMOVE THROTTLE CABLE RETAINING PLATE
Remove the bolt and plate.




4. REMOVE SOLENOID WIRE RETAINING PLATE
Remove the bolt and plate.

5. REMOVE GOVERNOR BODY




a. Remove the two bolts and cover brackets.




b. Using a screwdriver, remove the governor cover.

NOTE: Tape the screwdriver tip before use so as not to damage the cover or transaxle.




c. Remove the O-ring from the cover.




d. Remove the governor body with thrust washer.




e. Remove the three bolts and governor body adaptor with gasket.




6. REMOVE PAN AND GASKET
a. Remove the eighteen bolts.
b. Remove the pan by lifting the transmission case.

CAUTION: Do not turn the transmission 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 transmission on wooden blocks to prevent damage to the pipes.




7. 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 transmission:

Steel (magnetic) ... bearing, gear and plate wear
Brass (non-magnetic) ... bushing wear

8. TURN TRANSMISSION OVER

9. REMOVE OIL STRAINER




a. Remove the three bolts and oil strainer.




b. Remove the gasket.

10. REMOVE OIL TUBES




a. Remove the two bolts and tube bracket.
b. Remove the tube clamp bolt and clamp.




c. Pry up both ends with a large screwdriver and remove the five tubes.




11. REMOVE MANUAL DETENT SPRING




12. DISCONNECT SOLENOID CONNECTOR
13. REMOVE VALVE BODY




a. Remove the twelve bolts and wire retainer as shown.




b. Disconnect the throttle cable from the cam.
c. While disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body.




14. REMOVE THROTTLE CABLE FROM CASE
Pull out the throttle cable.




15. REMOVE SOLENOID WIRE




16. REMOVE SECOND BRAKE APPLY GASKET




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




18. REMOVE C3 ACCUMULATOR PISTON AND SPRING
Using low-pressure compressed air (1 kg/sq.cm, 14 psi or 98 kPa) pop out the piston into a rag. Force air into the hole shown and remove the piston and spring.

19. 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, gasket and spring on the B2 piston.




c. Remove the C1 piston and two springs.




d. Using low-pressure compressed air (1 kg/sq.cm, 14 psi, 98 kPa), pop out the C2 piston into a rag. Force air into the hole shown and remove the piston and spring.




e. Using low-pressure compressed air (1 kg/sq.cm, 14 psi, 98 kPa), pop out the B2 piston into a rag.
Force air into the hole shown and remove the piston and spring.

20. 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, 392 - 785 kPa) as shown.
SST 09240 - 00020

Piston stroke. 1.5 - 3 mm (0.059 - 0.118 in.)

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

21. REMOVE SECOND COAST BRAKE PISTON




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




b. Using low-pressure compressed air (1 kg/sq.cm, 14 psi, 98 kPa), pop out the cover into a rag.
Force air into the hole shown.




c. Remove the cover, piston and spring.




d. Remove the two O-rings from the cover.

22. REMOVE OIL PUMP




a. Remove the six bolts holding the oil pump to the transmission case.
b. Using SST, pull the oil pump free from the transmission case.
SST 09350 - 32014 (09351 - 32061)




c. Remove the oil pump with SST.
SST 09350 - 32014 (09351 - 32061)

CAUTION: Be careful not to drop or damage the races and bearing behind oil pump.

d. Remove SST from the oil pump.




e. Remove the race from the oil pump.




f. Remove the O-ring from the oil pump.




23. REMOVE DIRECT CLUTCH

24. REMOVE FORWARD CLUTCH




a. Remove the forward clutch with bearing and race.




b. Remove the thrust washer, bearing and races from the forward clutch.




25. 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.

26. REMOVE FRONT PLANETARY RING GEAR




a. Remove the front planetary ring gear with bearing and race.




b. Remove the bearing and race from the ring gear.

27. REMOVE FRONT PLANETARY GEAR




a. Remove the front planetary gear with race.




b. Remove the races and bearing from the planetary gear or sun gear.




28. REMOVE SUN GEAR, SUN GEAR INPUT DRUM AND THRUST WASHER




29. REMOVE SECOND BRAKE HUB AND NO.1 ONE-WAY CLUTCH




30. CONFIRM THAT SECOND BRAKE PISTON MOVES
Using compressed air, confirm that the second brake piston moves smoothly.




31. REMOVE SECOND COAST BRAKE BAND GUIDE




32. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE




33. REMOVE SECOND BRAKE DRUM

NOTE: If the brake drum is difficult to remove, lightly tap it with a wooden block.




34. REMOVE SECOND BRAKE PISTON RETURN SPRING
a. Remove the thrust washer.
b. Remove the return spring.




35. REMOVE PLATES, DISCS AND FLANGE




36. REMOVE SNAP RING HOLDING NO.2 ONE-WAY CLUTCH OUTER RACE TO CASE
Using a screwdriver, remove the snap ring.

37. REMOVE NO.2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR




a. Remove the No.2 one-way clutch and rear planetary gear with thrust washer.




b. Remove the thrust washer from the gear.