Page 41 of 2389
AT3538
AT3539
AT3599
Piston O-ring
AT3541 AT3540
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 B2 into a rag, using
low-pressure compressed air (1 kg/cm2, 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.
AT-22- AUTOMATIC TRANSAXLERemoval of Component Parts
Page 42 of 2389
AT3543
SST
AT3544
Cover Piston
AT3545
AT3546
SST
AT3542
(b) Using SST, measure the piston stroke applying and
releasing the compressed air (4 - 8 kg/cm2
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 (See page AT-41).
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
NOTICE: 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)
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-23
Page 43 of 2389
AT7700
AT3547
AT3548
Forward ClutchThrust Washer Direct Clutch
AT0121 AT3549
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.
HINT: For the method of inspection, refer to page
AT-41.
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Page 44 of 2389
AT3550
AT3551
AT3600
AT3553 AT3552
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.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-25
Page 45 of 2389
AT3601
AT3554
AT3555
AT3556AT0132
34. 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.
35. REMOVE SECOND COAST BRAKE BAND GUIDE
36. REMOVE SECOND BRAKE DRUM
(a) Remove the snap ring.
(b) Remove the second brake drum.
37. REMOVE SECOND BRAKE PISTON RETURN
SPRING
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Page 46 of 2389
AT3557
AT7701
AT3559
AT3560AT3558
38. REMOVE NO. 1 ONE-WAY CLUTCH
39. REMOVE PLATES, DISCS AND FLANGE
HINT: For the method of inspection, refer to page
AT-62.
40. REMOVE SECOND BRAKE DRUM GASKET
Remove the gasket.
41. REMOVE NO. 2 ONE-WAY CLUTCH AND REAR
PLANETARY GEAR
(a) Remove the snap ring.
(b) Remove the No. 2 one-way clutch and rear
planetary gear.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-27
Page 47 of 2389
AT5021
A540H only
AT3562
Bearing
AT3563
AT3564 AT3602
(c) Remove the thrust washer from the rear planetary
gear.
42. REMOVE REAR PLANETARY RING GEAR
(a) Remove the rear planetary ring gear.
(b) Remove the bearing from the ring gear.
43. CHECK FIRST AND REVERSE BRAKE
(a) Check the operation of the first and reverse brake
piston
Apply compressed air into the case passage and confirm
that the piston moves.
If the piston does not move, disassemble and inspect.
(b) Using a filler gauge, check the pack clearance of
the first and reverse brake.
Clearance: A540E
0.85 - 2.05 mm (0.033 - 0.081 in.)
A540H
1.04 - 2.16 mm (0.041 - 0.085 in.)
If the pack clearance is not within specification, disas-
semble and inspect.
44. REMOVE FLANGE, DISCS AND PLATES OF FIRST
AND REVERSE BRAKE
(a) Remove the snap ring.
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Page 48 of 2389
AT4169
AT4172
AT3568
AT4177
Brake Dram
AT3565
(b) Remove the flange, seven discs and seven plates.
HINT: For the method of inspection, refer to AT-66.
45. TURN TRANSAXLE CASE AROUND
46. REMOVE OVERDRIVE UNIT
(a) Remove the thirteen bolts.
(b) Tap on the circumference of the overdrive case
with a plastic hammer to remove the overdrive
case and gasket.
(c) Remove the overdrive planetary gear from trans-
axle case.
(d) Remove the overdrive brake drum from the trans-
axle case.
- AUTOMATIC TRANSAXLERemoval of Component PartsAT-29