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COMPONENTS (Cont'd)
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COMPONENTS (Cont'd)
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COMPONENTS (Cont'd)
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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. 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
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.
4. REMOVE UNION AND ELBOW
(a) Using an open end wrench, remove the union and el-
bow.
(b) Remove the O±rings from the union and elbow. 2. (A540H)
REMOVE APPLY GASKET
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10. REMOVE OIL PAN AND GASKET
(a) Remove the seventeen bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE: Do not turn the transaxle over as this will con-
taminate the valve body with the foreign material;
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 an(
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 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. 6. REMOVE THROTTLE CABLE RETAINING BOLT AND
PLATE
7. . REMOVE SOLENOID WIRE RETAINING BOLT
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14. REMOVE OIL TUBES
(A540E)
Pry up both tube ends with a large screwdriver and re-
move the six tubes.
(A540H)
(a) Remove the bolt.
(b) Pry up both tube ends with a large screwdriver and re-
move the seven tubes. (b) Remove the five bolts and manual valve body
with the manual valve.
(c) Remove the manual valve from the manual valve
body. 13. REMOVE MANUAL VALVE BODY
(a) Remove the two bolts and detent spring. 12. REMOVE OIL TUBE BRACKET AND STRAINER
15. DISCONNECT SOLENOID CONNECTORS
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17. REMOVE B3 APPLY TUBE
Pry up the tube with a screwdriver and remove the
tube.
(b) Disconnect the throttle cable from the cam and
remove the valve body. 16. REMOVE CONNECTOR CLAMP AND TUBE RETAINER
18. REMOVE VALVE BODY
(a) Remove the ten bolts.
19. REMOVE SECOND BRAKE APPLY GASKET
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(e) Pop out pistons for C2 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 pis-
tons and springs.
(f) Remove the 4±rings from the pistons. 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.
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. (e) Remove the C1 accumulator piston.
(d) Remove the O±ring. 20. REMOVE THROTTLE CABLE AND SOLENOID WIRE
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