Part 3

OVERHAUL





51. REMOVE BRAKE APPLY TUBE
a. Remove the bolt, clamp and apply tube.
b. Remove the clutch apply tube.
c. Remove the brake apply tube from the clamp.





52. REMOVE DIRECT CLUTCH ASSY
a. Remove the thrust bearing and the direct clutch assy from the transaxle case.





53. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSY
a. Remove the bearing race, thrust bearing and direct clutch hub from the planetary gear assy.





54. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSY
a. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
Standard inside diameter: 23.025 - 23.046 mm (0.9065 - 0.9073 inch)
Maximum inside diameter: 23.09 mm (0.9091 inch)

NOTICE:
^ When the diameter is over the maximum, replace the multiple disc clutch hub with new one.
^ Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, re place the direct clutch sub-assy with new one.

If the inside diameter is greater than the maximum, replace the forward clutch hub.
55. REMOVE REAR PLANETARY SUN GEAR ASSY





a. Remove the rear planetary sun gear assy from the transaxle case.





b. Remove the thrust bearing and bearing race from the rear planetary sun gear.





c. Remove the thrust washer No. 2 from the rear planetary sun gear.
56. REMOVE 1 WAY CLUTCH ASSY





a. Remove the 1-way clutch assy and the thrust bearing from the transaxle case.





b. Remove the inner race from the 1-way clutch assy.





57. REMOVE 1WAY CLUTCH SLEEVE OUTER
a. Remove the sleeve outer from the transaxle case.





58. REMOVE PLANETARY CARRIER THRUST WASHER NO.1
a. Remove the thrust washer No. 1 from the planetary gear assy.





59. REMOVE 2ND BRAKE CLUTCH DISC
a. Using a screwdriver, remove the snap ring.
b. Remove the flange, 4 discs and 4 plates from the transaxle case.





60. INSPECT 2ND BRAKE CLUTCH DISC
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
^ If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

61. REMOVE SECOND BRAKE PISTON ASSY





a. Using a screwdriver, remove the snap ring.





b. Remove the 2nd brake piston assy from the transaxle case.
62. REMOVE REAR PLANETARY GEAR ASSY





a. Using a screwdriver, remove the snap ring.





b. Remove the rear planetary gear from the transaxle case.





63. REMOVE INPUT SUN GEAR
a. Remove the 2 thrust bearings, bearing race and input sun gear from the transaxle case.





64. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
a. Remove the flange, 6 discs and 6 plates from the transaxle case.





65. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
a. Check to see if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.

NOTICE:
^ If the lining of the disc comes off or discolors, or even if a part of the groove is defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.

66. REMOVE FRONT PLANETARY GEAR ASSY





a. Using a chisel and hammer, unstake the lock washer.

NOTICE: Push down all claws of the washer. Otherwise SST cannot be fully pressed against the nut, and cannot loosen the nut.





b. Using SST, remove the nut.
SST 09387-00030,09387-00080





c. Using SST and a press, remove the front planetary gear assy from the counter drive gear.
SST 09950-60010 (09951-00450), 09950-70010 (09951-07100)





d. Remove the front planetary gear assy from the brake hub.





67. REMOVE FRONT PLANETARY RING GEAR
a. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.





68. REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY
a. Place SST on the return spring, and compress the return spring with a press.
SST 09387-00070
b. Using a snap ring expander, remove the snap ring.

NOTICE:
^ Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, to prevent the spring sheet from deforming.
^ Do not expand the snap ring excessively.





69. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY
a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 15.53 mm (0.6114 inch)
70. REMOVE 1ST & REVERSE BRAKE PISTON





a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove 1st & reverse brake piston.

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





b. Remove the 2 O-rings from the 1st & reverse brake piston.
71. REMOVE COUNTER DRIVE GEAR





a. Using SST and a press, remove the counter drive gear from the transaxle case.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)





b. As shown in the illustration, tighten 2 bolts evenly and make clearance of approximately 20.0 mm (0.797 inch) between the counter drive gear and the inner race.





c. Using SST, remove the tapered roller bearing.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100), 09950-00020, 09950-00030, 09950-40011(09957-04010)
72. REMOVE COUNTER DRIVE GEAR BEARING





a. Using a snap ring expander, remove the snap ring.





b. Using SST and a press, remove the bearing outer race.
SST 09950-60020 (09951-00910), 09950-70010 (09951-07100)
73. REMOVE BREATHER PLUG NO.2 (ATM)





74. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY
a. Place SST on the return spring, and compress the return spring with a press.
SST 09387-00020
b. Using a snap ring expander, remove the snap ring.

NOTICE:
^ Stop the press when the spring sheet is lowered 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, to prevent the spring sheet from deforming.
^ Do not expand the snap ring excessively.





75. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSY
a. Using a vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 14.04 mm (0.5528 inch)