Part 4
OVERHAUL76. REMOVE UNDERDRIVE BRAKE PISTON
a. Apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transaxle case to remove the U/D brake piston.
b. Remove the 2 O-rings from the U/D brake piston.
77. REMOVE NEEDLE ROLLER BEARING
a. Using SST, remove the needle-roller bearing from the transaxle case.
SST 09387-00041 (09387-01010, 09387-01030, 09387-01040)
78. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING
a. Remove the 2 oil seal rings from the transaxle case.
79. REMOVE PLUG, W/HEAD STRAIGHT SCREW
a. Remove the 2 transaxle case No. 1 plugs.
b. Remove the 2 O-rings from the 2 transaxle case No. 1 plugs.
80. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING
a. Using SST, remove the cylindrical roller bearing from the transaxle case.
SST 09514-35011
81. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
a. Remove the oil seal ring from the transaxle housing.
82. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
a. Remove the bolt, clamp and apply tube from the transaxle housing.
83. BEARING POSITION
84. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
a. Install the apply tube and clamp with the bolt to the transaxle housing.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
NOTICE: Make sure to insert the pipe to the stopper.
85. INSTALL TRANSAXLE CASE NO.1 PLUG
a. Install the 2 new O-rings to the 2 transaxle case No. 1 plugs.
b. Install the 2 transaxle case No. 1 plugs to the transaxle rear cover.
Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.)
86. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL RING
a. Coat the new oil seal ring with ATF and install it to the transaxle housing.
87. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
a. Using SST and a press, install the U/D cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010 (09951-07100)
NOTICE: Do not apply excessive pressure to it.
88. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL RING
a. Coat the 2 new oil seal rings with ATF, install them to the transaxle rear cover.
89. INSTALL NEEDLE ROLLER BEARING
a. Wind a vinyl tape around SST at the place 4.0 mm (0.157 inch) above from the bottom end until the thickness of the wound tape is about 5.0 mm (0.197 inch).
NOTICE: Clean SST to remove deposited oil, before winding a vinyl tape.
b. Using SST and a press, install the needle-roller bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
NOTICE: When the wound vinyl tape contacts the transaxle case, stop press-fitting.
90. INSTALL UNDERDRIVE BRAKE PISTON
a. Coat the 2 new O-rings with ATF, install them to the U/D brake piston.
b. Install the U/D brake piston to the transaxle case.
NOTICE: Be careful not to damage the O-ring.
91. INSTALL UNDERDRIVE CLUTCH 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, install the snap ring to the transaxle case.
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.
92. INSTALL BREATHER PLUG NO.2 (ATM)
93. INSTALL COUNTER DRIVE GEAR BEARING
a. Using SST and a press, install the bearing outer race.
SST 09950-60020 (09951-01030), 09950-70010 (09951-07150), 09649-17010
NOTICE:
^ Do not apply excessive pressure to it.
^ Press-fit the bearing outer race until it contacts the transaxle case.
b. Using a snap ring expander, install the snap ring.
NOTICE: Face the white mark side of the snap ring up.
94. INSTALL COUNTER DRIVE GEAR
a. Using SST and a press, install the tapered roller bearing to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE: Do not apply excessive pressure to it.
b. Using SST and a press, install the counter drive gear and bearing to the transaxle case.
SST 09223-15030, 09527-17011, 09950-60020 (09951-00750), 09950-70010 (09951-07150)
NOTICE: Do not apply excessive pressure to it.
95. INSTALL 1ST & REVERSE BRAKE PISTON
a. Coat the 2 new O-rings with ATF.
b. Install the 2 O-rings to the 1st & reverse brake piston.
c. Coat a 1st & reverse brake piston with ATF, install it to the transaxle case.
NOTICE: Be careful not to damage the O-ring.
96. INSTALL 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, install the snap ring to the transaxle case.
NOTICE:
^ Stop the press when the spring sheet is lowered to the place 1 - 2 mm (0.039 - 0.078 inch) from the snap ring groove, preventing the spring sheet from being deformed.
^ Do not expand the snap ring excessively.
97. INSTALL FRONT PLANETARY RING GEAR
a. Using a screwdriver, install the front planetary ring gear and snap ring to the brake hub.
98. INSTALL FRONT PLANETARY GEAR ASSY
a. Install the front planetary gear assy to the brake hub.
b. Using SST and a press, press-fit the front planetary gear assy.
SST 09950-60010 (09951-00500), 09950-70010 (09951-07100)
NOTICE: Do not apply excessive pressure to it.
c. Install the washer, as shown in the illustration.
d. Using SST, install the nut.
SST 09387-00030,09387-00080
Torque: 268 Nm (2,732 kgf-cm, 198 ft. lbs.)
e. Using SST and a torque wrench, measure the turning torque of the bearing while rotating SST at 60 rpm. When the measured value is not within the specified value, gradually tighten the nut until it reaches the specified value.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing 0.51 - 1.02 Nm (5.1 - 10.0 kgf-cm, 4.4 - 8.7 inch lbs.)
Used Bearing 0.26 - 0.51 Nm (2.7 - 5.2 kgf-cm, 2.3 - 4.5 inch lbs.)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 inch).
f. Using a chisel and hammer, stake the front planetary gear washer.
99. INSTALL INPUT SUN GEAR
a. Install the 2 thrust bearings, the bearing race and the front planetary sun gear to the front planetary gear assy.
Thrust bearing and bearing race diameter: mm (in.)
100. INSTALL REAR PLANETARY GEAR ASSY
a. Install the rear planetary gear to the rear planetary ring gear.
b. Using a screwdriver, install the snap ring.