Part 3

OVERHAUL





51. REMOVE FRONT PLANETARY SUN GEAR SUB-ASSY
a. Remove the front & center planetary sun gear from the case.





52. REMOVE 2ND BRAKE DISC SET
a. Remove the 6 discs, 5 plates, clutch plate and flange from the case.
b. Remove the spring from the case.
53. REMOVE OUTPUT SHAFT ASSY





a. Remove the output shaft with center & rear planetary gear from the case.





b. Remove the thrust washer from the output shaft with center & rear planetary gear.





54. REMOVE THRUST NEEDLE ROLLER BEARING NO.1
a. Remove the assembled bearing & race and 2 races from the rear planetary ring gear.
55. REMOVE REAR PLANETARY RING GEAR





a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)





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





56. REMOVE THRUST NEEDLE ROLLER BEARING NO.2
a. Remove the assembled bearing & race from the case.





57. INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE
a. Using feeler gauge, measure 1st & reverse brake pack clearance between the snap ring and the flange.
Pack clearance: 0.60 - 0.90 mm (0.024 - 0.035 inch)
58. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC





a. Using a screwdriver, remove the snap ring.





b. Remove the flange, 6 discs and 6 plates.





59. 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.

HINT:
^ If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers is defaced, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.





60. REMOVE 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY
a. Place SST on the spring retainer and compress the return spring.
SST 09350-30020 (09350-07050)
b. Using SST, remove the snap ring and return spring.
SST 09350-30020 (09350-07070)





61. INSPECT 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY
a. Measure the free length of the spring together with the spring seat.
Standard free length: 20.0 mm (0.787 inch)





62. REMOVE 1ST & REVERSE BRAKE PISTON NO.2
a. Hold No.2 brake piston by hand, apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to transmission case to remove brake piston No. 2.

HINT: If the piston dose not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the O-ring from brake piston No. 2.





63. REMOVE BRAKE REACTION SLEEVE
a. Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
b. Remove the O-ring from the reaction sleeve.





64. REMOVE BRAKE PISTON NO.2
a. Using SST, remove the brake piston No. 2.
SST 09350-30020 (09350-07090)
b. Remove the 2 O-rings from the piston No. 2.





65. BEARING POSITION





66. INSTALL BRAKE PISTON NO.2
a. Coat 2 new O-rings with ATF, install them to the brake piston No. 2.
b. Install the brake piston No. 2 to the reaction sleeve.





67. INSTALL BRAKE REACTION SLEEVE
a. Coat new O-ring with ATF, install it to the reaction sleeve.
b. With the brake piston No.1 underneath (the rear side), install the brake reaction sleeve and brake piston No.1 to the transmission case.

NOTICE: Be careful not to damage the O-rings.

68. INSTALL 1ST & REVERSE BRAKE PISTON NO.2





a. Coat new O-ring with ATF
b. Install the O-ring on brake piston No.2.
c. With the spring seat of the piston upwards (the front side), place the piston in the transmission case.

NOTICE: Be careful not to damage the O-ring.





d. Place the piston return spring onto the brake piston No.2.





69. INSTALL 1ST & REVERSE BRAKE RETURN SPRING SUB-ASSY
a. Place SST on the spring retainer and compress the return spring.
SST 09350-30020 (09350-07050)
b. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)
70. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC





a. Install the 6 plates, 6 discs and flange.
Install in order: P = Plate, D = Disc
P - D - P - D - P - D - P - D - P - D - P - D





b. Using a screwdriver, install the snap ring.

NOTICE: Be sure the end gap of the snap ring is not aligned with the cutout portion of the case.

71. INSPECT PACK CLEARANCE OF FIRST & REVERSE BRAKE





a. Make sure the 1st & reverse brake pistons move smoothly when applying and releasing the compressed air (392 kPa, 4 kgf/cm2, 57 psi) into the transmission case.





b. Using feeler gauge, measure 1st & reverse brake pack clearance between the snap ring and the flange.
Pack clearance: 0.60 - 0.90 mm (0.024 - 0.035 inch)
If the Pack clearance is less than limit of Pack clearance, parts may have been assembled incorrectly, so check and reassemble again.
If the Pack clearance is non-standard, select another plate.

HINT: There are 13 different plates in thickness for the bottom plate. For the other plates, the thickness is 1.8 mm (0.071 inch).





Plate thickness: mm (in.)





72. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSY
a. Install transmission case overhaul attachment.





73. INSTALL THRUST NEEDLE ROLLER BEARING NO.2
a. Install the assembled bearing & race.





Assembled bearing & race diameter: mm (in.)

74. INSTALL REAR PLANETARY RING GEAR





a. Install the rear planetary ring gear.





b. Using SST, install the snap ring.
SST 09350-30020