Multiple Disc Brake & Front Planetary Gear

OVERHAUL





1. INSPECT BRAKE PISTON NO.1
a. Using SST and a dial indicator, measure the 3rd brake piston stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
If the stroke is non-standard, inspect the disc.
Piston stroke: 0.70 - 1.00 mm (0.028 - 0.039 inch)

NOTICE: Do not applying compressed air into the 2nd brake hole.

2. REMOVE 3RD BRAKE DISC SET NO.2





a. Using a screwdriver, remove the snap ring from the brake drum.





b. Remove the flange, 5 plates and 5 discs.





3. INSPECT 3RD BRAKE DISC SET NO.2
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 discorded, 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.

4. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSY





a. Place SST on the spring retainer and compress the return spring with a press.
SST 09350-32014 (09351-32040)
b. Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)





c. Remove the retainer and piston return spring.





5. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSY
a. Measure the free length of the spring together with the spring seat.
Standard free length: 36.8 mm (1.449 inch)
6. REMOVE 2ND BRAKE PISTON





a. Push the 2nd brake piston down with fingers to remove.





b. Remove the 2 O-rings from the 2nd brake piston.
7. REMOVE BRAKE PISTON NO.1





a. Hold the brake piston No. 1 so that it dose not slant, and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) into the passage to remove the brake piston No. 1.





b. Remove the 2 O-rings from the brake piston No. 1.
8. INSPECT 1 WAY CLUTCH ASSY





a. Hold the front & center planetary sun gear and turn the hub. The hub must be able to turn freely clockwise and locks counterclockwise.





b. Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.2 - 0.6 mm (0.008 - 0.024 inch)
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance is greater than the maximum, replace the planetary gear assembly.





9. INSPECT FRONT PLANETARY SUN GEAR SUB-ASSY
a. Using a dial indicator, measure the inside diameter of the planetary sun gear bushing.
Maximum inside diameter: 24.79 mm (0.976 inch)
If the inside diameter is greater then the maximum, replace the planetary sun gear.
10. INSTALL BRAKE PISTON NO.1





a. Coat 2 new O-rings with ATF and install them on brake piston No.1.





b. Being careful not to damage the O-rings, press the brake piston No. 1 into the brake drum with both hands.
11. INSTALL 2ND BRAKE PISTON





a. Coat 2 new O-rings with ATF and install them on 2nd brake piston.





b. Being careful not to damage the O-rings, press the 2nd brake piston into the brake drum with both hands.
12. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSY





a. Install the piston return spring.
b. Install the piston retainer.





c. Place SST on the spring retainer, and compress the return spring with a press.
SST 09350-32014 (09351-32040)
d. Using SST, install the snap ring.
SST 09350-30020 (09350-07070)

NOTICE: Be sure the end gap of the snap ring is not aligned with the spring retainer claw.

13. INSTALL 3RD BRAKE DISC SET NO.2





a. Install the 5 plates and 5 discs.
Install in order: P = Plate, D = Disc
P - D - P - D - P - D - P - D - P - D
b. Install the flange, with the facing its beveled part downward.

HINT: Assemble the flange to the brake drum with facing a carved mark on the flange upward.





c. Using a screwdriver, install the snap ring.

NOTICE: Be sure the end gap of the snap ring is not aligned with cut out portion of the brake drum.





14. INSPECT BRAKE PISTON NO.1
a. Using SST and a dial indicator, measure the 3rd piston stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).
SST 09350-30020 (09350-06120)
Piston stroke: 0.70 - 1.00 mm (0.028 - 0.039 inch)

NOTICE: Do not applying compressed air into the 2nd brake piston hole.

If the piston stroke is less than the limit of piston stroke, parts may have been assembled incorrectly, so check and reassemble again.
If the clearance is non-standard, select another flange.

HINT: There are 6 different flanges in thickness.





Flange thickness: mm (in.)