Part 2

AUTOMATIC TRANSMISSION UNIT

COMPONENTS:

DISASSEMBLY (STEPS 36 - 70)

36. REMOVE 1 WAY CLUTCH ASSEMBLY
a. Remove the 1 way clutch assembly and the planetary carrier thrust washer No. 1 from the transmission case.

37. REMOVE 2ND BRAKE CYLINDER
a. Remove the 2nd brake cylinder from the transmission case.

38. REMOVE FRONT PLANETARY GEAR ASSEMBLY

a. Remove the front planetary gear assembly and the 1 way clutch inner race from the transmission case.

b. Remove the thrust needle roller bearing, the thrust bearing race No. 3 and the planetary carrier thrust washer No. 2 from the transmission case.

39. INSPECT FRONT PLANETARY GEAR ASSEMBLY
40. INSPECT 1 WAY CLUTCH ASSEMBLY

41. REMOVE FRONT PLANETARY RING GEAR
a. Remove the front planetary ring gear from the transmission case.

42. REMOVE CENTER PLANETARY RING GEAR

a. Using a screwdriver, remove the snap ring.
b. Remove the center planetary ring gear from the front planetary ring gear.

c. Using a screwdriver, remove the snap ring.
d. Remove the front planetary ring gear flange from the center planetary ring gear.
e. Remove the thrust needle roller bearing from the front planetary ring gear flange.

43. REMOVE BRAKE DISC NO. 1
a. Remove the flange, the 3 discs and the 3 plates from the transmission case.

44. INSPECT BRAKE DISC NO. 1

45. REMOVE BRAKE PISTON RETURN SPRING SNAP RING
a. Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.

46. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Remove the brake piston return spring and the brake piston No. 1 with the brake cylinder No. 1 from the transmission case.

47. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

48. REMOVE BRAKE PISTON NO. 1
a. Hold the brake cylinder No. 1 and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the brake cylinder No. 1 to remove the brake piston No. 1.

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

b. Remove the 2 O-rings from the brake piston No. 1.

49. REMOVE BRAKE DISC NO. 2

a. Using a screwdriver, remove the snap ring from the transmission case.

b. Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the transmission case.

50. INSPECT BRAKE DISC NO. 2
51. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO. 2

52. REMOVE BRAKE PISTON NO. 2
a. Hold the brake piston No. 2 and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the brake piston No. 2 with the cylinder.

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

b. Remove the piston from the cylinder.
c. Remove the 2 O-rings from the brake piston No. 2.

53. REMOVE CENTER PLANETARY GEAR ASSEMBLY
a. Remove the center planetary gear assembly, the planetary sun gear and the thrust bearing race No. 4 from the transmission case.

54. INSPECT CENTER PLANETARY GEAR ASSEMBLY
55. REMOVE INTERMEDIATE SHAFT

a. Using SST, remove the snap ring from the transmission case.
SST 09350-30020 (09350-07060)

b. Remove the intermediate shaft with the 1 way No. 3 clutch assembly from the transmission case.

56. INSPECT 1 WAY NO. 3 CLUTCH ASSEMBLY

57. REMOVE 1 WAY NO. 3 CLUTCH ASSEMBLY
a. Remove the 1 way clutch No. 3 assembly and the 1 way clutch inner race from the intermediate shaft.

58. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. Remove the thrust bearing race No.8, the thrust needle roller bearing, the thrust bearing race No.7 and the planetary ring gear flange from the intermediate shaft.

59. INSPECT INTERMEDIATE SHAFT

60. REMOVE BRAKE PLATE STOPPER SPRING
a. Remove the brake plate stopper spring from the transmission case.

61. REMOVE BRAKE DISC NO. 4
a. Remove the 4 plates, 5 discs and 2 flanges from the transmission case.

62. INSPECT BRAKE DISC NO. 4
63. REMOVE REAR PLANETARY GEAR ASSEMBLY

a. Remove the rear planetary gear assembly from the transmission case.

b. Remove the thrust bearing race No.9, thrust bearing race No.7 and the thrust needle roller bearing from the rear planetary gear assembly

c. Remove the thrust needle roller bearing from the transmission case.

64. INSPECT REAR PLANETARY GEAR ASSEMBLY

65. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
SST 09350-30020 (09350-07050)
b. Using SST, remove the snap ring and the brake return spring.
SST 09350-30020 (09350-07070)

66. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

67. REMOVE BRAKE APPLY TUBE
a. Remove the brake apply tube from the 1st and reverse brake piston.

68. REMOVE 1ST AND REVERSE BRAKE PISTON
a. Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2, 57 psi) into the transmission case to remove the brake piston.

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

b. Remove the brake apply tube from the piston.
c. Remove the O-ring from brake piston.

69. REMOVE BRAKE REACTION SLEEVE
a. Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
b. Remove the 2 O-rings from the reaction sleeve.

70. REMOVE BRAKE PISTON NO. 4
a. Using SST, remove the brake piston No. 4.
SST 09350-30020 (09350-07080)
b. Remove the 2 O-rings from the brake piston No. 4.