Part 5

INSPECTION

Rear Internal Gear, Forward Clutch Hub And Overrun Clutch Hub



- Check rubbing surfaces for wear or damage.

Snap Ring, End Bearings And Forward One-Way Clutch



- Check snap ring and end bearings for deformation and damage.
- Check forward one-way clutch for wear and damage.


ASSEMBLY



1. Install forward one-way clutch on forward clutch.
- Take care with the direction of forward one-way clutch.




2. Install end bearing on forward one-way clutch.
- Apply petroleum jelly to end bearing.




3. Install thrust washer on rear internal gear.
- Apply petroleum jelly to thrust washer.
- Align pawls of thrust washer with holes of rear internal gear.




4. Install end bearing on rear internal gear.
- Apply petroleum jelly to end bearing.




5. Install forward clutch hub on rear internal gear.
- Check operation of forward one-way clutch. Hold rear internal gear and turn forward clutch hub. Check forward clutch hub for correct locking and unlocking directions.
- If not as shown in illustration, check installation direction of forward one-way clutch.




6. Install thrust washer and overrun clutch hub.
- Apply petroleum jelly to thrust washer.
- Align pawls of thrust washer with holes of overrun clutch hub.




7. Install overrun clutch hub on rear internal gear.
- Align projections of rear internal gear with holes of overrun clutch hub.




8. Install snap ring to groove of rear internal gear.


OUTPUT SHAFT, OUTPUT GEAR, IDLER GEAR, REDUCTION PINION GEAR AND BEARING RETAINER





DISASSEMBLY



1. Remove seal rings from output shaft and bearing retainer.




2. Press out output shaft bearing inner race.




3. Remove output shaft bearing outer race from bearing retainer.




4. Remove output gear bearing inner race.




5. Remove output gear bearing outer race from bearing retainer.




6. Remove idler gear bearing inner race.




7. Remove idler gear bearing outer race from transmission case.




8. Press out reduction pinion gear bearing from reduction pinion gear.




9. Remove reduction pinion gear bearing outer race from transmission case.


INSPECTION

Output Shaft, Output Gear, Idler Gear And Reduction Pinion Gear



- Check shafts for cracks, wear or bending.
- Check gears for wear, chips and cracks.

Bearings
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace inner and outer race as a set.

Seal Ring Clearance



- Install new seal rings to output shaft.
- Measure clearance between seal ring and ring groove of output shaft.

Standard clearance: 0.10 - 0.25 Nm (0.0039 - 0.0098 inch)
Wear limit: 0.25 Nm (0.0098 inch)

- If not within wear limit, replace output shaft.
- Install new seal rings to bearing retainer.
- Measure clearance between seal ring and ring groove of bearing retainer.

Standard clearance: 0.10 - 0.25 Nm (0.0039 - 0.0098 inch)
Wear limit: 0.25 Nm (0.0098 inch)

- If not within wear limit, replace bearing retainer.

ASSEMBLY



1. Press reduction pinion gear bearing on reduction pinion gear.




2. Install reduction pinion gear bearing outer race on transmission case.




3. Press idler gear bearing inner race on idler gear.




4. Install idler gear bearing outer race on transmission case.




5. Press output gear bearing inner race on output gear.




6. Install output gear bearing outer race on bearing retainer.




7. Press output shaft bearing inner race on output shaft.




8. Install output shaft bearing outer race on bearing retainer.




9. Install new seal rings onto output shaft and bearing retainer.
- Apply petroleum jelly to seal rings.




10. Roll paper around seal rings to prevent seal rings from spreading.


BAND SERVO PISTON ASSEMBLY





DISASSEMBLY



1. Remove band servo piston snap ring.




2. Apply compressed air to oil hole in transmission case to remove OD servo piston retainer and band servo piston assembly.
- Hold band servo piston assembly with a rag or nylon waste.




3. Apply compressed air to oil hole in OD servo piston retainer to remove OD servo piston from retainer.
- Hold OD servo piston while applying compressed air.




4. Remove D-ring from OD servo piston.




5. Remove O-rings from OD servo piston retainer.




6. Remove band servo piston assembly from servo piston retainer by pushing it forward.




7. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, remove E-ring.




8. Remove OD servo return spring, band servo thrust washer and band servo piston stem from band servo piston.




9. Remove O-rings from servo piston retainer.




10. Remove D-rings from band servo piston.