Component Parts Removal (A240L) (Part 2)

38. REMOVE REAR PLANETARY RING GEAR




a. Remove the rear planetary ring gear with bearing and races.




b. Remove the bearing and races from the ring gear.




39. CONFIRM THAT FIRST AND REVERSE BRAKE PISTON MOVES
Using compressed air, confirm that the first and reverse brake piston moves smoothly.




40. REMOVE SNAP RING HOLDING FLANGE TO CASE
Using a screwdriver, remove the snap ring.




41. REMOVE FLANGES, PLATES AND DISCS

42. REMOVE TRANSAXLE REAR COVER




a. Remove the thirteen bolts.




b. Tap on the circumference of the cover with a plastic hammer to remove the cover from the transmission case, and remove the cover.




43. REMOVE INTERMEDIATE SHAFT
Remove the intermediate shaft from the transmission case.




44. REMOVE SNAP RING
Using snap ring pliers, remove the snap ring.




45. REMOVE TRANSAXLE HOUSING
Remove the eighteen bolts and transaxle housing.




46. REMOVE DIFFERENTIAL

47. REMOVE GOVERNOR DRIVEN GEAR




a. Remove the governor driven gear.




b. Remove the thrust washer.




48. REMOVE APPLY GASKETS
Remove the three gaskets.

49. REMOVE COUNTER SHAFT LOCK NUTS




a. Using a chisel and hammer, unstake the counter shaft lock nut on both sides.




b. Using SST, remove the lock nut of the driven gear side.
SST 09330 - 00021, 09350 - 32014 (09351 - 32031)




c. Using SST to hold the driven gear, remove the lock nut of the another side.
SST 09330 - 00021 and 09350 - 32014 (09351 - 32031, 09351 - 32170)




50. REMOVE COUNTER DRIVEN GEAR Using SST, remove the driven gear.
SST 09350 - 32014 (09351 - 32061)




51. REMOVE THRUST NEEDLE BEARING




52. REMOVE COUNTER SHAFT ASSEMBLY
Pull out the counter shaft assembly.




53. REMOVE THRUST BEARING WITH RACE
Remove the thrust bearing with race from the counter shaft assembly.

54. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH




a. Set a dial indicator (long type pick or SST) as shown.
SST 09350 - 32014 (09351 - 32190)




b. Applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi, 392 - 785 kPa), measure the underdrive clutch piston stroke.

Piston stroke: 1.50 - 1.86 mm (0.0591 - 0.0732 in.)

If the piston stroke is nonstandard, select another flange.

NOTE: There are two different flange thickness.

Flange thickness:
2.04 mm (0.0803 in.)
2.40 mm (0.0945 in.)




55. REMOVE UNDERDRIVE CLUTCH DRUM AND ANTIRATTLE CLIP




56. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES
Using compressed air, confirm that the underdrive brake piston moves smoothly.




57. REMOVE OIL SEAL RINGS
Remove the two oil seal rings.

58. REMOVE FLANGE. PLATES AND DISCS




a. Using SST and press, press in the flange until the snap ring is free from the flange.
SST 09350 - 32014 (09351 - 32070)
b. Using a screwdriver, remove the snap ring.




c. Remove the flange, three plates and discs.




59. REMOVE RETURN SPRING




60. REMOVE UNDERDRIVE BRAKE PISTON
Using low-pressure compressed air (1 kg/sq.cm, 14 psi, 98 kPa), pop out the brake piston into a rag. Force air into the hole shown and remove the brake piston.




61. REMOVE O-RINGS FROM PISTON
Remove the two O-rings from the piston.

62. REMOVE SNAP RING




a. Set SST, and tighten the bolt gradually to compress the springs until the snap ring is free from the spring seat.
SST 09350 - 32014 (09351 - 32040)




b. Using snap ring pliers, remove the snap ring.
c. Remove SST.
SST 09350 - 32014 (09351 - 32040)




63. REMOVE RETURN SPRING
Remove the return spring and snap ring.




64. REMOVE PISTON FROM TRANSMISSION CASE WITH COMPRESSED AIR
a. Apply compressed air into the oil passage of the case to remove the piston.

NOTE: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.

b. If the piston does not pop out with compressed air, use needle-nose pliers to remove it.




65. REMOVE O-RINGS FROM PISTON
Remove the two O-rings from the piston.




66. REMOVE PARKING LOCK PAWL STOPPER PLATE, TORSION SPRING AND SPRING GUIDE




67. REMOVE PAWL SHAFT CLAMP
Remove the bolt and paw shaft clamp.




68. REMOVE PARKING LOCK PAWL SHAFT AND LOCK PAWL




69. REMOVE PARKING LOCK SLEEVE




70. REMOVE CAM GUIDE BRACKET
Remove the cam guide bracket as shown.




71. REMOVE MANUAL VALVE SHAFT SPACER
Using a screwdriver and hammer, unstake the spacer and remove it.




72. REMOVE PEN
Using a punch and hammer, drive out the pin.

73. REMOVE MANUAL VALVE SHAFT AND LEVER




a. Remove the retaining spring.




b. Slide out the manual valve shaft and remove the manual valve lever and washer.

74. IF NECESSARY, REPLACE OIL SEAL OF MANUAL SHAFT




a. Using a screwdriver, remove the oil seal.




b. Using a 14 mm socket wrench and hammer, drive in a new oil seal.
c. Apply MP grease to the oil seal lip.




75. REMOVE OIL GALLERY COVER AND GASKET
a. Remove the six bolts.
b. Using a torx wrench, remove the three screws.
Remove the gallery cover and gasket.




76. REMOVE B4 ACCUMULATOR PISTON AND SPRING




77. REMOVE BEARING Using SST, remove the bearing.
SST 09308 - 00010

78. REMOVE OIL TUBES




a. Remove the four tube clamps.




b. Using a screwdriver, remove the four oil tubes.

79. REMOVE OIL TUBE APPLY COVER, GASKET AND STRAINER




a. Remove the three bolts, and remove the cover and gasket.




b. Remove the strainer.

80. REMOVE BEARING




a. Remove the bolt and stopper.




b. Using SST, remove the bearing.
SST 09308 - 00010