3. End Cover/Intermediate Housing

Forward Clutch, Reverse Brake, and Intermediate Housing Removal

Special Tools Required
Reverse brake spring compressor 07TAE-P4V0110

NOTE: Refer to the Exploded View as needed during the following procedure.

1. Remove the end cover (three; 6 mm bolts and 11; 8 mm bolts).
2. Remove the manual valve body lines A and B.
3. Remove the planetary carrier/input shaft assembly and ring gear.
4. Remove the snap ring securing the reverse brake discs and plates, then remove the reverse brake and plate, discs, plates, and disc spring.
5. Remove the snap ring securing the forward clutch end plate, then remove the forward clutch end plate, discs and plates.
6. Remove the snap ring securing the forward clutch to the drive pulley shaft, then remove the forward clutch.





7. Install the special tool to remove the snap ring securing the reverse brake return spring retainer.





8. Compress the return spring with the special tool, then remove the snap ring. Be sure the special tool set over the reverse brake return springs.





9. Remove the special tool, then remove the spring retainer/return spring assembly (A).
10. Apply air pressure to reverse brake pressure circuit hole (B) to remove the reverse brake piston (C).
11. Remove the snap ring retainer from the drive pulley shaft.
12. Remove the manual valve body (five bolts) and separator plate.
13. Remove the roller, and push the control shaft toward the outside of the transmission housing, then remove the intermediate housing (four bolts).

End Cover/Intermediate Housing
Input Shaft and Planetary Carrier Clearance Inspection





1. Measure the clearance between the 25 x 31 mm thrust shim (A) and the snap ring (B) with a feeler gauge (C).

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

STANDARD: 0.05 - 0.115 mm (0.018 - 0.030 inch)





2. If the clearance is out of standard, remove the 25 x 31 mm thrust shim (A) and measure its thickness.





3. Select and install the new thrust shim, and secure them with the snap ring, then recheck.
4. After replacing the 25 x 31 mm thrust shim, make sure that the clearance is within tolerance.
5. Verify that the snap ring outside diameter is 30.7 mm (1.21 inch) or less.

Planetary Carrier Bearing Inspection





1. Check the planetary carrier bearing for play by spinning it by hand. If there is excessive play, replace the planetary carrier assembly.

Manual Valve Body Disassembly, Inspection, and Reassembly
1. Clean all parts thoroughly in solvent or carburetor cleaner, and dry with compressed air. Blow out all passages.





2. Coat all parts with ATF during assembly.






Intermediate Housing, Reverse Brake, and Forward Clutch Installation

Special Tools Required
Reverse brake spring compressor 07TAE-P4V0110

1. Install the ATF feed pipe in the transmission housing, and install the three ATF feed pipes with the new O-rings in the transmission housing.
2. Install the two dowel pins and new transmission gasket on the transmission housing.
3. Push the control shaft toward the outside of the transmission housing, then install the intermediate housing (four bolts).
4. Install the manual valve body separator plate and two dowel pins on the intermediate housing, and install the manual valve body with the detent spring (five bolts).
5. Put the control shaft back, then install the roller in the intermediate housing with aligning the groove on the control shaft.





6. Install the reverse brake piston (A) with the new O-ring (B) in the intermediate housing (C).
7. Install the spring retainer/return spring assembly (D); Install the return springs on the spring guides (E) on the reverse brake piston.





8. Install the special tool through the drive pulley shaft to compress the return spring. Be sure the special tool (spring compressor attachment) is set over the return springs, not to over the reverse brake piston.





9. Compress the return springs while making sure that the special tool set over the return springs and the spring retainer tabs does not ride on the reverse brake piston.
10. Install the snap ring in the intermediate housing above the spring retainer.





11. Verify that the snap ring end gap (A) is 15 mm (0.59 inch) and above.
12. Soak the reverse brake discs thoroughly in ATF for a minimum of 30 minutes. Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt and other foreign matter.





13. Install the disc spring (A) in the direction shown.
14. Starting with a reverse brake plate (B), alternately install the plates and discs (C). Install the reverse brake end plate (D) and snap ring (E).





15. Verify that the snap ring end gap (A) is 18 mm (0.71 inch) and above, and the inside diameter (B) of the snap ring is 143.5 mm (5.65 inch) and above.





16. Set a dial indicator (A) on the clutch end plate (B). Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).
17. Release the clutch end plate to lower the clutch end plate, then put a steel plate (D) on the end plate (B).
18. Press the steel plate down with 39 N (4 kgs, 9 lbs) using a force gauge, and read the dial indicator (A). The dial indicator reads the clearance (E) between the clutch end plate and top disc (F). Take measurements in at least three places, and use the average as the actual clearance.
Reverse Brake End Plate-to-Top Disc Clearance:
Service Limit: 0.45 - 0.75 mm (0.018 - 0.030 inch)
19. If the clearance is out of the service limit, select a new reverse brake end plate from following table, then recheck.

NOTE: If the thickest end plate is installed, but the clearance is still over the standard, replace the reverse brake discs and plates.





REVERSE BRAKE END PLATE

20. After replacing the reverse brake end plate, make sure that the clearance is within tolerance.





21. Install the snap ring retainer (A) over the drive pulley shaft (B).
22. Wrap the drive pulley shaft splines with tape to prevent O-ring damage. Install new O-ring (c) in the drive pulley shaft O-ring grooves, then remove the tape.
23. Install the forward clutch (D) on the drive pulley shaft, then install the snap ring (E) to secure the forward clutch.





24. Verify that the snap ring outside diameter is 41.4 mm (1.63 inch) or less.





25. Install the ring gear (A) on the forward clutch (B).
26. Install the input shaft/planetary carrier assembly (c) through the drive pulley shaft (D) while aligning the sun gear (E) to the clutch discs and aligning the planetary carrier to the reverse brake discs.





27. Install the manual valve body lines A and B with the new O-rings (c) on the manual valve body (D) and the intermediate housing (E).
28. Install the ATF feed pipe (F) with the new O-rings (G).
29. Install the two dowel pins (H) and the new end cover gasket (I) on the intermediate housing, then install the new O-rings (J) over the ATF feed pipes (K).
30. Install the end cover (L) (three; 6 mm bolts and 11; 8 mm bolts).